Tunable Knee Blocker Energy Absorption System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing knee blocker assemblies in vehicles are not tunable for different force-displacement load responses, which limits their effectiveness in managing varying occupant sizes and impact scenarios during frontal collisions.
Innovation Solution
A tunable knee blocker energy absorption system featuring distinct left and right energy absorption brackets with adjustable flange widths, hole sizes, and corner radii to manage non-uniform load paths and kinematic responses, ensuring uniform presentation of occupant femurs to the instrument panel and airbag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a typical knee blocker assembly is used, then it absorbs impact energy during frontal collision, but it cannot be tuned for different force-displacement load responses for varying occupant sizes
Solution Approach 1:
The patent applies local quality by making different regions of the knee blocker assembly have different geometric properties. The left and right EA brackets have asymmetric designs with different flange widths, corner radii, and hole configurations to create non-uniform load paths that adapt to different occupant sizes and impact scenarios while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent implements asymmetry by designing the left EA bracket and right EA bracket as distinct, non-mirrored components. The left lower EA bracket has a 60-degree angled portion while the right lower EA bracket has a 45-degree angled portion, and their flange widths and hole patterns differ, enabling tailored force-displacement responses for different occupant anthropometry.
2Reliability
If distinct left and right EA brackets are used to manage non-uniform load paths, then occupant protection is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the knee blocker assembly into multiple discrete components: left lower EA bracket, left upper EA bracket, left EA bridge, right lower EA bracket, and right upper EA bracket. Each segment can be manufactured independently using standard fabrication processes, allowing for quality control and assembly flexibility while achieving the complex asymmetric geometry needed for reliable occupant protection.
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 system effectively absorbs impact energy across different occupant sizes, providing improved protection during frontal collisions by managing load paths and kinematic responses, ensuring efficient energy absorption and injury mitigation.
Implementation Method 1
a left energy absorption (EA) bracket configured to couple to the structural cross-car member... configured to absorb impact energy
Data Source
AI summary
A tunable knee blocker energy absorption system for a vehicle having an instrument panel, a structural cross-car member, and an occupant protection device includes a left energy absorption (EA) bracket configured to couple to the structural cross-car member and including a left lower EA bracket, a left upper EA bracket, and a left EA bridge. A right EA bracket is configured to couple to the structural cross-car member and includes a right lower EA bracket and a right upper EA bracket. The left EA bracket and the right EA bracket are distinct from each other to manage a non-uniform load path of occupant femurs into the instrument panel and alter the kinematic response of the occupant back to a uniform presentation to the occupant protection device.