Vehicle Door Impact Bar U-Shaped Front End
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Solution Overview
Problem
Conventional vehicle door structures require additional impact bars to effectively transmit vehicle-head-on collision loads and provide adequate resistance against vehicle side collisions, leading to increased complexity and potential weaknesses in collision load distribution.
Innovation Solution
A vehicle door structure featuring a single impact bar with a U-shaped front end and specific joint configurations that enhance contact area and load transmission, allowing for effective rearward transmission of head-on collision loads and improved resistance against side collisions through strategically positioned first and second joint portions and a W-shaped cross-section for increased rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional impact bar with a flat front end is used, then the door rigidity in vehicle side collision is improved, but the transmission performance of vehicle-head-on collision load to the impact bar is low
Solution Approach 1:
The impact bar front end is designed with a U-shaped portion having curved surfaces instead of a flat end. The U-shaped configuration with vertical and lateral face portions creates optimized contact geometry that simultaneously improves side collision rigidity and head-on collision load transmission, eliminating the need for additional impact bars
2Reliability
If another impact bar is added to improve head-on collision load transmission, then the load transmission performance is improved, but the device complexity increases
Solution Approach 1:
The impact bar is designed with a U-shaped front end configuration that enables it to perform multiple functions: it effectively transmits vehicle-head-on collision loads through its vertical face portion while simultaneously providing adequate resistance against vehicle side collisions through its lateral face portions, eliminating the need for separate impact bars for different collision types
Solution Approach 2:
The invention combines the functions of multiple impact bars into a single integrated impact bar structure. The U-shaped front end integrates the load transmission capabilities needed for both head-on and side collisions, simplifying the overall door structure while maintaining collision protection effectiveness
3Ease of manufacture
If the joint face is arranged in parallel to the collision load input direction, then the manufacturing is simplified, but the transmission performance of collision load is low
Solution Approach 1:
The U-shaped front end configuration with its curved geometry optimizes the joint face arrangement to be angled relative to the collision load input direction rather than parallel, improving load transmission performance while remaining manufacturable through standard forming processes
Data Source
AI summary
An impact bar includes a U-shaped portion formed by a vertical face portion and upper-and-lower lateral face portions at its front end. The impact bar further includes upper-and-lower outer face portions. A pair of first joint portions which are formed so as to extend upward and downward from respective front ends of the upper-and-lower lateral face portions are joined to a lateral face portion of a door inner panel. A pair of second joint portions which are formed so as to extend forward from respective front ends of the upper-and-lower outer face portions are joined to a longitudinal face portion of the door inner panel.