Vehicle Door Shut Face Collapsible Surface Design
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Solution Overview
Problem
Existing vehicle door designs are ineffective in minimizing thoracic or rib deflection during side impact events, particularly in longitudinal intrusions, and are often costly and heavy.
Innovation Solution
A door assembly with a collapsible inner surface featuring alternating raised and recessed areas on the shut face, which can be made from a hollow shell or foamed polymer, allowing for controlled collapse and reduced displacement of the thoracic region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional solid door shut face structures are used, then structural strength is maintained, but thoracic displacement during side impact events increases
Solution Approach 1:
The shut face is constructed with a honeycomb core structure that provides controlled collapse during side impact events. The porous honeycomb configuration allows the structure to deform in a predictable manner, absorbing impact energy while limiting thoracic displacement, rather than maintaining rigid solid construction that would transmit excessive force to occupants.
Solution Approach 2:
The door assembly utilizes a composite construction combining an outer skin, honeycomb core, and inner skin. This composite structure integrates materials with different properties to achieve both energy absorption capabilities and structural integrity, allowing the shut face to collapse controllably while maintaining overall door strength.
2Object-affected harmful factors
If door intrusion guard beams and structural upgrades are added, then side impact protection is improved, but manufacturing cost and weight increase
Solution Approach 1:
The shut face itself is designed to provide side impact protection by integrating the protective function directly into the door panel structure. This eliminates the need for separate door intrusion guard beams and additional structural upgrades, reducing device complexity and manufacturing cost while maintaining effective thoracic displacement control.
Solution Approach 2:
The shut face serves multiple functions: it provides the closed surface of the door, enables controlled collapse for energy absorption, and protects occupants during side impact events. This multi-functionality replaces the need for separate protective components, reducing overall device complexity.
3Object-affected harmful factors
If heavier structural upgrades are implemented, then thoracic displacement is reduced, but vehicle weight increases
Solution Approach 1:
The honeycomb core structure provides high strength-to-weight ratio, enabling effective energy absorption and thoracic displacement control without adding excessive weight. The porous configuration allows material to be distributed optimally to provide protection where needed while minimizing overall mass compared to solid structural upgrades.
Solution Approach 2:
The composite construction with outer skin, honeycomb core, and inner skin creates a lightweight yet effective protective structure. This composite approach achieves superior strength and energy absorption characteristics without the weight penalty of traditional heavy-duty structural upgrades.
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 engineered surface effectively reduces thoracic displacement during side impacts, maintaining low manufacturing costs and avoiding warping, while providing predictable collapse behavior and improved protection.
Implementation Method 1
The side impact event imposes severe loading on the structural members of the body... efforts have been made with varying degrees of success to reduce the displacement of the thoracic region of the occupant
Implementation Method 2
some vehicle door constructions may include a door intrusion guard beam, side bolsters of foam or honeycomb construction
Data Source
AI summary
A door assembly for an automotive vehicle that reduces or eliminates thoracic or rib deflection in a side impact event is disclosed. The door assembly of the disclosed invention includes an inner door structure, an interior trim panel attached to the door structure and a shut face. The inner surface of the shut face includes a collapsible surface having a plurality of alternating raised areas and recessed areas formed thereon. The raised areas and recessed areas extend between one side of the door assembly and the other side of the door assembly. The shut face may be composed of beads, a foamed polymer or a solid polymer. In addition, the engineered surface may also be formed on the inner side of the face of one of the pillars. This configuration may be used in conjunction with a door shut face having an engineered surface or may be used independently.