Patchwork-Welded Body Member to Eliminate Reinforcement Gaps
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Solution Overview
Problem
The configuration of the rocker reinforcement in existing vehicle body members creates gaps between the L-shaped reinforcement and the rocker reinforcement, reducing fully plastic moment and crash performance.
Innovation Solution
A body member comprising a main member and a reinforcing member, formed by press forming and welded together using a patchwork method, with the reinforcing member extending across the boundary of the main member's portions to inhibit gaps and improve crash performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the L-shaped reinforcement is welded to the rocker reinforcement with seating faces protruding from the outer peripheral surface, then the reinforcement structure is formed, but a gap is created between the L-shaped reinforcement and the rocker reinforcement, reducing fully plastic moment and crash performance
Solution Approach 1:
The invention removes the problematic seating faces that protrude from the outer peripheral surface of the L-shaped reinforcement. By eliminating these protruding seating faces, the gap formation between the L-shaped reinforcement and rocker reinforcement is prevented, thereby improving fully plastic moment and crash performance while maintaining the reinforcement structure's functionality
Solution Approach 2:
The invention integrates the L-shaped reinforcement and rocker reinforcement into a more unified structure by eliminating the gap-causing protruding seating faces. This merging approach ensures better contact and load transfer between the components, improving overall structural strength and crash performance
2Ease of manufacture
If the main member is formed by joining multiple plate portions together, then manufacturing flexibility and material optimization are improved, but the manufacturing process complexity increases
Solution Approach 1:
The main member is divided into multiple plate portions that can be manufactured separately with optimized materials and then joined together. This segmentation allows each portion to be tailored with appropriate materials and manufacturing processes, improving manufacturing flexibility and material optimization while managing complexity through modular construction
Solution Approach 2:
The plate portions are prepared and joined in advance to form the complete main member before final assembly. This preliminary action allows for optimized material selection and manufacturing processes for each portion, reducing overall manufacturing complexity by pre-assembling components with their optimal material properties
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 patchwork method enhances the fully plastic moment and crash performance of the body member, facilitating easier manufacturing and reducing weight and manufacturing processes.
Implementation Method 1
the top plate portion, the first side wall portion, the second side wall portion, the first flange, and the second flange are formed by press forming performed in the patchwork method
Implementation Method 2
The reinforcing member is joined to an inner peripheral surface of the main member by welding performed in a patchwork method
Data Source
AI summary
A body member includes a main member and a reinforcing member. The main member includes a top plate portion extending in an extending direction, a first side wall portion, a second side wall portion, a first flange, and a second flange. The first and second side wall portions each protrude from a corresponding one of two ends, in width direction, of the top plate portion. The first and second flanges are respectively provided at an end of the first side wall portion and an end of the second side wall portion, on a side opposite where the top plate portion is located. The reinforcing member is joined to an inner peripheral surface of the main member by welding performed in a patchwork method, and the top plate portion, the first and second side wall portions, the first and second flanges are formed by press forming performed in the patchwork method.