Energy-Absorbing Knee Bolter Frame With Deformation Segments
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Solution Overview
Problem
There is a need for an improved vehicle knee bolster device that can effectively absorb energy during collisions while minimizing weight and size, while also being cost-efficient and capable of large-scale manufacturing.
Innovation Solution
The energy-absorbing knee bolster frame features a longitudinal knee contact member with two transverse bracket members, each comprising deformation segments with openings and pre-bent frame regions, allowing for controlled plastic deformation in the transverse direction to absorb energy efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If energy-absorbing material elements are added to the knee bolster device, then energy absorption capability is improved, but device complexity increases
Solution Approach 1:
The transverse bracket members are divided into multiple deformation segments along their longitudinal extent. Each segment can independently deform to absorb energy, creating a segmented energy absorption system that is more efficient than a single monolithic structure while maintaining manufacturing simplicity through modular design
Solution Approach 2:
The frame regions are pre-bent during manufacturing to predetermined angles (e.g., 45 degrees) to prepare them for controlled deformation during collision. This preliminary shaping ensures that the energy absorption mechanism activates immediately and predictably upon impact, eliminating the need for complex real-time control systems
2Loss of energy
If the knee bolster device is designed to absorb more energy, then occupant protection is improved, but weight of the device increases
Solution Approach 1:
The energy absorption characteristics are adjusted by modifying geometric parameters of the deformation segments, such as the angle of pre-bending, the dimensions of openings, and the thickness of frame regions. These parameter changes allow tuning of energy absorption capacity without changing the fundamental structure or material, avoiding weight increase
Solution Approach 2:
The bracket members have non-uniform cross-sections with varying thicknesses and geometries along their length. Regions requiring higher energy absorption have thicker or more complex deformation segments, while other regions are optimized for weight reduction. This localized optimization achieves high energy absorption where needed without uniformly increasing device weight
3Loss of energy
If deformation segments with openings and pre-bent regions are used, then energy absorption efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The formation of openings and pre-bent frame regions is integrated into a single stamping or forming operation. The mold or die is designed to simultaneously create both features in one step, eliminating the need for separate punching, bending, or welding operations. This merging of operations maintains ease of manufacture while achieving high energy absorption efficiency
Solution Approach 2:
The same forming tooling and manufacturing processes used for other vehicle body components can be applied to create the deformation segments. The stamping dies and forming equipment are versatile enough to handle the complex geometries required, allowing existing manufacturing infrastructure to produce these advanced energy-absorbing structures without requiring entirely new production lines
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 configuration enables efficient energy absorption during collisions, is cost-effective to manufacture, and can be adjusted for different deformation levels to accommodate various vehicle requirements and occupant sizes, providing enhanced protection without the need for complex constructions.
Implementation Method 1
each one of the deformation segments includes an opening and a corresponding pre-bent frame region arranged along a transverse length of the opening for initiating a deformation of a corresponding deformation segment in a transverse direction when said knee bolster frame is subjected to a force from the knee of the occupant upon a collision
Data Source
AI summary
An energy-absorbing knee bolster frame (10) for a vehicle (1) comprises a longitudinal knee contact member (20), a first energy-absorbing transverse bracket member (30) and a second energy-absorbing transverse bracket member (40). The first energy-absorbing transverse bracket member (30) and the second energy-absorbing transverse bracket member (40) extend in a transverse direction (Y) and are spaced apart on the longitudinal knee contact member (20). The longitudinal knee contact member (20) has a knee contact surface (22) for receiving a part of a knee (80) of an occupant (P) upon a collision. The first energy-absorbing transverse bracket member (30) has a cross section defining an open profile, and is adapted at one end (32) to engage with a vehicle interior component (100), and includes a plurality of first deformation segments (34A-N) configured for absorbing energy generated by a knee impact.