DESC:A KNEE BOLSTER STRUCTURE FOR A VEHICLE

[0001] The present disclosure in general relates to a knee bolster energy absorption structure for a vehicle. More particularly, the present invention relates to providing the structure which is configured to obstruct the knee movement of a driver and/or co-driver, and reducing the pelvis movement which in turn reduces chest deflection values during a frontal collision.
BACKGROUND
[0002] In-vehicle knee bolster has been provided for protecting vehicle occupants during a crash event. A knee bolster that can be used on the driver’s side or on the passenger side of the dashboard. The knee bolsters are provided in the lower portion of a vehicle dashboard, facing the legs of passengers sitting in the front seats of an automobile.
[0003] The knee bolster is designated as a restraining device. The knee bolster can control the posture of the front passenger in an accident. Thus, the knee kinematics of the front passenger can be restricted, and collision energy can be distributed in the upper part and the low portion of the passenger's body equably through the knee bolster.
[0004] The injury of the knee acting on the front passenger can remain at a predetermined level by knee bolster in the event that an accident occurs. The knee bolster can prevent the knee of the front passenger from moving too far in lower dash panels. The restriction of the knee load in accidents, chest load, and chest displacement is by regulation and stipulation of the knee bolster.
[0005] In the existing design, foam knee pads are used to restrict pelvis movement through knee obstruction but the knee pads usage is costly.
[0006] Therefore, in order to minimize the deflection and injuries to the passenger, there is a need to design a knee bolsters bracket that obstructs the knee movement of the passenger, and reduces the pelvis movement which in turn reduces chest deflection values.

OBJECTS OF THE INVENTION:
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0008] The primary objective of the present subject matter is to reduce chest deflection values during a frontal offset crash.
[0009] Another objective of the present subject matter is to provide a knee bolster energy absorption structure for a vehicle.
[0010] Another objective of the present subject matter is to provide the knee bolster absorption structure that obstructs the knee movement of a driver and co-driver and reduces the pelvis movement which in turn reduces chest deflection values during a crash.
[0011] It is another object of the present disclosure to provide the structure that provides better performance, reliability, and cost effective.
SUMMARY OF THE INVENTION
[0012] This summary is provided to introduce concepts related to a knee bolster energy absorption structure for a vehicle. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0013] The subject matter disclosed herein refers to a knee bolster energy absorption structure for a vehicle having a steering cross support member, a cross support member, and a longitudinal support member. The knee bolster energy absorption structure comprising a left energy absorption (EA) bracket and a right energy absorption bracket. The left energy absorption (EA) bracket is configured to couple with the steering cross support member and the longitudinal support member. The left energy absorption (EA) bracket includes a left front EA bracket, and a left rear support EA bracket. The right EA bracket is spaced apart from the left EA bracket and configured to couple with the steering cross support member and the cross support member. The right EA bracket includes a right lower EA bracket, a right middle support EA bracket, and a right upper EA bracket. The left front EA bracket includes a longitudinal portion and a transverse portion extend from the longitudinal portion and combindly define ‘T’ shape profile. The left front EA bracket has flanges extending outwardly from adjacent sides of the longitudinal portion and the transverse portion, where the flanges of the transverse portion extend forward away from rear end to couple with the longitudinal support member. The longitudinal portion of the left front EA bracket defines a flat surface configured to receive front end of the left rear support EA bracket. The left rear support EA bracket coupled with the steering cross support member at rear end. The right lower EA bracket configured to couple with the steering cross support member at rear end. The right lower EA bracket has flanges extending from opposite sides. The right upper EA bracket is configured to couple with the cross support member at rear end. The right upper EA bracket includes a longitudinal portion and a transverse portion combindly defines a ‘L’ shape profile, where sides of the longitudinal portion and a transverse portion have flanges extending outwardly. The knee bolster energy absorption structure comprises the right middle support EA bracket provided in between the right upper EA bracket.
[0014] In an aspect, the left front EA bracket which defines a ‘U’ shaped notches on the flanges dividing the longitudinal portion and the transverse portion, where the ‘U’ shaped notches act as bending point.
[0015] In an aspect, the left rear support EA bracket includes a longitudinal portion and a transverse portion extending from the longitudinal portion and combinedly define a ‘T’ shape profile, where sides of the left rear support EA bracket have flanges extending outwardly. The flanges at the transverse portion defines a channel with flat middle surface.
