Rocker Reinforcement Bracket Apertures for Corrosion Control
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Solution Overview
Problem
Reinforcement brackets for vehicle rocker assemblies often cause galvanic corrosion due to the lack of a seal between the bracket and the rocker panel, leading to potential deformation and corrosion issues.
Innovation Solution
A steel rocker panel assembly with a reinforcement bracket featuring a flange with strategically placed apertures to direct E-coat fluid flow and relieve pressure, inhibiting oxidation and corrosion without a seal around the periphery, thereby providing structural rigidity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is added around the periphery of the flange to prevent oxidation, then corrosion resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the seal component entirely from the system. Instead of adding a seal around the periphery of the flange, the design extracts this element and replaces it with a different mechanism - apertures in the flange that allow E-coat fluid to flow and displace air, achieving corrosion protection without the seal.
Solution Approach 2:
The E-coat fluid acts as an intermediary substance that flows through the apertures in the flange. This fluid mediator displaces air from the interface between the bracket and rocker panel, creating a protective environment without requiring a mechanical seal. The apertures serve as conduits for this intermediary fluid.
2Strength
If the flange is made tight against the rocker panel to prevent deformation, then structural rigidity is improved, but pressure buildup from E-coat injection causes oxidation and corrosion
Solution Approach 1:
The flange is segmented with multiple apertures distributed across its surface. This segmentation allows the flange to maintain overall structural integrity while creating localized openings that enable air escape and E-coat fluid flow, preventing pressure buildup and oxidation at critical interface points.
Solution Approach 2:
The flange is designed with a porous structure containing multiple apertures. This porous configuration allows the flange to remain structurally rigid while permitting controlled flow of E-coat fluid and air escape, preventing the pressure buildup that would otherwise lead to oxidation and corrosion at the bracket-panel interface.
3Reliability
If apertures are added to the flange to release pressure and prevent oxidation, then corrosion resistance is improved, but structural strength may be reduced
Solution Approach 1:
The apertures are strategically positioned and sized to provide local functionality for air escape and fluid flow without compromising the overall structural quality of the flange. The local modifications are concentrated in specific areas where they serve the corrosion protection function while minimizing impact on global structural strength.
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 effectively enhances the structural rigidity of the rocker panel assembly while preventing corrosion, eliminating the need for a sealant around the periphery and reducing costs by ensuring effective E-coat coverage and air release through the apertures.
Implementation Method 1
The apertures being dimensioned so as to direct flow of an E-coat liquid injected therein between the flange of the bracket and rocker panel
Implementation Method 2
to relieve a pressure between the flange and rocker panel associated with the flow
Implementation Method 3
injected therein between the panel and flange to inhibit oxidation therebetween
Data Source
AI summary
A bracket for a rocker panel assembly includes a first flange and a second flange. The second flange is at an end of a body opposite the first flange and extends parallel to the first flange. The first and second flanges each define a plurality of apertures being dimensioned and configured to control flow of an E-coat fluid injected therein to provide a seal between the first and second flanges to inhibit oxidation in an absence of a seal around a periphery of the first and second flanges.