Torque Box Shear Planes Crash Force Redirection

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Solution Overview

Problem

Existing vehicle designs lack effective structures to redirect crash forces away from sensitive areas like the passenger compartment and energy storage components during impacts, necessitating improved crash-absorbing mechanisms.

Innovation Solution

A torque box comprising joined clamshells with specific shear planes and ridges, designed to channel impact forces from a vehicle crush rail towards a side sill, providing structural integrity and redirecting forces through a socket and attachment system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a torque box structure is added to redirect crash forces, then protection for sensitive components is improved, but device complexity increases

Engineering Contradiction:

Improvecrash force redirectionVSAvoidstructural complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The torque box is divided into two separate clamshells (first and second clamshells) that are joined together, allowing the structure to be manufactured and assembled in modular sections. This segmentation enables the complex crash force redirection function to be achieved through coordinated action of multiple simpler components rather than a single monolithic structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first and second enclosures formed by the clamshells are positioned nested relative to each other with shear planes between them, creating a compact nested arrangement that achieves force redistribution through multiple enclosed chambers in a space-efficient manner.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If multiple shear planes are created at the inner joint, then force distribution is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveforce distributionVSAvoidshear plane alignment

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The shear planes are created at specific localized regions (top and bottom edges of the inner joint) rather than throughout the entire structure. This local quality approach concentrates the force distribution function at critical shear planes while maintaining simpler geometry in other areas, reducing overall manufacturing precision requirements.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The shear planes are pre-formed as integral features of the clamshell designs during manufacturing, with predetermined locations and orientations. This preliminary action ensures proper force distribution pathways are built-in from the start, eliminating the need for complex post-assembly alignment procedures.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the clamshells are joined with adhesive at the inner joint, then structural integrity is improved, but ease of manufacture decreases

Engineering Contradiction:

Improvejoint strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Multiple joining methods (adhesive bonding, mechanical interlocking through flanges, and structural integration) are merged into a single comprehensive joint system. This combination allows the adhesive to provide continuous stress distribution across the joint surface while flanges provide mechanical interlocking, achieving superior joint strength without requiring complex multi-step assembly procedures.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9352789B2Torque box with shear planes at inner joint

Publication Date: 2016.05.31 TESLA INC

AI summary

A torque box for a vehicle includes: first and second clamshells joined to each other at respective top and bottom edges and configured to form at least first and second enclosures with an inner joint in between, the first and second enclosures configured to provide top and bottom shear planes at the top and bottom edges, respectively, and at least first and second shear planes at the inner joint.