[0016] In an aspect, a ‘U’ shape notches are provided on the flanges dividing the longitudinal portion and the transverse portion, where the ‘U’ shaped notches act as bending point to facilitate bending of the left front EA bracket.
[0017] In an aspect, the flanges are defined at front edge of the longitudinal portion of the left rear support EA bracket coupled with the flat surface of the left front EA bracket.
[0018] In an aspect, the longitudinal portion of the left rear support EA bracket defines a bead structure, where the bead structure is adjacent to the transverse portion at one end.
[0019] In an aspect, the right middle support EA bracket includes a longitudinal portion and a transverse portion extending at an angle from the longitudinal portion and combinedly defines a ‘T’ shape profile, where the sides of the right middle support EA bracket have flanges extending outwardly.
[0020] In an aspect, the transverse portion defines a flat surface that is configured to couple with the transverse portion of the right upper EA bracket and the longitudinal portion is configured to couple with the right lower EA bracket.
[0021] In an aspect, the left front EA bracket, the left rear support EA bracket, and the longitudinal support member define a triangular truss type arrangement.
[0022] In an aspect, a joining portion of the longitudinal portion and the transverse portion has smaller width as compared to the longitudinal portion and the transverse portion, the joining portion act as a bending point.
[0023] In an aspect, a “U’ shape notch is provided at the joining portion of the longitudinal portion and the transverse portion to facilitate the bending of the right EA bracket.
[0024] In order to further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit scope of the present subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Some non-limiting exemplary embodiments or features of the disclosed subject matter are illustrated in the following drawings.
[0026] Fig. 1 illustrates a knee bolster energy structure for a vehicle, in accordance with an embodiment of the present subject matter;
[0027] Fig. 2a, 2b, 2c, and 2d illustrate exploded view of a left energy absorption (EA) bracket and a right EA bracket and formation of a triangular thrust-shaped bracket arrangement, in accordance with one embodiment of the present invention;
[0028] Fig. 3a, 3b, 3c, 3d, and 3e illustrate different views of a left front EA bracket of the knee bolster energy absorption structure, in accordance with an embodiment of the present subject matter;
[0029] Fig. 4a, 4b, 4c, 4d, and 4e illustrate different views of a left rear support EA bracket, in accordance with an embodiment of the present subject matter;
[0030] Fig. 5 illustrate top view of assembled the left front EA bracket and the left rear support EA bracket with U notches and c-channel, in accordance with an embodiment of the present subject matter;
[0031] Fig. 6a, 6b, and 6c illustrate different views of a right middle support EA bracket of the knee bolster energy absorption structure, in accordance with an embodiment of the present subject matter; and
[0032] Fig. 7a, 7b, and 7c illustrate different views of a right upper EA bracket of the knee bolster energy absorption structure, in accordance with an embodiment of the present subject matter.
[0033] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of some embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.
[0034] Identical, duplicate, equivalent, or similar structures, elements, or parts that appear in one or more drawings are generally labelled with the same reference numeral, optionally with an additional letter or letters to distinguish between similar entities or variants of entities, and may not be repeatedly labeled and/or described. References to previously presented elements are implied without necessarily further citing the drawing or description in which they appear.
[0035] Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale or true perspective. For convenience or clarity, some elements or structures are not shown or shown only partially and/or with different perspective or from different point of views.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0036] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features that are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0037] These and other advantages of the present subject matter would be described in more detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0038] Fig. 1 illustrates a knee bolster energy absorption structure for a vehicle, in accordance with one embodiment of the present invention. In an embodiment of the present invention, the knee bolster energy absorption structure (100) for a vehicle is having a steering cross support member (101), a cross support member (102), and a longitudinal support member (103). The knee bolster energy absorption structure (100) comprises a left energy absorption (EA) bracket (200) that is configured to couple with the steering cross support member (101) and the longitudinal support member (103). The left energy absorption (EA) bracket (200) includes a left front EA bracket (300), and a left rear support EA bracket (400). A right EA bracket (500) is spaced apart from the left EA bracket (200). The right EA bracket (500) is configured to couple with the steering cross support member (101) and the cross support member (102), the right EA bracket (500) includes a right lower EA bracket (600), a right middle support EA bracket (700), and a right upper EA bracket (800). As shown in the figure, the right EA bracket (500) and the left EA bracket (200) are joined by known means such as welding on the cross members. The X-axis defines the transverse direction and the Y-axis defines the longitudinal direction.
