Chassis Brace Small Offset Rigid Barrier Reinforcement
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Solution Overview
Problem
Conventional vehicle architectures face challenges in the small offset rigid barrier (SORB) test due to uneven loading, which causes the rear wheel assembly to rotate inboard, leading to higher intrusions and reduced performance, as the frame rails and crush cans are not adequately loaded, transferring energy to less structurally sound areas like the dash and foot well.
Innovation Solution
A chassis brace and SORB reinforcement assembly that bridges between chassis and body components around the tire envelope, using C-channel shaped members with receivers and fasteners to secure the brace to sub-frame and inner rocker, allowing the wheel assembly to act as a load path and reducing the impact on weaker vehicle structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional front structure elements (frame rails, crush cans, bumper beam) are used in SORB test configuration, then the vehicle structure is not adequately loaded, but the wheel assembly rotates inboard and loads weaker elements (dash, foot well), causing higher intrusions
Solution Approach 1:
The chassis brace is pre-installed to create a load path between the wheel assembly and the body structure before the crash event occurs. This preliminary structural preparation ensures that during SORB testing, forces are directed through the reinforced path rather than allowing the wheel assembly to rotate inboard and load weaker elements.
Solution Approach 2:
The chassis brace acts as an intermediary structural element that mediates the force transfer between the wheel assembly and the body structure. It provides a controlled load path that prevents direct loading of weaker elements like the dash and foot well, while still utilizing the wheel assembly as part of the load path.
2Reliability
If the wheel assembly is allowed to rotate inboard during SORB impact, then suspension connections are engaged, but this causes higher measured intrusions and affects vehicle performance rating
Solution Approach 1:
The chassis brace is pre-installed to create a load path between the wheel assembly and the body structure before the crash event occurs. This preliminary structural preparation ensures that during SORB testing, forces are directed through the reinforced path rather than allowing the wheel assembly to rotate inboard and load weaker elements.
Solution Approach 2:
The invention converts the harmful inboard rotation of the wheel assembly into a beneficial load path. By providing the chassis brace, the wheel assembly's natural rotation tendency is channeled through the reinforced structure, transforming what would be harmful intrusions into useful force distribution that improves performance rating.
3Ease of manufacture
If bolt-on attachment method is used for chassis brace, then ease of installation is improved, but structural robustness must be maintained
Solution Approach 1:
The chassis brace system is segmented into modular components with standardized attachment points. The brace body is separate from the attachment hardware, allowing for easy installation and removal while maintaining structural integrity through properly engineered connection points at the chassis and body structure.
Data Source
AI summary
A chassis brace includes a body having a first end and a second end, a chassis structure abutment at the first end and a body structure abutment at the second end. Together, the chassis brace, the chassis component secured the chassis structure abutment of the chassis brace and the body component secured to the body structure abutment of the chassis brace form a small offset rigid barrier reinforcement assembly. A method of reinforcing a vehicle is also disclosed.