Variable Cross-Section Front Pillar for Visibility and Rigidity

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Solution Overview

Problem

The existing design of front pillars in vehicles lacks sufficient degree of freedom in design while maintaining rigidity, which affects driver visibility and the risk of windshield detachment during collisions.

Innovation Solution

A front pillar configuration featuring a front-side pillar with varying circumferences and a joint part positioned away from the windshield-opposed area, formed by joining plate members and using liquid-sealed molding to enhance design flexibility and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the front-side front pillar is made with a smaller cross-sectional area to improve driver visibility, then visibility is improved, but the rigidity of the front pillar is reduced

Engineering Contradiction:

Improvedriver visibilityVSAvoidfront pillar rigidity

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

The front-side front pillar employs varying cross-sectional areas at different positions along its length. The upper portion has a smaller cross-sectional area to improve driver visibility, while the lower portion has a larger cross-sectional area to maintain rigidity and strength. This local variation in geometry allows each section to be optimized for its specific functional requirement.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The front pillar design transitions from a uniform cross-section to a variable cross-section structure. The dynamic adjustment of cross-sectional area along the pillar's length enables the structure to adapt to different mechanical and optical requirements at different positions, balancing visibility and structural integrity.

Inventive Principle:

Principle #15Dynamics

2Illumination intensity

If the front-side front pillar is designed with varying cross-sectional areas to improve visibility, then visibility is improved, but the design complexity increases

Engineering Contradiction:

Improvedriver visibilityVSAvoidfront pillar design complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the joint part is positioned in the windshield-opposed part to simplify manufacturing, then manufacturing is simplified, but the windshield may detach during collision due to deformation

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwindshield attachment reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The joint part where plate member end faces are joined is extracted from the windshield-opposed part and repositioned to a location away from it. This separation ensures that the joint part does not interfere with windshield attachment and is not subjected to the same deformation patterns during collision, thereby maintaining windshield security while allowing manufacturing flexibility.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By positioning the joint part away from the windshield-opposed part, the design anticipates and prevents potential windshield detachment during collision. The joint part is placed in a location that is less susceptible to collision-induced deformation, providing a buffer that protects the windshield attachment integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

This configuration improves driver visibility and maintains the rigidity of the front pillar, reducing the risk of windshield detachment during collisions while allowing for broader design choices and cost-effective manufacturing.

Implementation Method 1

performing liquid-sealed molding on the formed different-diameter pipe

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS11383767B2Front pillar and manufacturing method therefor

Publication Date: 2022.07.12 TOYOTA JIDOSHA KK

AI summary

A front pillar includes a front-side front pillar and a rear-side front pillar disposed apart from each other in a longitudinal direction of a vehicle. The front-side front pillar is formed in a pipe-like shape in which end faces of a plate member are joined to each other. The front-side front pillar includes a first pillar part having a first circumference, and a third pillar part having a second circumference different from the first circumference.