Nerf Bar Tubular Member Collapse for Unibody Frame Protection
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Solution Overview
Problem
Existing nerf bar designs for body-on-frame vehicles are not suitable for unibody construction vehicles, as they require strong attachment points that can lead to deformation of the lighter unibody frame during side-impact collisions, and they are often specific to one side of the vehicle.
Innovation Solution
A nerf bar assembly featuring a tubular member that collapses to absorb impact, mounted to a support structure with channel veins and brackets, allowing for easy installation and removal, and capable of being mounted on either side of the vehicle without modifying the unibody frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing nerf bar designs for body-on-frame vehicles are used on unibody vehicles, then the nerf bar can be mounted to the vehicle, but the lighter unibody frame deforms at the attachment points during side-impact collisions
Solution Approach 1:
The nerf bar assembly is divided into separate components: a support structure with channel veins that distributes load across multiple attachment points, and a tubular member that can be independently replaced. This segmentation allows the support structure to bear the mounting load while protecting the unibody frame.
Solution Approach 2:
The design incorporates channel veins within the support structure that act as built-in reinforcement elements before impact occurs. These veins are positioned to provide structural support at attachment points, cushioning the unibody frame from concentrated loads during side-impact collisions.
2Strength
If a large C-channel frame member is used for mounting, then the nerf bar can be securely mounted, but a large lever is created requiring strong attachment points that deform the unibody frame
Solution Approach 1:
Instead of using a large C-channel that creates a long lever arm, the support structure uses channel veins distributed across the mounting surface. This changes the mounting geometry from a single-point lever to a distributed pattern, reducing the force concentration on any single attachment point.
Solution Approach 2:
The channel veins provide more structural support than minimally required at each attachment point, creating a distributed reinforcement pattern that collectively supports the mounting load without requiring any single point to bear excessive force that would deform the unibody frame.
3Strength
If the tubular member is permanently fixed to the support structure, then the structure is more rigid, but the nerf bar cannot be easily removed and replaced if damaged
Solution Approach 1:
The mounting system transitions from a static permanent fixation to a dynamic removable connection. The support structure provides rigid support during normal operation, while allowing the tubular member to be easily removed and replaced when damaged, adapting the structural behavior to different operational states.
Solution Approach 2:
The design accepts that the tubular member may be damaged and discarded, while the valuable support structure with channel veins remains intact and can be recovered and reused. This separates the sacrificial protective element from the permanent mounting structure.
4Ease of manufacture
If the nerf bar is designed for specific left or right side mounting, then the mounting can be optimized for each side, but the assembly cannot be used on both sides of the vehicle
Solution Approach 1:
The support structure with channel veins is designed with symmetrical or adaptable mounting patterns that allow the same assembly to be installed on either the left or right side of the vehicle. This universal design eliminates the need for separate left-side and right-side specific components.
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 nerf bar assembly effectively protects the vehicle body from side-impact damage by using the tubular member as a sacrificial component, minimizing stress on the support structure and unibody frame, and can be easily replaced or moved between sides without affecting the vehicle's integrity.
Implementation Method 1
The assembly is configured so that when the tubular member impacts an object, the tubular member can collapse and absorb the impact before damage occurs to the support structure or the vehicle body
Data Source
AI summary
A nerf bar assembly for mounting to the side of a vehicle having a unibody construction includes a tubular member comprising a tubular section and a plurality of mounting brackets fixed to and projecting generally perpendicularly from the tubular section. A support structure is configured for mounting to the body of a vehicle having a unibody construction. The support structure forms a channel and includes a plurality of channel veins and a plurality of support structure brackets disposed within the channel. The support structure brackets are configured so that the plurality of tubular member mounting brackets can be removably mounted to the plurality of support structure brackets. The nerf bar assembly is configured so that when the tubular member impacts an object, the tubular member can collapse and absorb the impact before damage occurs to the support structure or the vehicle body.