Crash Adapter Bridging Crush Rail and Torque Box
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Solution Overview
Problem
Existing vehicle designs face challenges in effectively directing and absorbing crash forces away from sensitive areas like the passenger compartment during frontal impacts, as traditional crash-absorbing structures may not efficiently manage energy distribution and can introduce higher moments on supporting structures when positioned higher in the vehicle.
Innovation Solution
An adapter is designed to bridge between a crush rail and a torque box, featuring a socket to enclose the crush rail and a plug to fit into the torque box, allowing the drive shaft to pass through, which directs crash forces into the torque box while being configured to deform and absorb energy, thus maintaining a low crash load path and reducing the need for higher positioning of crash absorption structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If crash-absorbing structures are positioned higher in the vehicle to direct crash forces away from the passenger compartment, then protection of the passenger compartment is improved, but higher moments are introduced on supporting structures
Solution Approach 1:
The adapter introduces a new spatial dimension by creating a dedicated crash load path that runs horizontally through the adapter body rather than vertically upward. The socket and plug configuration allows the crush rail to connect to the torque box at a lower position, changing the trajectory of crash forces from a vertical path to a horizontal path that bypasses the passenger compartment while avoiding high moments on supporting structures.
Solution Approach 2:
The adapter acts as an intermediary component between the crush rail and the torque box. It mediates the transfer of crash forces by providing a structured path through its body, distributing loads across multiple surfaces (first and second surfaces with side walls) and preventing direct transmission of high moments to the vehicle's supporting structures.
2Object-affected harmful factors
If traditional crash-absorbing structures are used to direct crash forces away from sensitive areas, then protection of energy storage components is improved, but energy distribution management becomes less efficient
Solution Approach 1:
The adapter body is segmented into functional zones: a socket portion for receiving the crush rail, a plug portion for connecting to the torque box, and an opening for the drive shaft. This segmentation allows each portion to be optimized for its specific function while collectively providing efficient energy distribution. The first and second surfaces with their respective side walls create segmented load paths that distribute crash energy systematically.
Solution Approach 2:
The adapter utilizes controlled deformation of its body material during crash events to change the mechanical parameters of the crash load path. By designing the adapter to deform in a controlled manner, the system optimizes energy absorption and distribution characteristics, transforming the rigid crush rail connection into a compliant energy-managing interface.
3Force
If crash absorption structures are positioned higher in the vehicle, then directional control of crash forces is improved, but the crash load path becomes more complex
Solution Approach 1:
The adapter merges multiple functions into a single integrated component: it connects the crush rail to the torque box, accommodates the drive shaft, provides crash force directionality, and absorbs energy. This consolidation simplifies the overall crash load path by eliminating the need for separate structural elements that would be required if crash absorption structures were positioned higher in the vehicle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adapter effectively directs and absorbs crash forces, reducing the risk to the passenger compartment by laterally redirecting forces and allowing the vehicle to maintain a lower crash load path, thereby minimizing damage and ensuring safer structural integrity during impacts.
Implementation Method 1
The adapter is configured to deform in response to crushing of the crush rail
Data Source
AI summary
An adapter for a vehicle includes: an adapter body configured to bridge between a crush rail at a vehicle end and a back-up structure, the adapter body having a socket configured to receive and enclose four sides of the crush rail, the adapter body having a plug configured to fit into the back-up structure; and an opening in the adapter body configured to have a drive shaft extend through the adapter.