V-Shaped Deflector-Catcher for Small Overlap Vehicle Impacts
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Solution Overview
Problem
Current technologies fail to effectively reduce intrusions into the passenger compartment of a vehicle during small overlap frontal crashes, as the frame rails do not provide sufficient resistance when impacting a rigid barrier, leading to increased deformation and intrusion in the passenger compartment.
Innovation Solution
A V-shaped deflector attached to the vehicle's bumper extends outboard and has a rear leg that slides along the frame rail until it engages a catcher bracket, which absorbs the impact force and reduces intrusion by transferring the force to the frame rail, while a crush-can between the bumper and frame rail absorbs energy without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a V-shaped deflector is attached to the bumper, then the intrusion into the passenger compartment is reduced, but the device complexity increases
Solution Approach 1:
The front-end assembly is segmented into distinct functional components: the V-shaped deflector with front and rear legs, the catcher bracket, and the crush-can. Each component performs a specific function in the impact sequence, allowing the system to manage the complex impact event through divided, specialized parts rather than a single complex structure.
Solution Approach 2:
The deflector is pre-positioned and pre-configured in a ready state before impact occurs. The rear leg is positioned to slide along the frame rail, and the catcher bracket is pre-attached at the appropriate location. This preliminary arrangement ensures that during impact, the components engage in the correct sequence without requiring complex real-time control mechanisms.
2Loss of energy
If the deflector is allowed to slide along the frame rail, then the impact force is absorbed and intrusion is reduced, but the manufacturing precision required increases
Solution Approach 1:
The deflector's rear leg is designed to automatically engage with the frame rail and slide along it during impact without requiring external actuation or complex guidance mechanisms. The geometry of the rear leg and frame rail create a self-guiding system where the impact force itself drives the sliding motion, reducing the need for precision manufacturing of guidance features.
Solution Approach 2:
The system allows for controlled changes in the position and orientation parameters of the deflector during impact. The rear leg transitions from a static pre-impact position to a dynamic sliding position along the frame rail, absorbing energy through this controlled parameter change. The catcher bracket then constrains the deflector at a specific position, managing the range of motion without requiring extreme precision throughout the entire travel path.
3Duration of action of moving object
If the catcher bracket is positioned spaced from the deflector, then the crush-can can collapse without interference, but the device complexity increases
Solution Approach 1:
The energy absorption function is segmented between multiple components operating in sequence: the deflector initially absorbs impact through sliding motion, then the crush-can collapses as the deflector engages the catcher bracket. This segmentation of the energy absorption process into distinct temporal and spatial phases allows each component to perform its function without interfering with others, managing complexity through functional separation.
Solution Approach 2:
The catcher bracket is pre-positioned at a specific distance from the deflector's initial position, and the crush-can is pre-installed in the spaced relationship between the frame rail and bumper. This preliminary arrangement ensures that when impact occurs, the crush-can has the necessary space to collapse freely before the deflector engages the catcher bracket, without requiring complex real-time coordination mechanisms.
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 solution significantly reduces intrusions into the passenger compartment by absorbing impact forces and transferring them to the frame rail, resulting in a substantial reduction of deformation and intrusion, meeting the requirements of the small overlap rigid barrier test with improvements of up to 150 mm compared to baseline measurements.
Implementation Method 1
A deflector, preferably V-shaped, is attached to the bumper and has a front leg extending outboard from the bumper. A rear leg extends from an outer end of the front leg toward the frame rail. The deflector is stretched and the distal end slides along the frame rail until the distal end engages the catcher bracket
Implementation Method 2
The deflector is stretched and the distal end slides along the frame rail until the distal end engages the catcher bracket that restrains the distal end of the deflector
Implementation Method 3
A catcher bracket is attached to the frame rail behind the rear leg that inhibits the rear leg from sliding rearward in a collision
Implementation Method 4
A crush-can may be disposed between the frame rail and the bumper that absorbs energy from the collision and collapses toward the frame rail
Data Source
AI summary
A front-end assembly including a deflector and a catcher bracket. The V-shaped deflector is attached to a bumper of a vehicle, a rear leg of the deflector has a distal end disposed adjacent to the frame rail. In a collision, the distal end of the rear leg engages the catcher bracket to reduce intrusion into the passenger compartment of the vehicle.