Grille Extensions Integrated with Energy Absorber for Impact Distribution
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Solution Overview
Problem
The grille in a vehicle's front fascia is prone to damage during frontal collisions, as it typically absorbs more impact than the bumper, leading to potential breakdown and damage to internal components.
Innovation Solution
A grille with integrated extensions that overlap with an energy management system, designed to mitigate impact forces by engaging with an energy absorber and beam, minimizing damage to the engine compartment and distributing impact effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the grille is made stronger to resist impact, then the reliability of the grille is improved, but the weight of the grille increases
Solution Approach 1:
The grille is divided into multiple sections including a upper grille assembly, lower grille assembly, and energy absorber assembly. These segmented components work together to distribute impact forces, allowing each section to be optimized for its specific function rather than requiring the entire grille to be uniformly strong and heavy.
Solution Approach 2:
The grille assembly combines different materials with complementary properties: the upper and lower grille assemblies use materials optimized for aesthetics and light-duty protection, while the energy absorber assembly uses materials specifically designed for impact energy absorption. This composite approach provides the necessary reliability without uniformly increasing the weight of the entire grille.
2Ease of manufacture
If the grille structure is simplified for easier manufacture, then the ease of manufacture is improved, but the ability to absorb impact energy deteriorates
Solution Approach 1:
By segmenting the grille into modular assemblies (upper grille, lower grille, energy absorber), each component can be manufactured using standardized processes and then assembled together. This segmentation maintains manufacturing simplicity while allowing the energy absorber assembly to be specifically designed and optimized for impact energy absorption.
Solution Approach 2:
The energy absorber assembly acts as an intermediary component between the grille assemblies and the vehicle's impact absorber. This intermediary structure is specifically designed to absorb and dissipate impact energy through controlled deformation, protecting the engine compartment while maintaining a relatively simple overall manufacturing process.
3Reliability
If extensions are added to the grille to engage with the energy absorber, then the impact mitigation is improved, but the device complexity increases
Solution Approach 1:
The extensions are integrated directly into the lower grille assembly, merging the structural support function with the impact engagement function. This consolidation allows the extensions to serve dual purposes: providing structural support for the lower grille while simultaneously engaging with the energy absorber assembly to mitigate impact forces, thereby reducing overall device complexity.
Solution Approach 2:
The extensions of the lower grille assembly perform multiple functions: they provide structural support for the lower grille, serve as attachment points for the energy absorber assembly, and act as force transmission elements during impact. This multi-functionality reduces the need for separate components, thereby managing device complexity while improving impact mitigation.
4Reliability
If the extensions are made larger to better integrate with the energy absorber, then the impact force distribution is improved, but the volume of the grille increases
Solution Approach 1:
The extensions are designed with localized dimensions optimized for their specific function of engaging with the energy absorber assembly. Rather than uniformly increasing the size of the entire grille, the extensions are strategically sized and shaped only where needed to achieve effective impact force distribution, thereby minimizing the overall volume increase of the grille assembly.
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 integrated energy management system reduces damage to internal components and the grille itself during low-speed collisions by distributing and absorbing impact forces, enhancing the vehicle's robustness and simplifying manufacturing.
Implementation Method 1
the energy absorber is configured to mitigate a force of an impact from being transmitted through the grille into an engine compartment
Implementation Method 2
the extensions of the grille are sized and shaped to integrate with the energy absorber and beam such that in the event of a low speed crash or collision, the extensions of the grill mitigate the damage to components in the engine compartment
Data Source
AI summary
A system includes a vehicle body which further includes a front beam. The system also includes an energy absorber that may be coupled to the front-end beam of the vehicle body. In an example, the energy absorber includes a first edge and a second edge that may be opposite to the first edge along a first direction. The energy absorber also includes a first exterior surface that extends between the first edge and the second edges of the energy absorber. Further, the first exterior surface includes a plurality of openings therein. The system also includes a grille having a first edge and a second edge which may be opposite to the first edge of the grille. In one example, the second edge of the grille may be coupled to the first edge of the energy absorber. The grille includes a plurality of extensions that may extend from the second edge in such a way that the plurality of extensions are positioned in the plurality of openings in the energy absorber.