Vehicle Door Energy Absorber with Interference Fit Bracket
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Solution Overview
Problem
Vehicle door internal components, such as locking mechanisms and window guides, are prone to damage and dislocation during impacts due to the collapse of the door cavity, necessitating an effective energy absorption solution within the vehicle door.
Innovation Solution
The integration of an absorption member with a deformable material, such as expanded polypropylene foam, configured to receive a bracket in an interference fit, providing energy absorption and protection to the door's internal components without the need for mechanical fasteners or adhesives, and featuring stabilizers and a location element for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting methods (mechanical fasteners or adhesives) are used to secure the absorption member, then the connection strength is improved, but the device complexity and installation cost increase
Solution Approach 1:
The absorption member performs self-mounting by utilizing its own deformable body to create an interference fit with the bracket. The deformable material deforms during installation to accommodate the bracket, then rebounds to create a secure friction fit, eliminating the need for external fasteners or adhesives.
Solution Approach 2:
The deformable material changes its physical parameters (shape, volume, density) during installation and operation. The material deforms under compression during mounting to allow bracket insertion, then rebounds to create a tight interference fit, dynamically adjusting its properties to achieve both easy installation and strong connection.
2Ease of manufacture
If the absorption member uses a simple mounting structure, then the ease of manufacture is improved, but the reliability of securement may worsen
Solution Approach 1:
The deformable material's ability to change physical parameters provides both manufacturing simplicity and securement reliability. The material can be molded in a single piece without complex assembly, then uses its elastic rebound to create a reliable interference fit, achieving both goals through material property changes rather than complex structures.
Solution Approach 2:
The use of deformable materials (such as foam or elastomeric compounds) provides inherent damping and friction characteristics that enhance the reliability of the interference fit. These materials combine structural support with energy absorption and friction-based locking in a single composite component.
3Strength
If the absorption member requires additional connectors or fasteners, then the connection strength is improved, but the productivity and installation speed worsen
Solution Approach 1:
The absorption member is self-installing through its deformable body that automatically creates the securement connection. The installer simply positions the member and applies compression force, allowing the material to deform around the bracket and then rebound to lock in place, completing the installation in one continuous action without stopping to attach separate fasteners.
Solution Approach 2:
The invention extracts and eliminates the separate fastening components (screws, clips, adhesives) from the mounting system. The securing function is integrated directly into the absorption member's body through the deformable material's inherent elastic properties, removing unnecessary steps from the installation process.
4Ease of manufacture
If the absorption member uses deformable material without stabilizers, then the ease of manufacture is improved, but the stability and positioning accuracy worsen
Solution Approach 1:
The deformable body is segmented into functional zones: a main body for energy absorption, stabilizing protrusions or ribs for positioning and preventing rotation, and a mounting interface for bracket engagement. This segmentation allows each zone to perform its specific function while maintaining manufacturability as an integrated component.
Solution Approach 2:
Different regions of the deformable material have different local properties: the main body provides bulk energy absorption, while localized stabilizing features (protrusions, ribs, or asymmetric shapes) provide positioning stability. The local quality of these features ensures proper orientation and prevents rotation without requiring complex overall structures.
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 absorption member effectively absorbs impact energy, preventing collapse and damage to internal components, simplifying installation and reducing costs by eliminating the need for additional connectors, while ensuring consistent and secure placement.
Implementation Method 1
an absorption member that is configured for mounting proximate (e.g., near or adjacent to) a locking mechanism of a vehicle door including a window that is supported by a bracket during opening and closing. The absorption member has a body that includes a deformable material, which allows the absorption member to absorb energy from an impact with the vehicle door to thereby protect the locking mechanism
Implementation Method 2
The body includes an internal channel that is configured to receive the bracket, wherein the internal channel defines a first width, and the bracket defines a second width that is greater than the first width. Due to the larger width of the bracket, upon insertion of the bracket into the internal channel, the internal channel is expanded to create an interference fit with the bracket and thereby secure the absorption member to the bracket
Data Source
AI summary
A vehicle door is described, including: a bracket that is configured to support a window during opening and closing; a door locking mechanism that is positioned proximate (e.g., near or adjacent to) the bracket; and an absorption member that is configured and positioned to absorb energy from an impact with the vehicle door to thereby protect the door locking mechanism. The absorption member includes a body defining an internal channel that is configured to receive the bracket in an interference fit such that the absorption member is fixedly securable to the bracket.