Door Trim Panel Pelvic Load Management

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Solution Overview

Problem

Conventional vehicle body structures and interior countermeasures to mitigate pelvic loads during side impacts increase vehicle cost and weight, necessitating alternative energy-absorbing solutions.

Innovation Solution

A door trim panel with a shaped pelvic load path energy-absorbing feature, defined by stepped surfaces, is integrated into the door panel to absorb side impact energy and reduce pelvic loads on occupants without additional structural countermeasures, using methods like molding, cutting, or sculpting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional body structure/body interior countermeasures are used to meet target pelvic load requirements, then pelvic load protection is improved, but vehicle cost and weight increase

Engineering Contradiction:

Improvepelvic load protectionVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The energy-absorbing feature is integrated directly into the door trim panel, merging the protective function with the existing trim component. This eliminates the need for separate body structure modifications or additional interior countermeasures, thereby reducing overall vehicle weight while maintaining pelvic load protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The door trim panel incorporates a shaped energy-absorbing feature with specific geometric parameters (concave surfaces, cavities, varying thickness regions) that enable controlled deformation during side impacts. By optimizing these dimensional parameters, the panel absorbs impact energy to reduce pelvic loads without requiring additional weight-bearing structures.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional body structure/body interior countermeasures are used to meet target pelvic load requirements, then pelvic load protection is improved, but vehicle cost increases

Engineering Contradiction:

Improvepelvic load protectionVSAvoidvehicle manufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The protective energy-absorbing feature is integrated into the door trim panel manufacturing process, combining multiple functions (aesthetic trim, impact energy absorption, pelvic load reduction) into a single component. This eliminates the need for separate parts and assembly steps, thereby reducing manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The door trim panel serves multiple functions: it provides the standard aesthetic and interior finishing role, while simultaneously acting as an energy-absorbing structure during side impacts. This multi-functionality eliminates the need for dedicated protective components, reducing overall vehicle cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of energy

If the door trim panel is made more collapsible to reduce pelvic loads, then energy absorption is improved, but structural strength may be compromised

Engineering Contradiction:

Improveimpact energy absorptionVSAvoiddoor trim panel strength

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The door trim panel features localized variations in structural properties, with specific regions (concave surfaces, cavities, thinner sections) designed to collapse during impact while other regions maintain sufficient strength for normal use. This local differentiation allows controlled energy absorption without compromising overall panel integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The door trim panel transitions from a static rigid structure to a dynamic energy-absorbing structure during side impacts. The shaped feature enables controlled deformation and collapse under impact loads, allowing the panel to adapt its structural response based on loading conditions - rigid during normal use, collapsible during impact.

Inventive Principle:

Principle #15Dynamics

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 effectively reduces pelvic loads on vehicle occupants during side impacts by enhancing the collapsibility of the door trim panel, thereby meeting target loading requirements without adding weight or cost to the vehicle.

Implementation Method 1

a shaped pelvic load path energy-absorbing feature disposed on a door panel-facing surface of the door trim panel. The shaped pelvic load path energy-absorbing feature may be defined by a plurality of stepped surfaces

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS10000112B2Pelvic load management using integrated collapsible features in door trim panel

Publication Date: 2018.06.19 FORD GLOBAL TECH LLC

AI summary

A door assembly for a vehicle includes a door panel and a door trim panel comprising a shaped pelvic load path energy-absorbing feature disposed on a door panel-facing surface of the door trim panel. The shaped pelvic load path energy-absorbing feature is defined by a plurality of stepped surfaces, which in turn may define as various cross-sectional shapes for the shaped pelvic load path energy-absorbing feature.