Integrated Knee Bolster Device for Vehicle Safety
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Solution Overview
Problem
Existing knee bolster devices in vehicles are inadequate in minimizing injury to seat occupants during collisions, as the plastic outer panels can create sharp edges upon breaking and the steel inner panels impede sufficient deformation of shock absorption members, leading to insufficient protection for the knees.
Innovation Solution
An integrated knee bolster device featuring a shock absorption foam member supported by a cowl cross bar and a lower-body-penetration-restriction support bracket, along with a composite-material sheet for reinforcing the lower crash pad panel, to restrict knee penetration depth and enhance energy absorption during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic outer panel is used in the knee bolster device, then the device can be lightweight and cost-effective, but the panel creates sharp edges upon breaking that may inflict injury on the knees
Solution Approach 1:
The patent employs composite materials by integrating a foam member (soft, energy-absorbing material) with a support bracket (rigid structural material). This combination allows the outer panel to be made of lighter materials while the foam interior absorbs impact energy and prevents sharp edge formation, thus reducing injury risk while maintaining structural integrity.
Solution Approach 2:
The patent changes the physical parameters of the knee bolster by introducing a foam member with specific density and elasticity characteristics. The foam member's cellular structure allows it to deform under impact, absorbing energy and preventing the formation of sharp edges, thereby transforming the harmful breaking characteristic into a beneficial energy-absorbing mechanism.
2Strength
If a steel inner panel is used in the knee bolster device, then structural strength is improved, but the panel impedes sufficient deformation of the shock absorption member
Solution Approach 1:
The patent applies local quality by using a support bracket with strategically designed reinforcement portions rather than a complete steel inner panel. The reinforcement portions are localized to areas requiring structural support, while other areas allow the foam member to deform freely, thus maintaining strength where needed without impeding shock absorption elsewhere.
Solution Approach 2:
The support bracket is segmented into multiple portions including reinforcement portions and connection portions, allowing different sections to perform different functions. The reinforcement portions provide localized strength, while the overall structure permits sufficient deformation of the foam member, resolving the contradiction between strength and deformation capability.
3Ease of manufacture
If a conventional knee bolster structure with separate outer panel, inner panel, and shock absorption member is used, then assembly flexibility is improved, but the device complexity increases and production cost rises
Solution Approach 1:
The patent merges the outer panel, inner panel, and shock absorption member into an integrated knee bolster device. The support bracket and foam member are combined as a unified structure, reducing the number of separate components while maintaining assembly flexibility. This integration simplifies the device structure and reduces production complexity without sacrificing manufacturability.
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 knee bolster device effectively reduces knee penetration depth, minimizes injury to seat occupants, and enhances safety performance by optimizing shock absorption and load distribution, while also simplifying the structure and reducing weight and production costs.
Implementation Method 1
a shock absorption foam member installed to be supported by a cowl cross bar disposed behind a lower crash pad panel with which knees of a seat occupant collide when a vehicle collision occurs
Data Source
AI summary
An integrated knee bolster device for a vehicle is configured to restrict the depth of penetration of the knees of a seat occupant which strike a lower crash pad panel when a vehicle collision occurs, thus minimizing injury to the seat occupant, and enhancing safety performance for the seat occupant.