Vehicle Door Beam Bracket Deformation for Impact Integrity
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Solution Overview
Problem
Existing vehicle door structures are prone to failure when subjected to significant side impacts, as the impact bar can split the support member, causing the door beam to detach from the inner panel.
Innovation Solution
A door structure featuring a door beam mounted on a bracket with a patch member that includes a first part and a second part forming an L-shape, where the second part is spaced from the bracket, and the bracket is connected to both the door beam and the inner panel with joint parts that allow for deformation, preventing breakage and maintaining the door beam's attachment during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the impact bar is mounted on the support member by welding, then the impact bar can be securely fixed to the inner panel, but the support member may split when large impacts are applied, causing the door beam to detach
Solution Approach 1:
The support member is divided into a first support member and a second support member that are separately attached to the inner panel. The door beam is supported by both members, distributing the impact load across multiple attachment points rather than concentrating it on a single welded support member, thereby preventing splitting while maintaining secure fixation.
Solution Approach 2:
The first and second support members are positioned at different locations on the inner panel, providing localized support at critical stress points. This distributed support structure ensures that impact forces are spread across different regions of the inner panel, preventing localized failure while maintaining overall attachment strength.
2Stability of the object's composition
If the support member is made rigid to prevent deformation during impact, then the door beam remains stable, but the support member is more prone to splitting under large impacts
Solution Approach 1:
The support members are designed with controlled flexibility, allowing them to deform elastically during impact to absorb energy and reduce peak stresses. This dynamic response prevents the rigid support member from splitting while maintaining door beam stability through the combined support of multiple flexible members that work together during deformation.
Solution Approach 2:
By using multiple segmented support members instead of a single rigid member, the structure gains both stability through distributed support and resistance to splitting through load distribution. Each segment can independently deform and recover, providing stable support while avoiding the stress concentration that causes splitting in rigid monolithic structures.
Data Source
AI summary
A rear side door 20 designed to open and close an opening formed in a body 40 includes an inner panel 21 and a door beam 24. The door beam 24 is mounted on an inner panel 21 through a bracket 25 placed between the door beam 24 and the inner panel 21, and a patch member 26 is disposed on a tip part 24A of the door beam 24 at a position overlapping the tip part 24A of the door beam 24 in the vehicle widthwise direction.