Instrument Panel Projections for Occupant Impact Energy Absorption

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Solution Overview

Problem

Current vehicle instrument panel components, such as glove boxes and knee bolsters, face design challenges in absorbing energy from occupants of varying sizes during impacts, as standardized tests often favor either stiff or flexible components, which may not adequately absorb energy from both large and small occupants.

Innovation Solution

The design incorporates an energy absorbing element with first and second projections of different lengths and materials, supported by a wall, which can deform to absorb a range of impact forces from variously sized occupants, allowing for effective energy absorption regardless of the occupant's size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a stiff component is used to absorb energy from large occupants, then energy absorption from large occupants is improved, but energy absorption from small occupants deteriorates

Engineering Contradiction:

Improvecomponent stiffnessVSAvoidadaptability to varying occupant sizes

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The energy absorbing component is divided into multiple segments or zones with different stiffness characteristics. The component includes a first portion and a second portion, where the first portion is more compliant and the second portion is stiffer, allowing different segments to engage depending on the impact force magnitude.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component are assigned different mechanical properties. The component incorporates zones of varying stiffness where certain areas are designed to be more compliant while others remain stiffer, enabling localized energy absorption tailored to different impact scenarios.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If a flexible component is used to absorb energy from small occupants, then energy absorption from small occupants is improved, but energy absorption from large occupants deteriorates

Engineering Contradiction:

Improveadaptability to varying occupant sizesVSAvoidcomponent stiffness

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The component transitions from a static structure to a dynamic system where the effective stiffness changes based on the applied load. Under small impacts, the component remains flexible and compliant, while under large impacts, it engages stiffer structural elements to provide adequate energy absorption.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The component utilizes composite construction combining materials or structures with different mechanical properties. This may include layered structures, hybrid materials, or composite geometries that exhibit different effective stiffness depending on the deformation mode and magnitude of applied force.

Inventive Principle:

Principle #40Composite materials

3Strength

If a stiff component is used, then protection against bottoming out is improved, but initial impact energy absorption deteriorates

Engineering Contradiction:

Improvecomponent stiffnessVSAvoidenergy absorption during initial impact

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The component incorporates pre-designed compliant zones or cushioning elements that engage first during impact to absorb initial energy. These softer zones are positioned to deform before the stiffer structural portions, providing progressive energy absorption that prevents bottoming out while capturing initial impact energy.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The component is designed to maintain continuous energy absorption capability throughout the impact event. The transition from compliant zones to stiffer structural elements occurs smoothly, ensuring that energy absorption continues effectively from initial contact through to the end of the impact, without interruption or bottoming out.

Inventive Principle:

Principle #20Continuity of useful action

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

This solution enables the instrument panel components to absorb energy from both small and large occupants by utilizing projections that deform in combination, ensuring effective energy dissipation across a spectrum of occupant sizes, thereby enhancing safety in vehicle impacts.

Implementation Method 1

The first projection (16) and the second projection (18) may alone or in combination absorb a range of impact forces

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

the first projection (16) and the second projection (18) may alone or in combination absorb a range of impact forces

Methodology Applied

Scientific EffectEnergy absorption: Damping

Data Source

PatentUS10583795B2Energy absorbing instrument panel component

Publication Date: 2020.03.10 FORD GLOBAL TECH LLC

AI summary

An instrument panel component includes a wall, a first projection, and a second projection. The wall is configured to be supported by the instrument panel. The first and second projections are supported by the wall and extend in a common direction away from the wall. The length of the first projection is different than the length of the second projection and both projections are of a different material than the material of the wall.