[0039] Fig. 2a, 2b, 2c, and 2d illustrate exploded view of a left energy absorption (EA) bracket and a right EA bracket and formation of a triangular thrust-shaped bracket arrangement on the left EA bracket, in accordance with an embodiment of the present subject matter. In an embodiment of the present subject matter, the left front EA bracket (300), the left rear support EA bracket (400), and the longitudinal support member (103) defines a triangular truss type arrangement (201) as can be shown in Fig 2a, 2b, and 2c. The triangular truss-shaped bracket arrangement (201) provides rigidity to the structure. The right lower EA bracket (600) is configured to couple with the cross support member (102) at rear end (601) using welding or arc welding or spot welding, as can be shown in Fig 2d. The right lower EA bracket (600) has flanges extending from opposite sides.
[0040] Referring to fig. 2a and 2b, together the left front EA bracket (300), and the left rear support EA bracket (400) are mounted on the steering cross support member 101 and the longitudinal support member 103. Referring to fig. 2c and 2d together, the right lower EA bracket (600) is configured to couple with the steering cross support member (101). Further, the right upper EA bracket (800) is configured to couple with the cross support member (102). Furthermore, the right middle support EA bracket (700) is provided in between the right lower EA bracket (600) and the right upper EA bracket 800 to form the right EA bracket 500.
[0041] Fig. 3a, 3b, 3c, 3d, and 3e illustrates different views of a left front EA bracket of the knee bolster energy absorption structure, in accordance with one embodiment of the present subject matter. In an embodiment of the present subject matter, the left front EA bracket (300) is including a longitudinal portion (301) (along the vehicle height) and a transverse portion (302) (along the vehicle width) that extends from the longitudinal portion (301) and combindly define ‘T’ shape profile, as can be shown in Fig 3a. The T shape profile that is selectively designed to provide enough or predetermined surface area for preventing knee movement. The ‘T’ shape bracket arrangement helps to save material wastage. Further, to prevent knee movement, sufficient reinforcement is required which is fulfilled by the left front EA bracket (300) and the left rear support EA bracket (400). The left front EA bracket (300) has flanges (303) extending outwardly from adjacent sides of the longitudinal portion (301) and the transverse portion (302), where the flanges (303) of the transverse portion (302) extend forward away from rear end (304) to couple with the longitudinal support member (103) as can be shown in Fig 3d. The left front EA bracket (300) that defines a ‘U’ shaped notches on the flanges (303) dividing the longitudinal portion (301) and the transverse portion (302), where the ‘U’ shaped notches act as bending point (306), as can be shown in Fig 3b and 3c. A ‘U’ shape notches are provided on the flanges (303) dividing the longitudinal portion (301) and the transverse portion (302), where the ‘U’ shaped notches act as bending point (306) to facilitate bending of the left front EA bracket (300). The longitudinal portion (301) of the left front EA bracket (300) that defines a flat surface (305), as can be shown in Fig 3e which is configured to receive front end of the left rear support EA bracket (400).
[0042] Fig. 4a, 4b, 4c, 4d, and 4e illustrate different views of a left rear support EA bracket of the knee bolster energy absorption structure, in accordance with one embodiment of the present invention. In an embodiment of the present invention, the left rear support EA bracket (400) coupled/mounted with the steering cross support member (101) at rear end (401). The left rear support EA bracket (400) includes a longitudinal portion (402) (along length of the vehicle when mounted on the steering cross support member) and a transverse portion (403) (along vehicle height when mounted on the steering cross support member) extending from the longitudinal portion (402) and combinedly define a ‘T’ shape profile, where sides of the left rear support EA bracket (400) have flanges (404) extending outwardly, as can be shown in Fig 4a and 4b. The flanges (404) at the transverse portion (403) defines a channel (405) with flat middle surface (406), as can be shown in Fig 4c and Fig 4d. The longitudinal portion (402) of the left rear support EA bracket (400) defines a bead structure (408), where the bead structure (408) is adjacent to the transverse portion (403) at one end and extend upto rear end of the left rear support EA bracket 400, as can be shown in Fig 4c and Fig 4e. The holes are provided on the flat surface of the left front EA bracket (300) and the left rear support EA bracket (400). The holes are configured to aligning the left front EA bracket (300) and the left rear support EA bracket (400) so that the front bracket and rear bracket may be joined together at the predetermined location.
