Reinforced Closed Section Assembly for Vehicle Crash Energy Absorption
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Solution Overview
Problem
Current vehicle structures face challenges in absorbing impact energy during crashes due to lateral buckling issues and increased weight and cost in conventional designs, and limited space for energy-absorbing components in existing vehicle body structures.
Innovation Solution
A reinforced closed section assembly with a closed section member featuring sloped holes for a reinforcement member, which can be inserted and affixed using projection welding or mechanical fasteners, enhancing energy absorption and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional tubular structures or crush tubes are used to absorb impact energy, then energy absorption capability is improved, but lateral stability deteriorates when load is offset from the tube center
Solution Approach 1:
The reinforcement member is divided into multiple segments or sections that can independently resist lateral loads. Each segment provides lateral support at different locations along the closed section member, preventing buckling while maintaining energy absorption capabilities.
Solution Approach 2:
The reinforcement member is constructed using composite material structures that provide both high compressive strength for energy absorption and high lateral stiffness for buckling resistance. This composite structure allows simultaneous improvement of energy absorption and lateral stability.
2Strength
If axial strength of tubular structures is increased to improve energy absorption, then impact resistance is improved, but lateral instability increases
Solution Approach 1:
The reinforcement member features varying cross-sectional properties along its length, with thicker sections at locations prone to buckling and thinner sections where energy absorption is prioritized. This local variation in quality provides lateral support where needed while maintaining overall energy absorption capability.
Solution Approach 2:
The reinforcement member introduces a secondary structural dimension by extending laterally from the closed section member. This additional dimensional element provides lateral stiffness without compromising the axial compression performance needed for energy absorption.
3Use of energy by moving object
If two-piece stamped body structure is used to house crush tube, then energy absorption is improved, but weight and manufacturing cost increase
Solution Approach 1:
The reinforcement member is integrated directly into the closed section member as a single unified component rather than requiring separate stamped body pieces. This merging eliminates redundant structural elements and reduces overall weight while maintaining energy absorption functionality.
Solution Approach 2:
The reinforcement member serves multiple functions simultaneously: it provides lateral support to prevent buckling, absorbs impact energy through controlled deformation, and reinforces the closed section member structure. This multi-functionality eliminates the need for separate dedicated components.
4Use of energy by moving object
If two-piece stamped body structure is used to house crush tube, then energy absorption is improved, but manufacturing time and cost increase
Solution Approach 1:
The reinforcement member and closed section member are designed as a single integrated component that can be manufactured in one piece using hydroforming or extrusion processes. This eliminates the need for separate assembly steps required for two-piece stamped structures, reducing manufacturing time and complexity.
Solution Approach 2:
The reinforcement member is pre-formed during the closed section member manufacturing process itself, rather than being added as a separate post-processing step. This preliminary integration of the reinforcement function into the base manufacturing process eliminates additional assembly operations.
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 solution provides improved energy absorption and reduced weight and manufacturing time by allowing for efficient integration of an anti-crush tube within the vehicle body structure, enhancing crash resistance without increasing lateral instability.
Implementation Method 1
The reinforcement member may be affixed to the closed section member via projection welding or other welding process
Data Source
AI summary
A reinforced closed section assembly is provided wherein the assembly includes a closed section member defining a first hole on a first side and a second hole on a second side opposite the first side. The reinforced closed section assembly further includes a reinforcement member disposed within the first and second holes of the closed section member.