Vehicle Door Panel Energy Absorption Arrays
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Solution Overview
Problem
Current vehicle door panel designs fail to effectively manage the reaction force on occupants during a side-impact collision, often exceeding the safe limit of 6 kN over a 55 mm displacement, due to variations in impact severity and occupant mass.
Innovation Solution
A panel assembly with a trim panel and multiple energy-absorbing structures arranged in arrays, featuring varying ranges of energy absorption, including weakening and stiffening structures, to distribute force and maintain occupant safety across different impact areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single uniform energy absorbing structure is used across the entire trim panel, then the device complexity is reduced, but the ability to effectively manage reaction force across different impact areas and occupant masses deteriorates
Solution Approach 1:
The energy absorbing structure is divided into multiple discrete structures arranged in arrays across the trim panel. Each structure can be independently sized and configured with specific weakening or stiffening features, allowing tailored energy absorption characteristics for different impact locations while maintaining manageable complexity through modular design
Solution Approach 2:
Different portions of the trim panel are equipped with energy absorbing structures having different energy absorption ranges based on local requirements. Front impact areas may use structures with lower energy absorption ranges while rear or side impact areas use structures with higher ranges, optimizing protection for each specific zone
2Reliability
If energy absorbing structures with high energy absorption range are used throughout, then occupant protection is improved, but the force exerted on lighter occupants exceeds safe limits
Solution Approach 1:
Energy absorbing structures are configured with different energy absorption ranges based on their location and expected impact scenarios. Structures in areas likely to be struck by lighter occupants or in less severe impact zones are designed with lower energy absorption ranges to prevent excessive force, while structures in areas for heavier occupants or severe impacts use higher ranges
Solution Approach 2:
The energy absorption range of each structure is adjusted as a design parameter based on location, occupant mass considerations, and impact severity expectations. This allows the system to optimize the balance between protecting all occupants while preventing excessive force on lighter occupants
3Reliability
If energy absorbing structures are made more compliant to reduce reaction force, then occupant safety is improved, but the structural strength and stability of the door panel deteriorates
Solution Approach 1:
The door panel structure is segmented into rigid load-bearing frames and compliant energy-absorbing elements. The energy absorbing structures are discrete components that can deform to protect occupants while the main door frame maintains its structural integrity and strength
Solution Approach 2:
Different regions of the door panel have different stiffness characteristics. Areas with energy absorbing structures have localized compliance for occupant protection, while other structural areas maintain high strength and rigidity for overall door integrity and load bearing
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 ensures that the force experienced by occupants during a side-impact collision is kept below 6 kN over a 55 mm displacement, effectively decelerating the occupant while accommodating different occupant masses and impact zones.
Implementation Method 1
The foam pads or brackets exert a reaction force through a range of displacement during a collision
Implementation Method 2
The foam pads or brackets are capable of absorbing significant amounts energy at a force-deflection rate safe for occupants
Data Source
AI summary
A panel assembly for a vehicle door has trim panel coupled to the door and having at least a portion thereof that is spaced from the door's outboard frame. The trim panel has first and second impact areas. A plurality of energy absorbing structures is arranged in an array between the trim panel and the door frame. Each energy absorbing structure has a base end, an outboard end, and at least one sidewall. The base end is adjacent to the trim panel. The outboard end engages the vehicle door. The sidewall may include either or both of a reinforcement structure and a weakening structure that are sized and configured so that the energy absorbing structure has a predetermined range of energy absorption against the occupant during a side-impact collision. Energy absorbing structures having different energy absorption characteristics are located adjacent to the first and second impact areas.