Steering Column Breakaway Strap for Tuned Crash Energy Absorption
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Solution Overview
Problem
Current steering column assemblies lack a customizable energy-absorbing mechanism that can effectively manage varying impact forces and driver masses during a crash, leading to inconsistent energy absorption profiles.
Innovation Solution
A method for optimizing an energy-absorbing strap formed from a single metal sheet with strategically designed connecting portions, a weakening, and a bent portion to achieve a desired energy-absorbance profile, allowing for adaptation to different vehicles and impact conditions, and a support bracket assembly incorporating this strap for controlled breakaway in crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single metal sheet is used to form the energy-absorbing strap, then manufacturing complexity is reduced and consistency is improved, but the ability to customize energy-absorbance profiles for different vehicles and impact conditions is limited
Solution Approach 1:
The patent applies local quality by creating specific geometric features (bent portions with varying radii, weakening locations, connecting portion configurations) at different locations along the single metal sheet strap. These localized structural variations enable customization of the energy-absorbance profile without changing the fundamental single-sheet construction method, thus maintaining manufacturing simplicity while achieving adaptability for different vehicles and impact conditions.
2Adaptability or versatility
If the energy-absorbing strap is designed with complex geometry (bent portions, weakenings, connecting portions), then the energy-absorbance profile can be optimized for different crash scenarios, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes by varying geometric parameters (bent portion radii, weakening depths, connecting portion dimensions, strap thickness) of the energy-absorbing strap to optimize the energy-absorbance profile for different crash scenarios. These parameter variations allow customization of energy absorption characteristics while maintaining a relatively simple single-sheet construction, balancing geometric complexity with manufacturability.
3Reliability
If the strap is designed to breakaway at a weakening, then controlled movement and energy absorption are achieved during crash, but the connection strength between support bracket and mounting bracket is reduced
Solution Approach 1:
The patent applies segmentation by introducing a weakening (partial cut or reduced thickness section) in the energy-absorbing strap that creates a predetermined breakaway point. This segmentation allows the strap to maintain full strength through the weakening during normal operation, then controlled breakaway at the weakening during crash to enable telescopic movement and energy absorption, thus achieving both reliable controlled behavior and appropriate connection strength.
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 optimized energy-absorbing strap provides a customizable energy-absorbance profile, ensuring consistent force distribution and efficient energy dissipation across various crash scenarios, enhancing safety by adapting to different vehicle masses and collision speeds.
Implementation Method 1
an energy-absorbing mechanism may be provided to absorb the energy associated with the movement so that one broken the movement is controlled
Data Source
AI summary
A method for optimising an energy-absorbing strap includes the steps of: (1) producing a single metal sheet, including a first connecting portion, for connecting to one of a support bracket and a fixed part of a vehicle, and a second connecting portion, for connecting to the other of the support bracket and the fixed part of the vehicle; and (2) producing a weakening in the single metal sheet to separate the first connecting portion from a tearable portion; bending a portion of the single metal sheet to produce a bent portion that interconnects the second connecting portion and the tearable portion, the second portion being bent back around in relation to the tearable portion; wherein the steps are selected to produce a desired energy-absorbance profile.