M-Profile Reinforcing Element for Vehicle Door Side Impact

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Solution Overview

Problem

Existing vehicle door designs lack effective energy absorption and intrusion reduction in side impact tests, particularly in the 'side pole test' and 'FMVSS214S test', where the depth of penetration into the vehicle door is not adequately managed.

Innovation Solution

A crash-absorbing reinforcing element with an M-profile is integrated into the lower portion of the vehicle door, featuring side walls with angled flanges and tabs for enhanced force absorption, and a V-shaped profile to distribute load and reduce intrusion, attached to the inner door panel for increased resistance and energy degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a reinforcing element is added to the vehicle door to increase energy absorption and reduce intrusion, then safety performance is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvesafety performanceVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The reinforcing element is divided into multiple functional segments: side walls for force distribution, an M-profile for energy absorption, flanges for attachment, and tabs for additional fastening. This segmentation allows each component to perform its specific function efficiently while maintaining overall structural integrity during side impact collisions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcing element combines different geometric profiles (side walls, M-profile, flanges, tabs) into a single integrated component made of energy-absorbing material. This composite structure provides both strength and controlled deformation characteristics, achieving enhanced safety performance without requiring multiple separate parts.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a reinforcing element with complex profile is used to effectively absorb energy and reduce intrusion, then safety performance is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidmanufacturing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The M-profile geometry is specifically designed with optimized parameters for energy absorption. The profile shape, wall thickness, and dimensional ratios are tuned to achieve controlled deformation characteristics during impact, allowing the component to absorb energy effectively while being manufacturable with standard precision tolerances.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The reinforcing element is pre-formed with the complete M-profile geometry including side walls, flanges, and tabs before installation. This preliminary shaping ensures that the energy-absorbing characteristics are built into the component itself, eliminating the need for complex assembly operations or post-installation adjustments that would require high precision.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If multiple fastening methods (flanges and tabs) are used to secure the reinforcing element, then structural stability is improved, but ease of manufacture decreases

Engineering Contradiction:

Improvestructural stabilityVSAvoidease of manufacture

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The flanges and tabs are integrally formed as part of the same reinforcing element component. This merging of fastening functions into a single piece eliminates the need for separate fastening components and reduces assembly steps, improving ease of manufacture while maintaining structural stability through multiple attachment points.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcing element is designed to be self-fastening through its integrated flanges and tabs that directly attach to the door structure. This self-service fastening system eliminates the need for additional fasteners or complex assembly operations, making the manufacturing process simpler while ensuring stable structural attachment.

Inventive Principle:

Principle #25Self-service

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 M-profile reinforcing element significantly enhances energy absorption and reduces overall intrusion during side impact tests by distributing forces and maintaining a constant load level through deformation, effectively managing pressure and torsion forces.

Implementation Method 1

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Implementation Method 2

effectively managing pressure and torsion forces

Methodology Applied

Scientific EffectForce resistance: Mechanical Force

Data Source

PatentUS11370278B2Motor vehicle

Publication Date: 2022.06.28 BAYERISCHE MOTOREN WERKE AG

AI summary

A motor vehicle with at least one vehicle door includes a reinforcement component arranged in the lower section of the door body of the vehicle door. The reinforcement component is an open profile with lateral walls and an M-profile formed thereon which extend in the vehicle transverse direction in order to absorb forces acting in the vehicle transverse direction in the event of a load.