Vehicle Rocker Spacer for Side Impact Load Transfer

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Solution Overview

Problem

During a side collision, the deformation of outboard structures in vehicles can cause the rocker to rotate and fail to handle the intended load, leading to potential injury from the incoming object sliding into the cabin.

Innovation Solution

A vehicle design incorporating a rocker with a spacer coupled to its second surface, aligned with crossmembers, which absorbs and transfers the load directly to the crossmembers and B-pillars, maintaining the rocker's orientation and preventing deformation of the B-pillar during impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the vehicle includes outboard structures (such as door hinges) positioned more outboard than the rocker for stylistic requirements, then the vehicle design flexibility is improved, but during side collision the outboard structure deforms and causes the rocker to rotate or twist, reducing the rocker's ability to handle the intended load

Engineering Contradiction:

Improvevehicle design flexibilityVSAvoidrocker load handling capability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A load transferring member is introduced as an intermediary component between the rocker and the outboard structure. This member transfers loads from the rocker to the outboard structure, preventing the rocker from rotating or twisting during side collisions while maintaining the desired vehicle design flexibility with outboard positioning of structures

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If the outboard structure is positioned more outboard than the rocker, then the vehicle can achieve desired styling and structural geometry, but the outboard structure receives initial impact and deforms, causing harmful effects such as rocker rotation and potential cabin intrusion

Engineering Contradiction:

Improvevehicle structural geometryVSAvoidrocker rotation and cabin intrusion risk

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The load transferring member serves as a mediator that connects the rocker to the outboard structure, ensuring that impact forces are properly transmitted through the structured load path to the outboard structure and ultimately to the B-pillar, preventing harmful rocker rotation and cabin intrusion while preserving the vehicle's structural geometry

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The load transferring member is pre-installed and positioned to ensure proper load distribution before collision occurs. It is configured to immediately engage and transfer loads when impact occurs, preventing the sequence of harmful events (outboard structure deformation → rocker rotation → cabin intrusion) from occurring

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11254362B2Vehicle rocker with load transferring spacer

Publication Date: 2022.02.22 TOYOTA JIDOSHA KK

AI summary

A vehicle including a rocker extending in a vehicle longitudinal direction having a first surface and a second surface, at least one crossmember extending in a vehicle width direction from the first surface of the rocker, and at least one spacer coupled to the second surface of the rocker, the at least one spacer being in line with the at least one crossmember.