Single Piece Extruded Vehicle Rocker Panel
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Solution Overview
Problem
Conventional rocker panel fabrication techniques are complex and result in structures with limited rigidity, requiring a lightweight, high-strength solution that is easy to manufacture.
Innovation Solution
A single piece rocker panel is fabricated using an extrusion process, incorporating an exterior and interior wall with enclosed cavities and reinforcing walls to enhance rigidity, and featuring a mounting flange for the floor panel and channel nut retainer for simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple panels are welded together to form the rocker panel, then the structural coverage and assembly flexibility are improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines multiple separate panels (outer panel, inner panel, reinforcement panel) into a single integrated rocker panel structure. This unifies the previously separate components into one monolithic piece, eliminating the need for welding operations while maintaining all necessary structural functions including side coverage, floor panel mounting surfaces, and torsional rigidity.
Solution Approach 2:
The single rocker panel structure performs multiple functions that were previously distributed across separate panels: it provides lateral structural coverage, incorporates mounting flanges for floor panels, includes reinforcement features for torsional rigidity, and integrates channels for fasteners. This multi-functional integration eliminates the need for separate reinforcement panels and simplifies the overall assembly.
2Shape
If multiple panels are welded together to form the rocker panel, then the structural coverage is improved, but the production time decreases
Solution Approach 1:
The patent combines multiple separate panels (outer panel, inner panel, reinforcement panel) into a single integrated rocker panel structure. This unifies the previously separate components into one monolithic piece, eliminating the need for welding operations while maintaining all necessary structural functions including side coverage, floor panel mounting surfaces, and torsional rigidity.
Solution Approach 2:
The rocker panel is designed as a single pre-formed extrusion that arrives at the assembly line ready for installation. All structural features, reinforcement elements, and mounting flanges are incorporated during the extrusion manufacturing process, eliminating the need for time-consuming welding and assembly operations that would otherwise be required to combine multiple panels.
3Device complexity
If a single piece extrusion is used, then the manufacturing complexity is reduced, but the torsional rigidity needs to be enhanced
Solution Approach 1:
The patent incorporates localized reinforcement features directly into the single extrusion structure. These include reinforcement flanges positioned at specific locations to enhance torsional rigidity, internal rib structures within the extrusion cross-section, and strategically placed mounting flanges that serve both as attachment points and structural strengtheners. The extrusion profile is designed with varying wall thicknesses and geometric features at different locations to optimize rigidity where needed while maintaining manufacturability.
4Adaptability or versatility
If multiple panels are welded together, then the assembly flexibility is improved, but the manufacturing time increases
Solution Approach 1:
The patent combines multiple separate panels (outer panel, inner panel, reinforcement panel) into a single integrated rocker panel structure. This unifies the previously separate components into one monolithic piece, eliminating the need for welding operations while maintaining all necessary structural functions including side coverage, floor panel mounting surfaces, and torsional rigidity.
Solution Approach 2:
The rocker panel is designed as a single pre-formed extrusion that arrives at the assembly line ready for installation. All structural features, reinforcement elements, and mounting flanges are incorporated during the extrusion manufacturing process, eliminating the need for time-consuming welding and assembly operations that would otherwise be required to combine multiple panels.
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
This approach reduces manufacturing time and expense while achieving improved torsional rigidity and consistency, allowing for easier integration of features like battery pack enclosures and reduced complexity in vehicle assembly.
Implementation Method 1
A single piece, extruded, vehicle rocker panel is disclosed that includes at least an exterior wall, an interior wall, and at least one enclosed cavity running longitudinally throughout the panel
Data Source
AI summary
A vehicle rocker panel is provided that is extruded as a single piece. As extruded, the rocker panel may include one or more interior reinforcing walls as well as interior and exterior design features.