Hybrid Rocker Reinforcement for Small Overlap Energy Absorption
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Solution Overview
Problem
Existing vehicle structures struggle to effectively absorb energy during small overlap impacts, leading to increased intrusion into the occupant compartment and potential injury, while current solutions are heavy and lack tunable deformation rates.
Innovation Solution
Integrate plastic reinforcements into rocker panels to absorb axial load and side impact energy, using a hybrid metal-plastic solution that includes localized plastic honeycomb structures to enhance structural integrity and deformation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal energy absorbing structures are used, then structural strength is maintained, but weight increases and small overlap impact energy absorption is insufficient
Solution Approach 1:
The patent employs a hybrid structure combining metal rocker panel with plastic reinforcement elements. The plastic reinforcement includes a hollow outer shell and internal honeycomb structure, creating a composite material system that leverages the strength of metal and the energy absorption characteristics of plastic foam and honeycomb structures, achieving both weight reduction and improved impact performance
Solution Approach 2:
The plastic reinforcement is strategically positioned within the rocker panel channel at specific locations where impact forces are concentrated. The reinforcement features varying wall thicknesses and honeycomb densities in different zones, providing localized strength enhancement exactly where needed during small overlap impacts, rather than uniformly strengthening the entire structure
2Loss of energy
If plastic reinforcement is added to absorb energy, then energy absorption improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single unified reinforcement component. The plastic reinforcement simultaneously provides impact energy absorption, structural strengthening, and deformation control through its integrated hollow shell and honeycomb structure design, eliminating the need for separate energy absorption devices and reducing overall system complexity
Solution Approach 2:
The plastic reinforcement element serves multiple functions: it absorbs impact energy through foam compression and honeycomb collapse, strengthens the rocker panel structure, controls the rate of deformation, and reduces overall vehicle weight. This multi-functional design simplifies the overall vehicle structure by replacing what would otherwise require multiple separate components
3Weight of moving object
If hollow metal rocker channel with plastic reinforcement is used, then weight is reduced, but control over axial deformation rate is limited
Solution Approach 1:
The patent controls deformation rate by varying key parameters of the plastic reinforcement: the density and cell structure of the foam material, the wall thickness distribution in the hollow shell, and the geometry of the honeycomb structure. These parameter variations allow tuning of the energy absorption characteristics and deformation behavior to match specific impact scenarios
Solution Approach 2:
The reinforcement structure is designed to dynamically adapt during impact: the foam compresses and the honeycomb structure collapses in a controlled sequence, transitioning from a rigid state during normal operation to a progressively deforming state during impact. This dynamic response allows the structure to control axial deformation rate in real-time during the impact event
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 hybrid rocker panel assembly provides a lightweight, compact solution that improves crashworthiness by reducing intrusion and deformation, offering enhanced protection and weight savings without compromising safety.
Implementation Method 1
A plastic reinforcement can be integrated into a rocker panel to absorb axial load from a small overlap impact and side impact energy
Data Source
AI summary
An apparatus for providing structural support for a vehicle, the apparatus comprising a rocker panel component defining a channel extending along an axis, a partition disposed in the channel to define a first channel portion and a second channel portion, a first plastic reinforcement disposed in the first channel portion and coupled to the rocker panel component, the first plastic reinforcement defining a plurality of voids such that the first plastic reinforcement plastically deforms under a load at a first rate of deformation along the axis, a second plastic reinforcement disposed in the second channel portion and coupled to the rocker panel component, the second plastic reinforcement defining a plurality of voids such that the second plastic reinforcement plastically deforms under the load at a second rate of deformation along the axis, wherein the first rate of deformation is different than the second rate of deformation.