Press-Hardened Steel Reinforcement for Vehicle Underbody Small Overlap Crash Protection
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Solution Overview
Problem
Conventional vehicle underbody structures fail to adequately protect occupants during a small overlap crash, as the impact causes deformation of the floor panel where the feet are located, leading to potential injury due to the wheel rotating inward and deforming the floor panel.
Innovation Solution
Incorporating a reinforcement element made of press-hardened steel with a tensile strength of at least 1200 MPa, positioned between the longitudinal beam and the lowerside sill part under the floor panel, to maintain the transverse distance and prevent deformation of the floor panel during a small overlap crash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional reinforcement elements are used in the underbody structure, then the structure is sufficient for side impacts and full front impacts, but the floor panel deforms during small overlap crashes causing occupant injury
Solution Approach 1:
The patent changes the material parameter of the reinforcement element by using press-hardened steel with tensile strength of at least 1200 MPa, which is significantly higher than conventional materials. This parameter change enables the reinforcement element to resist the deforming forces during small overlap crashes while maintaining compatibility with existing structural components
Solution Approach 2:
The patent employs composite material strategy by combining press-hardened steel reinforcement elements with the existing underbody structure components. This creates a hybrid structure where the high-strength material provides targeted reinforcement in critical areas without requiring complete restructuring of the entire underbody
2Loss of energy
If the wheel rotates inward during small overlap crash, then the impact force is absorbed, but the floor panel deforms at the occupant's foot area causing injury
Solution Approach 1:
The reinforcement element acts as an intermediary structural component between the longitudinal beam and the lowerside sill part. It mediates the force distribution during small overlap crashes, preventing the direct transmission of deforming forces to the floor panel while allowing the wheel to rotate inward for energy absorption
3Manufacturing precision
If the reinforcement element is made of press-hardened steel with high tensile strength, then the transverse distance is maintained preventing floor panel deformation, but the manufacturing complexity increases
Solution Approach 1:
The press-hardened steel reinforcement element is pre-formed with the required geometric precision and structural characteristics before assembly. The press-hardening process creates the final shape and mechanical properties in advance, eliminating the need for complex on-site manufacturing or adjustment operations
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 reinforcement element effectively reduces deformation of the floor panel, preserving the space for occupants' feet and enhancing the vehicle's structural integrity during a small overlap crash, thereby protecting the occupants from injury.
Implementation Method 1
the reinforcement element is made of a press-hardened steel part having a tensile strength higher or equal to 1200 MPa
Data Source
AI summary
A vehicle underbody structure containing a floor panel, at least one longitudinal beam extending in a longitudinal direction of the vehicle under said floor panel and at least one lowerside sill part extending in the longitudinal direction adjacent to the floor panel, and at least one reinforcement element extending in a transversal direction, substantially perpendicular to the longitudinal direction, said reinforcement element made of a press hardened steel part having a tensile strength higher or equal to 1200 MPa and extending under the floor panel and being attached at one of its transversal ends to the longitudinal beam and at the other of its transversal ends to the lowerside sill part is provided. A vehicle body including the vehicle underbody structure is also provided.