Composite Vehicle Rock Rail Assembly for Point Load Distribution
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Solution Overview
Problem
Existing rock rail assemblies for off-road vehicles are inadequate in distributing point loads and providing sufficient protection against obstacles, as they lack effective energy absorption and reinforcement.
Innovation Solution
A rock rail assembly comprising a steel beam with a foamed polymer-based energy absorbing structure and an outer polymer-based skin, secured together to form a reinforced subassembly that distributes point loads and provides enhanced protection, manufactured through roll forming and extrusion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rock rail assemblies are used, then the structure is simple and easy to manufacture, but they are inadequate in distributing point loads and providing sufficient protection against obstacles
Solution Approach 1:
The rock rail assembly uses a composite structure combining a metal beam structure with a polymer-based energy absorbing structure. The metal beam provides structural strength and load distribution, while the polymer material absorbs impact energy and provides cushioning. This composite approach resolves the contradiction by achieving superior protection capability through material combination while maintaining a relatively simple overall structure that can be manufactured using standard processes.
Solution Approach 2:
The energy absorbing structure is positioned within or alongside the beam structure, creating a nested configuration where the polymer material is contained within or adjacent to the metal framework. This nesting approach allows the complex protective function to be integrated within a compact form factor, maintaining structural simplicity while providing enhanced protection through the multi-layered defense mechanism.
2Stress or pressure
If a reinforced structure with energy absorbing material is used, then point loads are distributed effectively, but the manufacturing process becomes more complex
Solution Approach 1:
The energy absorbing structure is pre-formed and then integrated with the beam structure during assembly. The polymer material is prepared in advance with the appropriate geometry and properties, then attached to the metal beam using standard joining methods. This preliminary preparation resolves the manufacturing complexity issue by breaking down the complex reinforcement task into simpler, pre-fabricated components that can be assembled using conventional techniques.
3Strength
If a complex multi-material structure is used, then protection against obstacles is enhanced, but the surface finish quality may be compromised
Solution Approach 1:
The rock rail assembly applies different material properties to different regions: the metal beam structure provides structural strength and load-bearing capability, while the polymer energy absorbing structure provides impact cushioning and surface protection. By assigning specific functions to specific materials in specific locations, the design achieves superior overall protection while maintaining a high-quality exterior surface through the use of appropriate materials for each functional requirement.
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 a tougher and more durable rock rail assembly that effectively distributes point loads across a larger surface area, enhancing protection against obstacles and maintaining a high-quality surface finish.
Implementation Method 1
an energy absorbing structure secured to a bottom surface of the beam structure to establish a reinforced subassembly of the rock rail assembly
Implementation Method 2
The material composition of the energy absorbing structure may further include an adhesive resin that helps bond the energy absorbing structure to the beam structure
Data Source
AI summary
Rock rail assemblies are provided for motor vehicles. An exemplary rock rail assembly may include a beam structure, an energy absorbing structure, and an outer skin. The energy absorbing structure may reinforce the beam structure and may be configured to distribute point loads when an obstacle impinges upon the rock rail assembly. The beam structure may be made of a metallic material, the energy absorbing structure may be made of a foamed polymer-based material, and the outer skin may be made of a polymer-based material. The rock rail assemblies may be constructed in a manufacturing method that involves roll forming and extrusion processes.