Passive Knee Bolster with Integrated Brackets and Energy Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional passive bolster systems in vehicles are complex, expensive, and produce non-optimal load-deflection profiles with excessive displacement and peak loads, failing to effectively absorb energy during crashes while maintaining appearance characteristics.
Innovation Solution
A bolster assembly with integral brackets and energy-absorbing elements, where paired brackets are aligned with vehicle frame structures, allowing controlled deformation to absorb energy and reduce displacement, eliminating the need for a metal backplate and separate brackets, and achieving a Class "A" surface through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional passive bolster systems use injection molded parts with wall structures of 3 mm or less to avoid warping and shrinkage issues, then appearance characteristics are improved, but the overall strength of the bolster system is limited
Solution Approach 1:
The patent merges the bolster component with the bracket structure into a single integrated injection-molded piece. This eliminates the need for separate metal back-plates and brackets, while the integrated design allows for optimized wall thickness distribution that maintains both appearance quality and structural strength through strategic reinforcement in key areas.
Solution Approach 2:
The injection-molded bolster incorporates locally reinforced wall structures in specific areas where strength is needed for energy absorption, while maintaining thinner walls in areas where appearance is critical. This localized variation in wall thickness and reinforcement allows the single component to satisfy both appearance requirements and structural strength requirements.
2Strength
If conventional passive bolster systems use separately formed brackets and metal back-plates for strengthening, then overall strength is improved, but the structure becomes complicated and expensive to manufacture
Solution Approach 1:
The patent combines multiple separate components (bolster, brackets, and metal back-plate) into a single integrated injection-molded component. This merging eliminates the complexity of assembling multiple parts and reduces manufacturing steps while maintaining the necessary structural strength through intelligent design of the integrated structure.
Solution Approach 2:
The single injection-molded component performs multiple functions simultaneously: it provides the bolster surface for appearance, incorporates brackets for mounting and energy absorption, and includes reinforced structures for overall strength. This multi-functionality in a single component eliminates the need for separate specialized parts.
3Loss of energy
If conventional passive bolster systems use conventional bracket structures for energy absorption, then energy dissipation is achieved, but the load-deflection profile shows excessively long displacement and high peak loads
Solution Approach 1:
The patent modifies the structural parameters of the injection-molded bolster, including wall thickness distribution, reinforcement placement, and bracket geometry, to optimize the load-deflection profile. These parameter changes enable the structure to dissipate energy through a more favorable deformation pattern that reduces peak loads and shortens displacement distance during impact.
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 solution simplifies construction, reduces weight and cost, and achieves a controlled energy dissipation with reduced peak loads and consistent resistance, enhancing safety by optimizing load-deflection profiles within injury threshold limits.
Implementation Method 1
the energy absorbing elements deforming during the forward displacement to absorb energy
Data Source
AI summary
A bolster assembly for a vehicle is provided, the bolster assembly comprising a body, and a plurality of brackets provided on a front surface of the body, the plurality of brackets being arranged in paired sets. Also provided is a plurality of energy absorbing elements, wherein each of the plurality of energy absorbing elements is operably associated with a respective bracket, and where within each paired set of brackets, the energy absorbing elements are disposed in adjacent relationship separated by a gap. Each paired set of brackets is aligned with a frame structure provided in the vehicle, the frame structure having a width greater than the gap. Upon a crash event and forward displacement of the body, the paired sets of brackets engage the frame structure, the energy absorbing elements deforming during the forward displacement to absorb energy.