Multi-layered Torque Box with Oblique Reaction Wall
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Solution Overview
Problem
Existing torque boxes are inefficient in managing external loads, particularly offset loads, and often result in noise and vibration issues due to complex joint structures and high tooling investments, which limits their ability to provide multiple load paths in a compact design.
Innovation Solution
A multi-layered torque box design featuring a lower reaction wall with a rib pattern, an upper layer with a back-up wall and rib pattern, and a transitioning 3-D shaped hollow/tubular bridge rail with ribs, which allows for efficient load transfer between frame rails and rocker panels, minimizing joints and tooling investment while optimizing load management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional torque box designs with multiple joints are used, then load management capability is improved, but device complexity and risk of joint separation increase
Solution Approach 1:
The patent integrates multiple load paths into a single monolithic torque box structure, eliminating the need for separate joints and connections. The torque box incorporates frontal, offset, and torsional load paths as integrated structural features within one piece, thereby reducing device complexity and eliminating joint separation risks while maintaining comprehensive load management capability.
2Strength
If multiple separate torque box components are used to provide multiple load paths, then load management capability is improved, but manufacturing cost and tooling investment increase
Solution Approach 1:
The patent combines multiple load path functions into a single torque box component that can be manufactured as one piece. This integration eliminates the need for multiple separate components and their associated tooling, significantly reducing manufacturing complexity and tooling investment while providing comprehensive load management for frontal, offset, and torsional loads.
3Strength
If traditional torque box designs are used, then structural strength is maintained, but space utilization increases
Solution Approach 1:
The patent employs three-dimensional load path routing within the torque box structure, utilizing vertical, horizontal, and diagonal dimensions to create efficient load transfer paths. This multi-dimensional approach allows the torque box to achieve high structural strength with optimized space utilization, as loads are distributed through multiple spatial dimensions rather than requiring additional horizontal space.
Data Source
AI summary
A torque box includes a box body extending along a longitudinal axis and a reaction wall coupled to the box body. The reaction wall is obliquely angled relative to the longitudinal axis to receive an offset load. The torque box further includes a plurality of ribs coupled to the reaction wall. Each of the plurality of ribs is oriented perpendicularly to the reaction wall to resist the offset frontal load received by the reaction wall. The torque box also includes a bridge rail coupled to the box body. The bridge rail is configured to allow load transfer between the frame rail and the rocker panel. At least a portion of the bridge rail is obliquely angled relative to the longitudinal axis.