Segmented Load Transmittal Bracket for Side Impact Energy Dissipation
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Solution Overview
Problem
Current vehicle body structures face challenges in effectively absorbing and transferring energy during a side impact while accommodating design, manufacturing, and cost constraints, leading to inadequate energy dissipation and potential floor deformation.
Innovation Solution
The vehicle body structure incorporates a load transmittal bracket system with a first and second segment, welded together, which transfers impact force from the door frame to a cross-member and floor panel, dispersing energy to other components, and includes features like a load transmitting wall, end wall, and flanges for efficient energy dissipation and manufacturing accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the body structure is designed to absorb energy during side impact, then energy absorption capability is improved, but manufacturing accessibility and assembly constraints are worsened
Solution Approach 1:
The load transmittal bracket is divided into multiple segments including a first segment, second segment, and third segment. This segmentation allows the bracket to be manufactured separately and then assembled through welding, improving manufacturing accessibility while maintaining energy absorption capability through the distributed structural design
Solution Approach 2:
The bracket design incorporates three-dimensional spatial arrangement with segments extending in different directions (first segment in first direction, second segment in second direction, third segment in third direction). This multi-dimensional configuration enables weld accessibility from multiple angles while preserving the energy absorption function
2Reliability
If the load transmittal bracket uses multiple segments welded together, then energy transfer efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple segments of the load transmittal bracket are merged through welding to form an integrated structure that efficiently transfers energy. The welding joints combine the segments into a unified load-bearing system, achieving energy transfer efficiency comparable to a monolithic structure while allowing for manufacturing and assembly advantages
3Loss of energy
If the bracket design includes multiple segments and welding requirements, then energy dissipation is improved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The bracket segments are designed and prepared in advance with predetermined welding locations and orientations. This preliminary configuration allows for efficient assembly operations where welding can be performed at accessible locations without requiring complex positioning or reconfiguration during the assembly process
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 enhances energy absorption and transfer efficiency, reducing floor deformation during side impacts by dispersing impact forces effectively across the vehicle body structure, while also improving manufacturing efficiency through accessible welding points.
Implementation Method 1
transfers impact force from the door frame to a cross-member and floor panel, dispersing energy to other components
Implementation Method 2
The second segment 24 is welded to the first segment 22 and to the floor panel 12
Data Source
AI summary
A vehicle body structure includes a floor panel, a door frame, a cross-member, and a load transmittal bracket. The door frame and the cross-member are fixed relative to the floor panel. The door frame defines a door opening. The load transmittal bracket is disposed between the door opening and the cross-member. The load transmittal bracket includes a second segment welded to a first segment and to the floor panel. During a side impact of the vehicle, the load transmittal bracket transfers impact force from the door frame to the cross-member to dissipate the impact force and reduce deformation of the floor.