Vehicle Trim Energy Absorption Member with Tunable Ribs
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Solution Overview
Problem
Existing vehicle trim members lack effective energy absorption capabilities while maintaining aesthetic quality, particularly prone to sink marks on visible surfaces due to material shrinkage.
Innovation Solution
An energy absorption member is integrated into the trim member, featuring a base with sidewalls and a connecting wall, and ribs extending from the base, which are tunable for strength and aesthetics, reducing sink marks and enhancing energy absorption by compressing to decelerate forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If energy absorption structures are added to trim members, then energy absorption capability is improved, but device complexity increases
Solution Approach 1:
The energy absorption member is integrated directly into the trim member body, combining the aesthetic trim function with the safety energy absorption function into a single unified structure. This eliminates the need for separate energy absorption components while maintaining both aesthetic appearance and crash protection capabilities.
Solution Approach 2:
The energy absorption member utilizes a thin-walled structured base with controlled wall thickness (0.040-0.060 inches) that provides flexibility for energy absorption while maintaining structural integrity. The thin-walled design allows the structure to deform controllably during impact events without requiring bulky additional components.
2Manufacturing precision
If material thickness is increased to reduce sink marks, then manufacturing precision is improved, but weight increases
Solution Approach 1:
The base features variable wall thickness with different sections optimized for their specific functions: thicker walls (0.060-0.080 inches) in areas requiring structural support and sink mark prevention, and thinner walls (0.040-0.060 inches) in areas where weight reduction is prioritized. This localized optimization achieves aesthetic quality without unnecessary weight increase throughout the entire component.
Solution Approach 2:
The trim member is constructed from polymeric materials with specific density ranges (0.020-0.040 lb/in³ for the trim member, 0.030-0.050 lb/in³ for the energy absorption member) that provide optimal balance between weight, strength, and sink mark resistance, allowing thin-walled construction without compromising aesthetic quality.
3Reliability
If rib structures are added to the base, then energy absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The energy absorption member is divided into distinct functional segments: a base portion providing structural support and a rib portion providing energy absorption through controlled deformation. This segmentation allows each part to be optimized independently while being manufactured as an integrated unit, simplifying the manufacturing process while maintaining complex functionality.
Solution Approach 2:
The ribs are pre-formed as integral features of the base during the molding process, with predetermined geometry and thickness that ensure proper energy absorption characteristics. This preliminary formation eliminates the need for post-manufacturing assembly steps or complex tooling, reducing manufacturing complexity while ensuring consistent 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 solution effectively absorbs energy, reduces sink marks on visible surfaces, and maintains the aesthetic appeal of the trim member, while being integrally formed to reduce manufacturing costs.
Implementation Method 1
an energy absorption member is coupled to the trim member. The energy absorption member includes a base and at least one rib extending from the base
Implementation Method 2
enhancing energy absorption by compressing to decelerate forces
Data Source
AI summary
A vehicle includes a vehicle body including a pillar. The pillar includes a support structure. A passenger compartment is defined by the vehicle body. A trim member disposed in the passenger compartment on the pillar. An energy absorption member is coupled to the trim member. The energy absorption member includes a base and at least one rib extending from the base.