Vehicle Pillar Reinforcement via Sill Aperture

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Solution Overview

Problem

There is a challenge in improving the narrow offset and roof crush test performance of vehicle frame structures without significantly increasing production costs.

Innovation Solution

A vehicle body structure comprising a pillar structure with a box section cavity, a sill structure with an aperture, and a reinforcement member that extends through the aperture and is attached to the sill structure, utilizing hydroformed tubular members for enhanced stiffness and cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the vehicle body structure is redesigned to improve narrow offset and roof crush test performance, then the strength and stiffness of the pillar structure are improved, but the cost of producing the vehicle increases

Engineering Contradiction:

Improvepillar structure strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The reinforcement system is divided into separate modular components: hydroformed tubular members inserted into the pillar box sections, distinct from the main pillar structure. This allows the reinforcement to be manufactured separately using cost-effective hydroforming processes and then assembled, avoiding the need to redesign the entire pillar structure at higher cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hydroformed tubular reinforcement members are nested within the existing pillar box sections, utilizing the cavity space already present in the pillar structure. This nested configuration provides additional strength and stiffness without requiring external attachments or structural redesign, maintaining cost-effectiveness while improving performance.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If reinforcement members are added to the pillar structure, then the stiffness and strength are improved, but the device complexity increases

Engineering Contradiction:

Improveframe structure strengthVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The reinforcement members are integrated with the existing pillar structure by inserting them into the box section cavities and attaching them to the sill structure. This merging approach combines the reinforcement function with the existing structural elements, avoiding the need for separate external reinforcement systems and reducing overall complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tubular reinforcement members are nested within the pillar box sections, utilizing the existing cavity space. This nested configuration adds strength without requiring external attachments or complex structural modifications, as the reinforcement is contained within the existing structural envelope.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS9248862B1Vehicle body structure

Publication Date: 2016.02.02 NISSAN MOTOR CO LTD

AI summary

A vehicle body structure includes a pillar structure, a sill structure and a reinforcement member. The pillar structure has a box section defining a cavity. The sill structure has an upper surface defining an aperture. The reinforcement member is disposed within the cavity of the pillar structure, extends through the aperture and is attached to the sill structure.