Rear Header Intermediate Portion for Vehicle Collision Safety
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Solution Overview
Problem
In vehicles with a rear door opening, the collision load from rear-end collisions often causes significant deformation of the vehicle body due to the transmission of force through the hinge mounting portion, leading to potential interference with the door and increased deformation.
Innovation Solution
A vehicle body configuration featuring a rear header with an intermediate portion between the frame and the hinge mounting portion, where the intermediate portion has lower flexural strength than the frame, allowing it to deform or fracture and absorb the collision load, thereby reducing the transmission of force to the vehicle body and minimizing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the hinge mounting portion is located rearward of the frame to close the opening, then the door can effectively close the opening, but the collision load is transmitted from the door to the vehicle body through the hinge mounting portion causing significant deformation of the vehicle body
Solution Approach 1:
The rear header is segmented into three distinct portions: a front portion connected to the frame, an intermediate portion with lower flexural strength, and a rear portion forming the hinge mounting portion. This segmentation allows the intermediate portion to act as a sacrificial element that deforms during collision to absorb energy, while the front and rear portions maintain structural integrity for normal door operation and overall frame strength.
Solution Approach 2:
The intermediate portion of the rear header serves as an intermediary element between the frame and the hinge mounting portion. During rear-end collision, this intermediate portion deforms or fractures to interrupt the transmission path of collision load from the door to the vehicle body frame, thereby protecting the overall structural integrity while still allowing the door to function normally when closed.
2Strength
If the intermediate portion of the rear header has lower flexural strength to absorb collision load, then vehicle body deformation is reduced, but the intermediate portion deforms or fractures during collision
Solution Approach 1:
The intermediate portion is deliberately designed with lower flexural strength so that it becomes the preferred location for deformation during collision. By converting the potential harm of structural failure to a controlled benefit, the intermediate portion absorbs collision energy through its deformation or fracture, protecting the more critical frame and vehicle body structures from damage.
Solution Approach 2:
Different portions of the rear header are assigned different flexural strengths to fulfill different functions. The front portion maintains high strength for frame connection, the intermediate portion has lower strength for collision energy absorption, and the rear portion provides sufficient strength for hinge mounting. This local differentiation of material properties allows the structure to simultaneously achieve both strength and controlled deformation characteristics.
3Object-affected harmful factors
If the intermediate portion is located below the hinge mounting portion to move the hinge away from the opening during collision, then door interference with the vehicle body is prevented, but the hinge mounting portion must be positioned rearward of the frame
Solution Approach 1:
The hinge mounting portion is positioned in the rear portion of the vehicle body, separated from the frame in the front-rear direction, while the intermediate portion extends below the hinge mounting portion. This spatial arrangement in multiple dimensions allows the hinge to be positioned away from the opening to prevent door interference during collision, while maintaining a relatively simple overall structure through the extended rear header design.
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 effectively reduces vehicle body deformation during rear-end collisions by allowing the intermediate portion of the rear header to absorb the collision load, moving the hinge mounting portion away from the opening and minimizing interference, thus enhancing collision safety and reducing deformation.
Implementation Method 1
the intermediate portion of the rear header is likely to undergo flexural deformation when deformed or fractured by a collision load to the door
Implementation Method 2
the intermediate portion of the rear header is relatively easily deformed or fractured. Thus, the collision load is less likely to be transmitted to the vehicle body
Data Source
AI summary
A vehicle may include: a vehicle body including an opening in a rear portion thereof; a door configured to close the opening; and a hinge swingably connecting the door to the vehicle body. The vehicle body may further include: a frame extending along an upper edge of the opening in a left-right direction of the vehicle; and a rear header located between the frame and the upper edge of the opening. The rear header may include: a hinge mounting portion to which the hinge is attached; and an intermediate portion located between the hinge mounting portion and the frame. The intermediate portion may be located below the hinge mounting portion in an up-down direction of the vehicle. The intermediate portion of the rear header may have a lower flexural strength than the frame against a collision load that acts in a front-rear direction of the vehicle.