Vehicle Rocker Brace for Side-Impact Body Disconnection
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Solution Overview
Problem
In body-on-frame vehicles, the conventional rocker structure absorbs collision loads during side-impact collisions, leading to delayed disconnection of the vehicle body from the ladder frame, which can result in increased intrusion of external objects into the cabin, especially when batteries and accessories are installed in a manner that reduces the distance between them and the rocker.
Innovation Solution
A vehicle lower structure design that incorporates a brace within the rocker's battery flanking portion to restrict crushing deformation, allowing for quicker disconnection of the body from the ladder frame by facilitating the breakage of fastening members during a pole side-impact collision, with the brace's size and positioning optimized to manage collision loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rocker has a closed cross-sectional structure that absorbs collision load through crushing deformation, then the mount bolt is protected from breaking, but the disconnection of the body from the ladder frame is delayed in pole side-impact collisions
Solution Approach 1:
The rocker is divided into a first rocker part with closed cross-section (for absorbing collision energy) and a second rocker part with open cross-section (for facilitating quick disconnection). This segmentation allows different portions of the rocker to perform different functions: the first part protects the mount bolt by absorbing collision load through controlled crushing, while the second part enables timely disconnection when subjected to pole impact, thus resolving the contradiction between mount bolt reliability and disconnection timing.
2Length of moving object
If the battery and battery accessories are installed closer to the rocker to save space, then the vehicle width dimension is reduced, but the intrusion of external objects into the cabin increases during side-impact collisions
Solution Approach 1:
The rocker is segmented into two functional parts: the first rocker part with closed cross-section positioned near the battery accessories to absorb collision energy and protect them, and the second rocker part with open cross-section that facilitates controlled disconnection. This segmentation allows the battery and accessories to be installed closer to the rocker (reducing vehicle width) while the first rocker part provides protective crushing deformation that prevents direct transmission of impact forces to the cabin, thus resolving the contradiction between compact layout and cabin protection.
3Force
If the rocker undergoes crushing deformation to absorb collision load, then the shearing load on the mount bolt is reduced, but the body remains connected to the ladder frame longer than necessary
Solution Approach 1:
The rocker is divided into a first rocker part with closed cross-section that undergoes crushing deformation to absorb collision energy and reduce shearing load on the mount bolt, and a second rocker part with open cross-section that is designed to fail or disconnect more easily. This segmentation creates a progressive failure mode: initially the first part absorbs energy through controlled crushing, protecting the mount bolt, while the second part eventually disconnects to separate the body from the ladder frame, thus resolving the contradiction between load absorption and connection duration.
Solution Approach 2:
The rocker transitions from a static unified structure to a dynamic segmented structure that changes its mechanical behavior during collision. The first rocker part with closed cross-section provides initial rigidity and energy absorption through controlled deformation, while the second rocker part with open cross-section allows for progressive failure and disconnection. This dynamic response enables the system to adapt its stiffness and strength characteristics during the collision process, achieving both mount bolt protection and timely disconnection.
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 design enables rapid disconnection of the vehicle body from the ladder frame, reducing the inertial force and intrusion of external objects into the cabin by controlling collision loads and absorbing deformation, thus enhancing safety in side-impact collisions.
Implementation Method 1
a brace that is a reinforcing member is housed in a battery flanking portion of each of the rockers
Implementation Method 2
the rocker 112 having a closed cross-sectional structure absorbs the collision load to some extent by undergoing crushing deformation
Data Source
AI summary
A first body cross-member is disposed on body mounts and fixed to the body mounts through outer brackets and mount bolts that are fastening members. A battery and a cooling blower that is a battery accessory provided on an outer side of the battery in a vehicle width direction are installed on a vehicle body, between a pair of rockers. The rockers have a closed cross-sectional structure, and a brace that is a reinforcing member is housed in a battery flanking portion of each rocker that is a portion corresponding to the cooling blower in position in a vehicle front-rear direction.