Crash Load Absorption Structure with Load Transfer Element

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Solution Overview

Problem

In motor vehicles, existing crash load absorption structures may not effectively manage occupant acceleration during frontal collisions, particularly when using engines with longer blocks, leading to increased injury risks due to sequential crush stages not fully utilizing available inertia and resulting in higher deceleration rates.

Innovation Solution

A crash load absorption structure with a compressible load-absorbing structure and a load transfer element that applies crash loads part-way along the structure, promoting earlier initiation of tertiary crush stages and breaking of structural joints, thereby extending deceleration duration and reducing occupant acceleration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If sequential crush stages are used in crash load absorption structures, then repair costs for minor collisions are minimized, but occupant acceleration during collision is not sufficiently reduced

Engineering Contradiction:

Improverepair costVSAvoidoccupant acceleration

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The crash load absorption structure is divided into multiple crushable components (first, second, and third crushable components) with different crush strengths. The load transfer element segments the force application by transferring crash load from the first component to the third component, enabling controlled sequential deformation that extends deceleration duration while maintaining repairability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The load transfer element acts as an intermediary between the first crushable component and the third crushable component. It transfers crash load through the second crushable component, which has intermediate crush strength, thereby controlling the sequence of deformation and extending the overall deceleration pulse duration to reduce occupant acceleration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If engines with longer blocks are used, then power output is improved, but available inertia for crash management is reduced leading to higher deceleration rates

Engineering Contradiction:

Improvepower outputVSAvoiddeceleration rate

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The invention changes the parameters of the crash load absorption structure by introducing a load transfer element that modifies the force distribution and deformation sequence. This allows the structure to better utilize the reduced inertia from longer-block engines, extending deceleration duration and reducing peak acceleration forces on occupants.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If deceleration duration is extended, then occupant acceleration is reduced, but crash structure complexity increases

Engineering Contradiction:

Improveoccupant accelerationVSAvoidcrash structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The crash load absorption structure employs dynamic characteristics through components with different crush strengths that deform in a controlled sequence. The load transfer element dynamically transfers load as components deform, automatically adjusting the force distribution during the crash event to extend deceleration duration without requiring complex active control systems.

Inventive Principle:

Principle #15Dynamics

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

This solution effectively lowers occupant injury risks by managing crash energy distribution, ensuring a longer deceleration pulse and lower acceleration forces, while maintaining performance across various crash tests without detrimental effects on other safety assessments.

Implementation Method 1

a compressible load absorbing structure having a front portion and a rear portion and being arranged to compress under a crash load along a generally longitudinal direction

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

a load transfer element for applying crash load to the load absorbing structure at a location part-way along the load absorbing structure

Methodology Applied

Scientific EffectImpact Force: Impact Force

Data Source

PatentUS9039070B2Crash load absorption structures for motor vehicles

Publication Date: 2015.05.26 ASTON MARTIN LAGONDA LIMITED

AI summary

A crash load absorption structure for a motor vehicle. The structure includes a compressible load absorbing structure. The compressible load absorbing structure includes a front portion and a rear portion. The front portion and the rear portion are arranged to compress under a crash load along a generally longitudinal direction. The compressible load absorbing structure also includes a structural joint located within the compressible load absorbing structure, the joint is between at least two structural members. A load transfer element is configured to promote breaking of the structural joint during a vehicle crash.