Corrugated Rocker Insert for EV Side-Impact Load Redirection
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Solution Overview
Problem
Vehicle frames struggle to effectively redirect side impact forces away from battery trays in electric and hybrid electric vehicles, necessitating improved structural reinforcement to enhance safety and compliance with regulatory standards.
Innovation Solution
A vehicle rocker assembly incorporating a corrugated rocker insert within the vehicle sill assembly, which includes a sill inner and outer with a corrugated portion oriented laterally to stiffen the structure and redirect impact forces, utilizing a metal or plastic/metal hybrid material for enhanced strength and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rocker assembly structure is used, then manufacturing simplicity is maintained, but stiffness and impact force redirection capability are insufficient
Solution Approach 1:
The rocker insert incorporates a corrugated structure with curved ridges and valleys that redirect impact forces laterally away from the battery tray. The curved geometry transforms vertical impact loads into lateral force components, enhancing stiffness and impact resistance without requiring additional reinforcement components.
Solution Approach 2:
The rocker insert is formed as a composite structure combining metal reinforcement elements with plastic matrix material. This composite construction provides enhanced stiffness and strength-to-weight ratio compared to traditional solid plastic rockers, while maintaining manufacturing efficiency through integrated molding processes.
2Strength
If heavier reinforcement materials are used to increase stiffness, then impact resistance improves, but vehicle weight increases
Solution Approach 1:
The rocker insert utilizes a composite construction with metal reinforcement embedded in a plastic matrix, providing high stiffness and impact resistance at reduced weight compared to solid metal alternatives. The plastic matrix distributes loads while the metal ridges provide structural reinforcement.
Solution Approach 2:
The corrugated geometry with optimized ridge curvature enhances structural efficiency, allowing thinner wall sections and reduced material usage while maintaining impact resistance. The curved structure distributes stress more effectively than flat configurations, reducing the need for excessive material.
3Object-affected harmful factors
If corrugated structure is added to redirect impact forces, then inboard intrusion is reduced, but manufacturing complexity increases
Solution Approach 1:
The corrugated structure is integrated into the rocker insert design with continuous curved ridges that redirect impact forces laterally. This geometric feature is formed during the molding process rather than requiring post-manufacturing assembly, maintaining manufacturing efficiency while achieving superior impact force redirection and reduced inboard intrusion.
Solution Approach 2:
The rocker insert combines multiple functions into a single integrated component: structural reinforcement, impact force redirection, and battery tray protection. The corrugated structure performs both structural support and force redirection functions simultaneously, eliminating the need for separate reinforcement components and simplifying assembly.
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 corrugated rocker insert provides increased stiffness and reduces vehicle intrusion by up to 22% while minimizing mass by approximately 42%, enhancing safety and compliance with regulatory impact standards.
Implementation Method 1
the structure of the corrugated shape is configured to stiffen the rocker assembly for lateral impact forces received at the vehicle
Data Source
AI summary
A vehicle rocker assembly may include a sill inner comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly may also include a sill outer comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior, the rocker insert comprising: an upper wall, a lower wall, and a side wall extending between the upper wall and the lower wall. At least one of the upper wall or the lower wall comprises a corrugated portion that has a ridge oriented to extend in a lateral vehicle direction.