Segmented Vehicle Bulkhead for Steering Column Protection
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Solution Overview
Problem
In frontal collisions with side offset, the engine bay deformation leads to rotation of the drive train, causing force transfer into the bulkhead and steering column, potentially separating it from the vehicle interior, increasing the risk of injury to occupants.
Innovation Solution
A structural component comprising elongate longitudinal and transverse elements connected by a structural support web, which is designed to absorb and redirect forces, reducing the drive train's movement towards the steering column and preventing excessive bulkhead deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bulkhead is made of metal plate of specific thickness to resist drive train rotation forces, then the strength and rigidity of the bulkhead is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The bulkhead is divided into multiple longitudinal bulkhead sections instead of using a single solid metal plate. This segmentation allows each section to be independently managed and connected via hinge joints, reducing the overall complexity while maintaining the required strength through distributed structural support.
Solution Approach 2:
The bulkhead structure transitions from a rigid solid plate to a hinged segmented structure, changing the mechanical parameters from fixed rigidity to controlled flexibility. This allows the bulkhead to adapt to drive train rotation forces through controlled movement rather than relying solely on increased material thickness.
2Reliability
If the bulkhead is made thicker to prevent separation during collision, then the reliability is improved, but the weight of the stationary object increases
Solution Approach 1:
By segmenting the bulkhead into multiple sections connected by hinges, the structure achieves improved reliability in preventing separation through distributed connection points, while avoiding the weight penalty of a single thick plate by using thinner, multi-section construction.
Solution Approach 2:
The bulkhead sections are merged with the longitudinal members of the vehicle superstructure through hinge connections, creating a combined structural system that enhances separation prevention reliability while distributing the weight across multiple lighter components rather than concentrating it in a single heavy plate.
3Loss of energy
If capture devices are added to the drive train to engage with counterpieces during collision, then the energy dissipation capability is improved, but the device complexity increases
Solution Approach 1:
The longitudinal members of the vehicle superstructure serve multiple functions: they provide structural support for the vehicle body and simultaneously act as counterpieces for the capture devices during collision. This multi-functionality improves energy dissipation capability without adding separate dedicated components, thereby avoiding increased device complexity.
4Loss of energy
If longitudinal members are deformed or crumpled to engage with capture devices, then the energy absorption is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The longitudinal members are designed with controlled deformation zones that dynamically crumple during collision to engage capture devices. This dynamic deformation capability allows energy absorption through predictable structural collapse, while the deformation zones are pre-designed with specific geometries that reduce manufacturing precision requirements compared to rigid components.
Data Source
AI summary
Systems are provided for a structural element. In one example, a system comprises a structural element arranged between a steering column and a front bumper, wherein the structural element at least partially surrounds the steering column.