Load Path Control Mechanism for Side Impact Load Transfer
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Solution Overview
Problem
In typical body-on-frame vehicles, the significant gap between the body and frame rails leads to excessive deformation and undesired seat shifts during side impacts, as the body's floor crossmembers bear the initial impact force alone, with limited lateral load transfer to the frame until the deforming body engages the frame rail, resulting in inadequate structural strength and excessive frame rail deformation.
Innovation Solution
The implementation of a load path control mechanism, comprising a coupling bracket and a spacer bracket, which are strategically positioned between the rocker panel and the frame rail, to enhance lateral load transfer and distribute impact forces more effectively across the frame, reducing frame rail deflection and seat displacement by engaging the frame crossmember earlier in the impact sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the body's floor crossmembers sustain the initial impact force alone due to the significant gap between the body and frame rails, then the body structure must be significantly strengthened to reduce seat position shifts, but this results in excessive deformation of the frame rail and inadequate lateral load transfer
Solution Approach 1:
The patent introduces body-to-frame mounting brackets as intermediary elements that directly connect the body structure to the frame rails. These brackets serve as load transfer intermediaries, enabling direct lateral load transfer from the body to the frame during side impacts, eliminating the need for the body structure to sustain the entire impact force alone while preventing excessive frame rail deformation through controlled load distribution
Solution Approach 2:
The body-to-frame mounts are designed to engage and transfer loads before the body deforms significantly. By establishing predetermined load paths through these mounts, the system prepares for impact by creating alternative load transfer routes that activate during side impacts, allowing the frame to begin absorbing load before the body structure reaches its deformation limit
2Shape
If brackets are placed directly between the rocker panel and the side rail to transfer impact loading to the frame, then body deflection is reduced, but this allows for undesired or excessive deformation of the proximate frame rail
Solution Approach 1:
The patent segments the load transfer function by introducing multiple body-to-frame mounting brackets at different locations along the body and frame structure. This segmentation distributes the impact load across multiple attachment points rather than concentrating it at a single bracket location, reducing the deformation burden on any single frame rail section while maintaining effective body deflection control
Solution Approach 2:
The mounting brackets are strategically positioned at specific locations where they can effectively transfer loads to portions of the frame structure with higher load-bearing capacity. By placing brackets at locations that optimize the structural properties of the connected frame sections, the system achieves effective load transfer while minimizing localized frame rail deformation
Data Source
AI summary
A load path control mechanism is fixed to a frame rail and includes a coupling bracket, a spacer bracket and a frame crossmember. The frame rail defines an inner chamber therein. The frame crossmember is fixed to the frame rail. The coupling bracket is disposed in the inner chamber and is fixed to the frame rail, paralleling the frame crossmember. The coupling bracket has a first projected area on a plane normal to a lateral axis. The spacer bracket, disposed on an outboard side of the frame rail, has a second projected area on a plane normal to the lateral axis. The projected areas at least partially overlap. The spacer bracket has a deformation mode responsive to a first load under which the space bracket deflects against the first side of the frame rail which deflects against the coupling bracket.