SOL Pusher Block with Outriggers for Lateral Crash Energy Distribution
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Solution Overview
Problem
Current small overlap rigid barrier (SOL) pushers in vehicles are heavy, complex, and result in excessive vehicle deceleration and cabin deformation during frontal crashes, as they fail to effectively engage the vehicle's structural members and distribute crash energy efficiently.
Innovation Solution
A novel SOL pusher block structure that includes a first frame cross member, a second frame cross member, an outrigger, and a connection arm to distribute crash forces laterally, engaging the vehicle's strong structural members early in the collision and redirecting energy to reduce cabin intrusion and deceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional SOL pushers are used to distribute forces laterally across the number one cross brace, then the vehicle structure can engage structural members during small overlap crashes, but the vehicle experiences excessive deceleration and cabin deformation
Solution Approach 1:
The push force is segmented into two independent load paths: one through the outrigger to the number one cross brace, and another through the connection arm to the number two cross brace. This segmentation allows each structural member to share the crash energy absorption, reducing the burden on any single component and thereby reducing excessive deceleration and cabin deformation while maintaining reliable energy absorption.
2Reliability
If heavy, complex SOL pusher structures are used to engage structural members, then energy distribution is improved, but the device complexity and vehicle weight increase
Solution Approach 1:
The SOL pusher structure is designed to perform multiple functions: the outrigger engages the number one cross brace for lateral force distribution, while the connection arm engages the number two cross brace for additional energy absorption. This multi-functional design improves energy distribution effectiveness without requiring a complex multi-component system, as the two arms work together as an integrated solution.
3Loss of energy
If the vehicle remains in contact with the barrier longer during small overlap crashes, then more energy can be absorbed through deformation, but the cabin is exposed to prolonged direct contact and severe deformation
Solution Approach 1:
The SOL pusher structure performs preliminary action by actively pushing the vehicle off the barrier immediately upon impact. The outrigger and connection arm work together to generate lateral pushing force that rapidly moves the vehicle away from the barrier, reducing the duration of direct contact. This preliminary pushing action occurs before severe cabin deformation can occur, thereby protecting the cabin while still allowing controlled energy absorption through the structural members.
Data Source
AI summary
Disclosed is an apparatus for improving lateral crash pushing and distributing crash energy within a vehicle. The apparatus comprises a first frame cross member extending laterally between a left hand frame rail and a right hand frame rail of a vehicle, and a second frame cross member, aft of the first frame cross member, extending laterally between the left hand frame rail and the right hand frame rail. The apparatus further comprises an outrigger projecting outward laterally from the first frame cross member and an impact member selected from the left hand frame rail or right hand frame rail; and a connection arm projecting diagonally from a distal end of the outrigger to a connection point on the second frame cross member, beneath the impact member, such that when an impact force travels longitudinally into the outrigger, the impact force is distributed to both the first frame cross member through the outrigger and the second frame cross member through the connection arm.