Deformable Headlight Subassembly for Pedestrian Impact Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing headlight subassemblies for motor vehicles primarily rely on a separate deformation body for impact absorption, limiting the contribution of other components to injury reduction during pedestrian impacts.
Innovation Solution
A subassembly design that incorporates a deformation body formed by a sealing channel body, headlight cup, and bracket body, with clinch connections and strategically positioned cutouts, allowing for distributed deformation across multiple components to absorb impact energy effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate deformation body is used for impact absorption, then the deformation capability is concentrated in one component, but the overall impact energy absorption is limited
Solution Approach 1:
The patent combines multiple components (sealing channel body, headlight cup, bracket body, and wing) into an integrated deformation system. These components are connected through clinch connections that allow them to deform together during impact, distributing the deformation across the entire assembly rather than concentrating it in a single separate deformation body.
Solution Approach 2:
The deformation body is segmented into multiple functional components (sealing channel body with indentation, headlight cup, bracket body, and wing) that can deform independently yet cooperatively. The segmentation allows each component to contribute to impact absorption through its own deformation characteristics while maintaining overall structural integrity.
2Manufacturing precision
If the sealing channel body is made rigid for structural stability, then alignment precision is improved, but deformation capability during impact is reduced
Solution Approach 1:
The sealing channel body exhibits local quality variation: the outer structure maintains rigidity for stable mounting and precise alignment, while the indentation region is designed with reduced stiffness to enable controlled deformation during impact. This local differentiation allows simultaneous achievement of alignment precision and deformation capability.
Solution Approach 2:
The sealing channel body transitions from a static rigid structure to a dynamic deformable structure during impact. The indentation is designed to deform under impact forces while the rest of the structure maintains its rigid mounting function, creating a dynamic response that adapts to the impact condition.
3Strength
If cutouts are added to the sealing channel body to enhance deformation, then impact energy absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The cutouts modify the geometric parameters of the sealing channel body, creating localized stress concentration points that facilitate controlled deformation during impact. These geometric parameter changes enhance energy absorption while maintaining compatibility with standard manufacturing processes for metal forming and cutting.
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
Enhances impact absorption and reduces pedestrian injury risk by enabling deformation across multiple components, including the wing, headlight cup, and bracket body, ensuring precise alignment and efficient energy absorption.
Implementation Method 1
The deformation of the sealing channel body results primarily from the deformability of the indentation between the two limbs of the sealing channel body in the event of an application of force that has a predominant force component from above
Implementation Method 2
The open cutouts enable the limb of the sealing channel body to buckle in the event of an impact force acting on the wing
Implementation Method 3
The headlight cup is configured to be deformed in the event of an impact and also is mounted in a manner that it is suitable for deformation
Implementation Method 4
The limbs of the sealing channel body preferably are connected to the wing and the headlight cup by clinch connections
Data Source
AI summary
A deformable subassembly (1) for mounting of headlight in the region of a recess (5) in a wing (4) of a motor vehicle has a sealing channel body (6) connected to the wing (4) in the region of a joint with a motor vehicle bonnet. A headlight cup (3) for mounting the headlight is connected on one side to the sealing channel body (6) spaced from the wing (4). A lower side of the headlight cup (3) is connected to a bracket body (7) that is connected to a supporting structure (8) of the motor vehicle. The sealing channel body (6), headlight cup (3) and/or the bracket body (7) are configured to deform in the event of an impact with a pedestrian so that the risk of injury to the pedestrian is reduced.