Integrated Shotgun Rail Deflector for Offset Barrier Impact
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Solution Overview
Problem
Land vehicles face challenges in meeting the requirements of the small offset rigid barrier crash test while reducing weight and manufacturing costs, as existing structural rails are complex, costly, and compromise crashworthiness when subjected to lateral impacts.
Innovation Solution
A deflector system comprising a rail attached to the hinge pillar, frame, and sub-frame with a bulkhead at an oblique angle and a curved intermediate portion that distributes load through multiple longitudinal and lateral paths to deflect the vehicle during a small offset rigid barrier impact, reducing intrusion into the passenger compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-piece structural rails are used to provide crashworthiness, then strength is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple structural rail components into a single integrated deflector assembly that includes a bulkhead, longitudinal rail, and transverse rail formed as one piece. This merging eliminates the need for separate multi-piece construction while maintaining the structural integrity and crashworthiness required for small offset frontal impact protection.
Solution Approach 2:
The integrated deflector assembly serves multiple functions simultaneously: it provides structural support, distributes impact loads through multiple load paths, and protects the passenger compartment. The single component performs the roles of multiple separate rails would have played, reducing complexity while maintaining protective capabilities.
2Strength
If multi-piece structural rails with multiple welds are used, then strength is improved, but manufacturing cost increases due to weld quality control
Solution Approach 1:
By forming the deflector assembly as a single integrated component, the patent eliminates multiple weld joints that would require quality control monitoring. The unified structure removes the need for welding operations between separate rail pieces, thereby reducing manufacturing complexity and cost while maintaining structural integrity.
3Productivity
If vehicle weight is reduced to improve fuel efficiency, then productivity is improved, but crashworthiness deteriorates under small offset rigid barrier impact
Solution Approach 1:
The deflector assembly is designed with segmented load paths that distribute impact forces through multiple routes: a first load path through the bulkhead and longitudinal rail to the hinge pillar, and a second load path through the bulkhead and transverse rail to the opposite hinge pillar. This segmentation of force distribution allows the structure to maintain strength with reduced material usage, supporting weight reduction goals while preserving crashworthiness.
Solution Approach 2:
The patent introduces a transverse dimension to the load distribution by incorporating a transverse rail that creates a second load path across the vehicle width. This dimensional expansion of the load distribution network allows impact forces to be dispersed more efficiently through the structure, enabling weight reduction while maintaining protective performance.
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 deflector system enhances crashworthiness by redirecting impact forces, allowing the vehicle to glance off the barrier while maintaining reduced weight and part count, thus meeting test requirements and lowering manufacturing costs.
Implementation Method 1
the vehicle impacts a rigid barrier having a six inch pole-like radiused corner with a 25% overlap at 40 MPH
Implementation Method 2
The deflector distributes the load of the frontal impact with a small offset rigid barrier between the frame and the rail
Implementation Method 3
the curved intermediate portion is partially deformed into a concave shape as the rail progressively collapses towards the frame during the test
Implementation Method 4
The tubular intermediate portion is convex, but during a small offset rigid barrier test the curved intermediate portion is partially deformed into a concave shape
Data Source
AI summary
A shotgun rail, or deflector, is provided as part of a front end structure of a vehicle. The shotgun rail includes a triangular shaped bulkhead having a front surface disposed at an oblique angle relative to the front of a vehicle and a rear surface that is disposed at an oblique angle relative to the rear of the vehicle. A laterally facing surface of the bulkhead is attached to a frame rail. Loads resulting from an impact with a small offset rigid barrier are distributed between longitudinal load paths and lateral load paths through the shotgun rails, frame rails, and sub-frame.