[0043] Fig. 5a illustrate a left front EA bracket and a left rear support EA bracket with U notches and c-channel, in accordance with one embodiment of the present invention. In an embodiment of the present invention, the flanges (404) defined at front edge of the longitudinal portion (402) of the left rear support EA bracket (400) coupled with the flat surface (305) of the left front EA bracket (300). The open C-channel (409) with U-notches provides two bending centres 410 which help a left front EA bracket (300), and a left rear support EA bracket (400) to deform and absorb crash impacts using the strain energies. The C-channel (409) enables the left rear support EA bracket (400) to bend and absorb strain energies. The U-notches 410 is configured to facilitate the desired direction of bending of the brackets which in turn governs the direction of movement of the knee after impact. The triangular truss-shaped bracket arrangement (201) is configured to reduce degree of freedom to zero and allow the Open C-channel area (409) to deform and absorb the crash impact energy. The triangular truss-shaped bracket arrangement (201) that provides sufficient reinforcement, which optimizes the knee and chest injuries leading to a good safety rating during crash tests.
[0044] Fig. 6a, 6b, and 6c illustrate different views of a right middle support EA bracket of the knee bolster energy absorption structure, in accordance with one embodiment of the present subject matter. In an embodiment of the present subject matter, the right middle support EA bracket (700) provided in between the right upper EA bracket (800) and the right lower EA bracket (600). The right middle support EA bracket (700) includes a longitudinal portion (701) (along vehicle length when mounted) and a transverse portion (702) (along vehicle height when mounted) extending at an angle from the longitudinal portion (701) and combinedly define a ‘T’ shape profile, where sides of the right middle support EA bracket (700) have flanges (703) extending outwardly, as can be shown in Fig 6b and Fig 6c. The transverse portion (702) defines a flat surface (704) as can be shown in Fig 6a. The flat surface (704) is configured to couple with the transverse portion (805) of the right upper EA bracket (800) and the longitudinal portion (701) configured to couple with the right lower EA bracket (600) through welding.
[0045] Fig. 7a, 7b, and 7c illustrate different views of a right upper EA bracket of the knee bolster energy absorption structure, in accordance with one embodiment of the present invention. In an embodiment of the present invention, the right upper EA bracket (800) configured to couple with the cross support member (102) at rear end (801) using welding. The right upper EA bracket (800) includes a longitudinal portion (802) (along vehicle length when mounted) and a transverse portion (803) (along vehicle height when mounted) combindly defines a ‘L’ shape profile, where sides of the longitudinal portion (802) and a transverse portion (803) have flanges (804) extending outwardly, as can be shown in Fig 7c and Fig 4e.
[0046] The bent portion (805) which joins the longitudinal portion (802) and the transverse portion (803) has smaller width as compared to the longitudinal portion (802) and the transverse portion (803), hence the bent portion (805) act as a bending point.
[0047] The bent portion (805) includes a “U’ shape notch (806) which facilitates bending of the right upper EA bracket (500) inward direction during collision.
[0048] Technical Advantages
[0049] All in all, the invention described in the present disclosure is having the following advantages:
a) The knee bolster brackets have been made such that the line of movement of the knee will be perpendicular to the knee bolsters to maximize energy absorption.
b) The knee bolster brackets are designed to restrict pelvis movement through knee obstruction to avoid chest deflections during frontal offset crash.
c) The knee bolster brackets are designed to restrict pelvis movement through knee obstruction.
d) The knee bolsters brackets have been designed to reduce chest deflection values during a crash.
e) During the crash the combination of the knee bolsters brackets bend in such a way to optimize knee movement while keeping knee injury values within permissible limits.

[0050] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprising", “including” and/or "having" and other conjugations of these terms, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0051] The terminology used herein should not be understood as limiting, unless otherwise specified, and is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosed subject matter. While certain embodiments of the disclosed subject matter have been illustrated and described, it will be clear that the disclosure is not limited to the embodiments described herein. Numerous modifications, changes, variations, substitutions and equivalents are not precluded.
