Vehicle Headlight Sheet Metal Crash Protection
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Solution Overview
Problem
Existing headlight protection systems fail to prevent damage to the headlight and its plastic lens during crashes, particularly due to shearing off of the thrust element by sharp-edged components like the mounting flange on the fender, leading to unusability even with repair sets.
Innovation Solution
A sheet metal element with a sliding surface is integrated onto the headlight housing to prevent damage by forming a ramp-like molded thrust feature, allowing parts of the vehicle body to slide without interlocking, and featuring a clip section for secure fastening without additional fasteners, using spring steel for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a molded thrust feature is used to guide the headlight in a predetermined direction during a crash, then the headlight is systematically guided past collision points and can remain undamaged, but the thrust element may be sheared off by sharp-edged components like the mounting flange on the fender
Solution Approach 1:
A sheet metal element is introduced as an intermediary component between the molded thrust feature and the mounting flange. This intermediate element absorbs the shearing forces from sharp-edged components, preventing direct contact between the thrust element and the mounting flange, thereby eliminating the shearing problem while maintaining the crash guidance function
Solution Approach 2:
The protection system is divided into separate functional components: the molded thrust feature provides directional guidance, while the separate sheet metal element provides shear protection. This segmentation allows each component to optimize its specific function without compromising the other
2Reliability
If the headlight housing is reinforced to prevent damage from contact with the vehicle body, then damage protection is improved, but the complexity of the headlight assembly increases
Solution Approach 1:
A thin sheet metal element is applied to the housing surface to provide protection. This thin film approach offers adequate crash protection while minimizing the increase in assembly complexity and maintaining a relatively simple structural configuration
Data Source
AI summary
An arrangement of a headlight on a vehicle with protection from damage for the event of a crash, wherein the headlight has a housing with which it is attached to a body of the vehicle by at least one molded attachment feature. A sheet metal element is designed such that it forms a sliding surface for the body in the event of a crash and is arranged on the housing of the headlight.