Contoured Reinforcing Bracket for Vehicle Body
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Solution Overview
Problem
During off-center impact events, existing vehicle body structures experience relative movement and deformation between the sill structure and the floor panel, leading to potential separation due to shearing forces, which existing technologies fail to adequately address.
Innovation Solution
The implementation of reinforcing brackets with a first flange fixed to the sill structure and a second flange fixed to the floor panel, featuring a mid-section that elongates in response to shearing forces, thereby restricting relative movement between the sill structure and the floor panel by absorbing and distributing the impact energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid bracket is used to connect the floor panel and sill structure, then the connection strength is improved, but the bracket cannot absorb impact energy and restrict relative movement effectively
Solution Approach 1:
The bracket transitions from a rigid structure to one with controlled flexibility through the contoured mid-section. The contoured surface with length greater than the straight-line distance creates an inherent flexibility that allows the bracket to deform elastically under impact loads, absorbing energy while maintaining connection integrity.
2Reliability
If the bracket is made flexible to absorb impact, then energy absorption is improved, but the connection strength may be compromised
Solution Approach 1:
The bracket employs local quality differentiation where the mid-section has a contoured geometry providing flexibility for energy absorption, while the flange portions maintain sufficient rigidity for strong connections to the floor panel and sill structure. This localized variation in structural properties allows simultaneous achievement of both flexibility and strength.
3Ease of manufacture
If a straight bracket design is used, then manufacturing is simplified, but the bracket cannot effectively distribute shearing forces during impact
Solution Approach 1:
The mid-section incorporates a contoured surface with curvature rather than a straight geometry. This curvature allows the bracket to better distribute shearing forces during impact by creating a more favorable stress distribution path, while still being manufacturable using standard forming processes.
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 reinforcing brackets effectively limit or prevent separation of the floor panel from the sill structure by elongating and distributing shearing forces, ensuring a continuous connection and enhanced structural integrity during impact events.
Implementation Method 1
The mid-section has a contoured surface with an overall surface length as measured along the contoured surface from the first flange to the second flange that is greater than a distance measured between the first flange and the second flange
Data Source
AI summary
A vehicle body structure includes a sill structure, a floor panel and a reinforcing bracket. The sill structure extends along a lower end of a door opening in a vehicle longitudinal direction. The floor panel is fixed to the sill structure. The reinforcing bracket has a first flange fixed to the sill structure, a second flange fixed to the floor panel and a mid-section that extends from the first flange to the second flange. The mid-section has a contoured surface with an overall surface length as measured along the contoured surface from the first flange to the second flange that is greater than a distance measured between the first flange and the second flange.