Rocker Assembly with Internal Crush Pods for Side Impact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle side structures lack effective energy absorption mechanisms in side impact collisions, particularly in areas like rocker assemblies and underfloor batteries, which can lead to inadequate protection and increased risk of intrusion into the passenger compartment.
Innovation Solution
The implementation of a rocker assembly with an outer panel, side sill, and insert pods featuring interconnected walls defining transversely extending open cells, along with a mounting guide and attachment assembly that includes metallic flanges and guide rails, to enhance energy absorption and resistance during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rocker assemblies are used without internal energy absorbing members, then the structure is simpler and lighter, but the energy absorption capability and protection against intrusion into the passenger compartment is insufficient
Solution Approach 1:
The insert pod is nested within the cavity formed by the outer panel and side sill of the rocker assembly. This nested configuration allows the energy-absorbing insert pod to be integrated into the existing rocker structure without requiring complete structural redesign, thereby improving protection against intrusion while maintaining relative structural simplicity.
Solution Approach 2:
The rocker assembly combines different materials and structures: the outer panel and side sill form a cavity that houses an insert pod made of energy-absorbing material with interconnected walls defining open cells. This composite structure integrates the strength of the outer shell with the energy absorption characteristics of the cellular insert, achieving both protection and controlled complexity.
2Loss of energy
If strengthening members are designed to maximize energy absorption through crushing and bending, then impact energy absorption improves, but the mass of the strengthening member increases
Solution Approach 1:
The insert pod employs a porous cellular structure with interconnected walls defining open cells. This porous configuration provides high energy absorption capacity through controlled crushing and deformation of the cell walls during impact, while the cellular geometry allows for reduced material usage compared to solid structures, thereby managing mass effectively.
Solution Approach 2:
The strengthening structure is segmented into the outer panel, side sill, and the insert pod with its cellular walls. This segmentation allows each component to be optimized for specific functions: the outer shell provides structural integrity while the segmented cellular insert pod handles energy absorption through controlled deformation of individual cells, improving energy absorption efficiency relative to mass.
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
This configuration significantly improves the vehicle's ability to absorb impact energy, reduce mass, and prevent intrusion into the passenger compartment, providing enhanced safety and structural integrity during side impact collisions.
Implementation Method 1
When a compressive force is exerted longitudinally on a strengthening member (for example, a force due to a side impact load on a vehicle's side rocker rail or other member), the strengthening member may crush in a longitudinal direction to absorb the energy of the collision.
Implementation Method 2
When a bending force is exerted on a strengthening member (for example, a force due to a side impact load on a vehicle's front side sill, B-pillar or other strengthening member), the strengthening member may bend to absorb the energy of the collision.
Data Source
AI summary
A rocker assembly for a vehicle includes an outer panel and a side sill secured to the outer panel and defining a cavity with the outer panel. The rocker assembly further includes an attachment assembly including a mounting plate secured to the side sill and a mounting guide secured to the mounting plate. The mount guide includes a side rail that extends within the cavity. The rocker assembly further includes an insert pod disposed within the cavity and secured to the attachment assembly. The insert pod includes a plurality of interconnected walls defining a plurality of transversely extending open cells. The insert pod further includes a slot region extending through a side wall and sized to receive a portion of the mounting guide. The insert pod further includes guide channels walls extending from the side wall and defining a guide channel sized to receive the side rail therein.