Multi-Panel Torque Box Assembly for Crash Energy Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current torque box assemblies in vehicles lack sufficient strength to effectively absorb energy during impacts, such as in small offset rigid barrier frontal crash tests, leading to inadequate performance in crash tests.
Innovation Solution
A torque box assembly comprising three panels fixed to both the inner and rocker rails, with specific geometries and attachments, including bends, openings, and flanges, to enhance rigidity and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional torque box assembly is used, then the structure is simple, but the strength and energy absorption capability are insufficient during impacts
Solution Approach 1:
The torque box assembly is divided into multiple panels (first panel, second panel, third panel) that are fixed to the inner rail and rocker rail. This segmentation allows each panel to contribute to energy absorption through controlled deformation while maintaining overall structural integrity, resolving the contradiction between strength and complexity by distributing the load across multiple discrete elements.
Solution Approach 2:
The patent introduces a multi-panel three-dimensional structure instead of a conventional single-panel design. The first, second, and third panels are arranged in space with specific geometric relationships, creating a volumetric structure that absorbs energy more effectively. This dimensional expansion resolves the contradiction by utilizing spatial arrangement to enhance strength without merely increasing material quantity.
2Loss of energy
If the torque box assembly uses a conventional design, then manufacturing is simple, but energy absorption during crash tests is inadequate
Solution Approach 1:
Each panel is designed with specific local geometric features (bends, openings, flanges) that optimize energy absorption at critical locations. The first panel includes a depression, the second panel includes bends, and the third panel includes openings with flanges. These localized geometric modifications enable targeted energy dissipation through controlled deformation modes, resolving the contradiction between energy absorption and complexity by concentrating functional features where most needed.
Solution Approach 2:
The panels incorporate various curved features including bends in the second panel, circular openings in the third panel, and a depression in the first panel. These curved geometries facilitate progressive crushing and energy absorption during impact by creating stress distribution patterns that maximize energy dissipation. The curvature elements resolve the contradiction by providing efficient energy absorption mechanisms that are more effective than simple flat panel designs.
3Reliability
If the torque box assembly is enhanced with multiple panels and geometric features, then crash test performance improves, but manufacturing complexity increases
Solution Approach 1:
The complex geometry is divided into separate panel components that can be manufactured independently using standard stamping and forming processes. Each panel (first, second, third) is a discrete piece that can be produced separately and then assembled by fixing to the inner rail and rocker rail. This segmentation resolves the contradiction between crash test performance and manufacturability by allowing complex geometries to be achieved through modular assembly rather than monolithic manufacturing.
Solution Approach 2:
The multiple panels serve multiple functions simultaneously: they provide structural strength, absorb energy through controlled deformation, and maintain geometric integrity during impact. The first panel provides initial impact resistance, the second panel with its bends provides progressive crushing, and the third panel with openings provides additional energy absorption pathways. This multi-functionality resolves the contradiction by making the enhanced structure achieve multiple performance goals without requiring separate components for each function.
Data Source
AI summary
An assembly includes an inner rail and a rocker rail outboard of the inner rail. The assembly includes a torque box having a first panel fixed to the inner rail and the rocker rail, a second panel fixed to the inner rail and the rocker rail, and a third panel fixed to the inner rail and the rocker rail.