Deformable Tab Mechanism for Vehicle Component Force Absorption
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Solution Overview
Problem
Existing vehicle components, such as headlights, may undesirably retract due to incidental forces like bumpy road surfaces rather than impact forces, potentially causing injury to pedestrians or malfunction, and there is a need for a system that distinguishes between these forces to ensure components remain stationary during normal operation while safely retracting during impacts.
Innovation Solution
A system comprising a mounting module, a component-support module, and a motion-guiding module with a deformable tab that resists motion towards the mounting module at forces below a predetermined level but deforms to allow retraction at higher forces, using magnets and friction to manage the component's position relative to the mounting module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the component-support module is allowed to move freely toward the mounting module, then the component can retract during impact forces, but the component will undesirably retract during normal operation due to incidental forces like bumpy road surfaces
Solution Approach 1:
The deformable tab transitions between two states: a first configuration that resists motion under normal forces, and a second configuration that allows motion under impact forces. This dynamic state change enables the system to adapt its mechanical properties based on the magnitude of applied force, resolving the contradiction between stability and safety.
Solution Approach 2:
The system changes the mechanical parameter of the deformable tab (its structural configuration) based on the applied force magnitude. Under normal operation, the tab maintains a rigid configuration that prevents movement. Under impact forces exceeding the threshold, the tab deforms to a different configuration that allows component retraction, thus changing the force resistance parameter dynamically.
2Reliability
If a deformable tab is used to prevent motion under normal forces, then component stability is improved, but the device complexity increases due to the additional motion-guiding mechanism
Solution Approach 1:
The deformable tab is designed to automatically respond to applied forces without requiring external control systems. It self-regulates the component's motion based on the force magnitude, eliminating the need for sensors, actuators, or control electronics. This self-service mechanism reduces overall system complexity despite the added structural element.
Solution Approach 2:
The deformable tab utilizes a flexible, thin-walled structure that can elastically deform under load. This flexible design allows the tab to transition between rigid and compliant states without complex mechanisms, using material flexibility to achieve the desired motion control function with minimal added complexity.
3Reliability
If the deformable tab is designed to deform at a predetermined force level, then impact forces can be absorbed safely, but the manufacturing precision requirements increase to ensure consistent force threshold
Solution Approach 1:
The motion-guiding module is segmented into multiple deformable tabs distributed around the component-support module. This segmentation allows the force absorption function to be distributed across multiple identical elements, reducing the precision requirement for each individual tab while maintaining overall system reliability through redundancy.
Solution Approach 2:
The deformable tab may utilize composite material construction that combines materials with different mechanical properties to achieve the desired force threshold. By using composite materials, the force absorption characteristics can be tuned through material selection rather than relying solely on precise geometric dimensions, thereby reducing manufacturing precision requirements.
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 system effectively prevents unnecessary retraction of vehicle components during normal operation while ensuring safe retraction during impact forces, enhancing pedestrian safety and component stability by distinguishing between incidental and impact-related forces.
Implementation Method 1
The motion-guiding module or the mounting module comprises a magnet configured to absorb an impact force via an attractive magnetic force between the magnet and the motion-guiding module or the mounting module
Implementation Method 2
in response to the deformable tab absorbing a force that is greater than the predetermined level, deform to a position that allows the component-support module to move toward the mounting module
Data Source
AI summary
An example apparatus includes (i) a mounting module configured to be coupled to a support frame of a vehicle, (ii) a component-support module configured to support a component of the vehicle, and (iii) a motion-guiding module coupled to the component-support module and the mounting module. The motion-guiding module is configured to guide motion of the component-support module toward the mounting module. The apparatus further includes (iv) a deformable tab coupled to the motion-guiding module. The deformable tab is configured to (a) in response to the deformable tab absorbing a force that is less than a predetermined level, resist motion of the component-support module toward the mounting module and (b) in response to the deformable tab absorbing a force that is greater than the predetermined level, deform to a position that allows the component-support module to move toward the mounting module in response to force applied to the component-support module.