[0052] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0053] Further, the terminology used herein is for describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0054] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0055] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
,CLAIMS:We claim:
1. A knee bolster energy absorption structure (100) for a vehicle having a steering cross support member (101), a cross support member (102), and a longitudinal support member (103), the knee bolster energy absorption structure (100) comprising:
a left energy absorption (EA) bracket (200) configured to couple with the steering cross support member (101) and the longitudinal support member (103), the left energy absorption (EA) bracket (200) includes a left front EA bracket (300), and a left rear support EA bracket (400); and
a right EA bracket (500) spaced apart from the left EA bracket (200) and configured to couple with the steering cross support member (101) and the cross support member (102), the right EA bracket (500) includes a right lower EA bracket (600), a right middle support EA bracket (700), and a right upper EA bracket (800);
wherein the left front EA bracket (300) includes a longitudinal portion (301) and a transverse portion (302) extend from the longitudinal portion (301) and combindly define ‘T’ shape profile, the left front EA bracket (300) has flanges (303) extending outwardly from adjacent sides of the longitudinal portion (301) and the transverse portion (302), where the flanges (303) of the transverse portion (302) extend forward away from rear end (304) to couple with the longitudinal support member (103);
wherein the longitudinal portion (301) of the left front EA bracket (300) defines a flat surface (305) configured to receive front end of the left rear support EA bracket (400), the left rear support EA bracket (400) coupled with the steering cross support member (101) at rear end (401);
wherein the right lower EA bracket (600) configured to couple with the cross support member (102) at rear end (601), the right lower EA bracket (600) has flanges extending from opposite sides;
the right upper EA bracket (800) configured to couple with the cross support member (102) at rear end (801), the right upper EA bracket (800) includes a longitudinal portion (802) and a transverse portion (803) combindly defines a ‘L’ shape profile, where sides of the longitudinal portion (802) and a transverse portion (803) have flanges (804) extending outwardly; and
the right middle support EA bracket (700) provided in between the right upper EA bracket (800).

2. The knee bolster energy absorption structure (100) as claimed in claim 1, wherein the left front EA bracket (300) defines a ‘U’ shaped notches on the flanges (303) dividing the longitudinal portion (301) and the transverse portion (302), where the ‘U’ shaped notches act as bending point (306).

3. The knee bolster energy absorption structure (100) as claimed in claim 1, wherein the left rear support EA bracket (400) includes a longitudinal portion (402) and a transverse portion (403) extending from the longitudinal portion (402) and combinedly define a ‘T’ shape profile, where sides of the left rear support EA bracket (400) have flanges (404) extending outwardly, the flanges (404) at the transverse portion (403) defines a channel (405) with flat middle surface (406).
4. The knee bolster energy absorption structure (100) as claimed in claim 3, wherein a ‘U’ shape notches are provided on the flanges (303) dividing the longitudinal portion (301) and the transverse portion (302), where the ‘U’ shaped notches act as bending point (306) to facilitate bending of the left front EA bracket (300).
5. The knee bolster energy absorption structure (100) as claimed in claim 3, wherein the flanges (404) defined at front edge of the longitudinal portion (402) of the left rear support EA bracket (400) coupled with the flat surface (305) of the left front EA bracket (300).
6. The knee bolster energy absorption structure (100) as claimed in claim 3, wherein the longitudinal portion (402) of the left rear support EA bracket (400) defines a bead structure (408), where the bead structure (408) is adjacent to the transverse portion (403) at one end.

7. The knee bolster energy absorption structure (100) as claimed in claim 1, wherein the right middle support EA bracket (700) includes a longitudinal portion (701) and a transverse portion (702) extending at an angle from the longitudinal portion (701) and combinedly define a ‘T’ shape profile, where sides of the right middle support EA bracket (700) have flanges (703) extending outwardly.
8. The knee bolster energy absorption structure (100) as claimed in claim 7, the transverse portion (702) defines a flat surface (704) configured to couple with the transverse portion (805) of the right upper EA bracket (800) and the longitudinal portion (701) configured to couple with the right lower EA bracket (600).
9. The knee bolster energy absorption structure (100) as claimed in claim 1, wherein the left front EA bracket (300), the left rear support EA bracket (400), and the longitudinal support member (103) defines a triangular truss type arrangement (201).
10. The knee bolster energy absorption structure (100) as claimed in claim 1, wherein a bent portion (805) defined in between the longitudinal portion (803) and the transverse portion (802) has smaller width as compared to the longitudinal portion (803) and the transverse portion (802), the bent portion (805) act as a bending point to facilitate deformation of the right upper EA bracket (800).
11. The knee bolster energy absorption structure (100) as claimed in claim 10, wherein the bent portion (805) defines a “U’ shape notch (806) that is provided to facilitate bending of the right EA bracket (500).