Integrated Vehicle Rocker Beam with Multi-Hollow Cross-Section
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Solution Overview
Problem
Current vehicle structural components, such as rocker components, face challenges in efficiently distributing impact forces and meeting regulatory requirements while minimizing weight and material usage, particularly in integrating reinforcement beams that provide both strength and flexibility.
Innovation Solution
A multi-hollow reinforcement beam with a metal sheet cross-sectional shape and integral flange portions is used, which can be roll-formed to span vehicle components, reducing the need for additional panels and allowing for spot welding, thus enhancing structural support and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional separate reinforcement beams and panels are used, then structural strength is achieved, but weight and material usage increase
Solution Approach 1:
The patent combines the reinforcement beam and sill panel into a single integrated component formed from one continuous metal sheet. The multi-hollow cross-sectional shape integrates the structural beam function and panel function, eliminating the need for separate components and reducing overall weight while maintaining required structural strength.
Solution Approach 2:
The integrated component performs multiple functions simultaneously: it provides reinforcement beam structural support, acts as a sill panel, and offers impact force distribution. This multi-functionality reduces the number of separate components needed, thereby reducing weight and material usage.
2Loss of substance
If multi-hollow reinforcement beam with integral flange portions is used, then material usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs roll-forming technology to create the complex multi-hollow cross-sectional shape from a continuous metal sheet. This manufacturing process parameter change allows the integrated structure to be produced efficiently in a continuous operation, reducing manufacturing complexity despite the intricate geometry.
Solution Approach 2:
The metal sheet is divided into functional zones during roll-forming, with different sections creating the beam portion, flange portions, and panel sections. This segmentation occurs during the forming process itself, allowing complex geometry to be manufactured efficiently without post-processing assembly.
3Ease of manufacture
If separate components are used for reinforcement beam and sill panel, then ease of manufacture is maintained, but structural stiffness and impact resistance decrease
Solution Approach 1:
By merging the reinforcement beam and sill panel into a single integrated component with continuous material flow, the patent eliminates weak joints and interfaces between separate parts. This integration significantly improves structural stiffness and impact resistance while the roll-forming process maintains manufacturing efficiency.
4Weight of moving object
If traditional reinforcement structures are used, then weight is higher, but impact force distribution capability is proven
Solution Approach 1:
The patent creates a composite-like structure within a single material by forming multiple hollow cavities and thickened sections in specific locations. This internal composite structure optimizes impact force distribution throughout the component while reducing overall material usage and weight compared to traditional solid structures.
Data Source
AI summary
A rocker component for a vehicle having a reinforcement beam including a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of the reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion and includes an edge of the metal sheet. The rocker component also includes a sill panel having flanges extending longitudinally along upper and lower edges of the sill panel relative to the vehicle, the flange portion of the reinforcement beam joined to one of the flanges of the sill panel to secure the reinforcement beam to the sill panel in replacement of a separate second sill panel.