Vehicle Fender Attachment Bracket with Deformation Bends

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Solution Overview

Problem

Current fender structure assemblies for vehicles are inadequate in absorbing impact energy during pedestrian head impacts, leading to higher head injury values and unsatisfactory safety performance in crash testing.

Innovation Solution

The proposed fender structure assembly incorporates an attachment bracket with a top portion connected to the fender and two vertical legs that extend downwardly from the side structural member, featuring bends and central openings along their lengths to create predictable deformation patterns and absorb impact energy upon collision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional rigid fender attachment brackets are used, then structural strength is maintained, but impact energy absorption is insufficient leading to higher head injury values

Engineering Contradiction:

Improvestructural strengthVSAvoidhead injury values

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The bracket's geometric parameters are changed by introducing bends and openings, transforming it from a rigid structure to one with controlled deformation characteristics. This allows the bracket to absorb impact energy through deformation while maintaining sufficient strength, thereby reducing head injury values without sacrificing structural integrity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bracket is segmented into multiple sections by introducing bends and openings along its length. These segments can deform independently during impact, creating a progressive deformation pattern that absorbs energy while maintaining overall structural strength

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the attachment bracket is made more rigid to maintain structural integrity, then manufacturing simplicity is maintained, but impact energy absorption capability is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidimpact energy absorption

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The bracket design modifies geometric parameters (adding bends and openings) rather than changing material properties or complex manufacturing processes. This approach maintains manufacturing simplicity while significantly improving impact energy absorption through controlled deformation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bracket effectively creates a composite structure by combining rigid sections (for strength) with flexible deformation zones (bends and openings). This composite approach enables both structural integrity and energy absorption without requiring complex manufacturing

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If the bracket structure is simplified for ease of manufacture, then production cost is reduced, but impact energy absorption and safety performance deteriorate

Engineering Contradiction:

Improveproduction simplicityVSAvoidsafety performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention achieves improved safety performance through geometric parameter changes (bends and openings) that can be integrated into standard manufacturing processes. This maintains production simplicity while creating controlled deformation patterns that enhance impact energy absorption and reduce head injury criteria

Inventive Principle:

Principle #35Parameter changes

4Strength

If the attachment bracket uses a solid continuous structure, then structural strength is maximized, but head deceleration during impact is excessive

Engineering Contradiction:

Improvestructural strengthVSAvoidhead deceleration

Core Design Contradiction:

StrengthVSSpeed

Solution Approach 1:

The continuous solid structure is segmented into multiple sections by introducing bends and openings. During impact, these segments deform progressively, extending the deformation distance and time, thereby reducing head deceleration while maintaining sufficient structural strength through the overall bracket configuration

Inventive Principle:

Principle #1Segmentation

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 attachment bracket design results in lower head decelerations and greater vertical displacement, reducing head injury criteria (HIC) values by 15% to 20% during pedestrian impact tests, enhancing vehicle safety performance.

Implementation Method 1

The first and second vertical legs buckle at each of their respective two or more openings upon an impact to the fender structure assembly

Methodology Applied

Scientific EffectBuckling: Deformation

Data Source

PatentUS8403391B2Fender structure assemblies for vehicles

Publication Date: 2013.03.26 TOYOTA MOTOR CO LTD

AI summary

An attachment bracket for mounting a fender of a vehicle to a side structural member includes a top portion that connects to the fender. A first vertical leg connects to the side structural member. The first vertical leg extends downwardly from an edge of the top portion. A second vertical leg connects to the side structural member. The second vertical leg extends downwardly from an opposite edge of the top portion. The first vertical leg includes a bend separating the first vertical leg into an upper portion and a lower portion. The first vertical leg has a central opening at the bend that is spaced vertically from the top portion and a bottom end of the first vertical leg.