Vehicle Push Arm and Support Bracket for Off-Center Impact
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Solution Overview
Problem
Conventional vehicle structures are inadequate in absorbing and redirecting impact energy during off-center impact tests, leading to inefficient energy dissipation and potential damage to critical components like the dash-wall and A-pillar.
Innovation Solution
The vehicle frame is enhanced with a push arm and support bracket configuration that guides the push arm rearward upon impact, distributing the energy through a gap and energy-absorbing structures, thereby redirecting the force laterally and reducing the load on critical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vehicle structures are used during off-center impact tests, then the vehicle frame maintains simple structural design, but the impact energy is not effectively absorbed or redirected, causing damage to critical components
Solution Approach 1:
The vehicle frame is segmented into distinct functional components: a push arm for initial impact absorption, energy absorbing structures with crushable cells, and a support bracket system. This segmentation allows each component to perform its specific function in the impact energy management sequence, protecting critical components while maintaining a manageable structural complexity
Solution Approach 2:
The push arm is pre-positioned and pre-configured to engage first during off-center impact, redirecting impact forces before they reach critical components. The energy absorbing structures are pre-designed with crushable cells that deform in a controlled sequence, performing preliminary energy absorption actions before the main frame structure is subjected to damaging forces
2Loss of energy
If additional structural elements are added to absorb impact energy, then the energy absorption capability is improved, but the vehicle frame complexity increases
Solution Approach 1:
The energy absorbing structures utilize crushable cells with controlled deformation parameters. The cells are designed with specific geometric parameters that control the force-displacement characteristics during crushing, allowing predictable energy absorption. This parameter-based design enables effective energy dissipation while maintaining relatively simple structural elements that can be integrated into the existing frame
Solution Approach 2:
The push arm acts as an intermediary component between the impact source and the vehicle frame. It mediates the impact forces by redirecting them through a controlled path, preventing direct transmission to critical components. This intermediary element simplifies the overall energy management by creating a buffer zone that handles the most severe initial loading
3Reliability
If the push arm is rigidly fixed to the frame, then the structural integrity is maintained, but the impact energy cannot be effectively redirected
Solution Approach 1:
The connection between the push arm and the frame is designed to be dynamic rather than statically rigid. The support bracket allows controlled movement and rotation of the push arm during impact, enabling the system to adapt its stiffness characteristics. This dynamic connection maintains structural integrity through controlled flexibility, allowing force redirection while preventing catastrophic failure
Solution Approach 2:
The support bracket and connection elements utilize composite construction combining rigid and flexible components. This allows the assembly to maintain overall structural integrity while incorporating localized flexibility for energy absorption and force redirection. The composite approach enables simultaneous achievement of strength and redirectibility
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 effectively absorbs and redirects impact energy, reducing the load on critical components and improving the vehicle's stability during off-center impacts by moving the vehicle laterally away from the barrier, thus enhancing safety and structural integrity.
Implementation Method 1
in response to an off-center impact event against the front surface of the push arm, the support bracket initially guides movement of the push arm in a rearward direction relative to the support bracket
Implementation Method 2
The push arm extends forward and laterally outward such that the front surface of the push arm is located laterally outboard of and spaced apart from the front end of the first side member. The support bracket is configured such that in response to an off-center impact event against the front surface of the push arm, the support bracket initially guides movement of the push arm in a rearward direction
Data Source
AI summary
A push arm has a rear surface and a front surface. A rear surface of the push arm is located adjacent to and spaced apart from a first cross-member defining a gap therebetween. The push arm extends forward and laterally outward such that the front surface of the push arm is located laterally outboard of and spaced apart from a front end of a first side member of a vehicle frame. A support bracket has a front section releasably attached to the push arm and a rear section releasably attached to a first cross-member of the vehicle frame adjacent to an intersection of the first side member and the first cross-member. The support bracket is configured such that in response to an off-center impact event against the front surface of the push arm, the support bracket guiding movement of the push arm in a rearward direction.