Vehicle Load Transfer Deflector for Offset Crash Loads
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Solution Overview
Problem
Existing vehicle load management systems fail to effectively transfer and dissipate laterally offset loads applied to the bumper to the frame rail, potentially bypassing the energy-absorbing capabilities of the frame rail under certain load conditions.
Innovation Solution
A load transfer apparatus comprising a first deflector member secured to a body mount bracket and the frame rail, and a second deflector member that contacts the body mount bracket or first deflector member only under sufficient offset load, directing the load laterally inward to the frame rail and components like the engine assembly for energy dissipation, while maintaining the full energy-absorbing capability of the frame rail under centrally applied loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a load transfer apparatus with deflector members is added to direct offset loads to the frame rail, then the energy dissipation capability under offset loads is improved, but the device complexity increases
Solution Approach 1:
The load transfer apparatus is divided into two separate deflector members (first and second deflector members) that can independently engage with the body mount bracket. This segmentation allows each deflector to handle specific portions of the offset load, improving energy dissipation while maintaining a relatively simple overall structure that only activates when needed.
Solution Approach 2:
The deflector members act as intermediary components between the bumper and the frame rail/body mount bracket. They mediate the load transfer by engaging with the body mount bracket under offset loads, directing forces through the frame rail without requiring direct modification of the bumper or bracket structure.
2Reliability
If the second deflector member is configured to contact the body mount bracket under offset load, then the load path formation is improved, but the device complexity increases
Solution Approach 1:
The second deflector member is designed to dynamically engage with the body mount bracket only under sufficient offset loads. This dynamic configuration allows the load path to form automatically when needed, while remaining inactive during normal operation or centrally applied loads, thus improving reliability without requiring complex control mechanisms.
Solution Approach 2:
The engagement of the second deflector member with the body mount bracket is triggered by changes in load parameters (magnitude and direction). When the offset load exceeds a certain threshold, the geometric relationship between components changes, causing the second deflector to contact the bracket and form the load path.
3Strength
If the second deflector member moves with the bumper free from contact under centrally applied load, then the frame rail's energy-absorbing capability is maintained, but the load transfer efficiency under offset loads may be reduced
Solution Approach 1:
The load transfer apparatus provides different load paths based on the local conditions of load application. Under centrally applied loads, the frame rail maintains its full energy-absorbing capability through direct loading. Under offset loads, the deflector members create a localized load path through the body mount bracket and frame rail, optimizing the load transfer for that specific condition.
Data Source
AI summary
A load transfer apparatus for a vehicle includes a first deflector member that is securable both to a body mount bracket that extends from a frame rail and to the frame rail so that a first portion of the frame rail is between the body mount bracket and the bumper, and a second portion of the frame rail is between the body mount bracket and the first deflector member. The first deflector member at least partially forms a load path from the bumper to the frame rail under a sufficient offset load applied to the bumper. The load transfer apparatus may also include a second deflector member securable to the bumper to extend from the bumper such that the second deflector member is spaced from and free from contact with the body mount bracket and the first deflector member prior to application of the sufficient offset load to the bumper.