Vehicle Frame Bracket Managing Load Transfer via Deformation
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Solution Overview
Problem
Existing vehicle frame designs face challenges in selectively managing load transfers between components while maintaining sufficient stiffness, particularly in preventing load transfer to the occupant cabin during impacts.
Innovation Solution
A bracket system is introduced that couples shotgun beam components and hinge pillar components with a defined space, allowing lateral deflection of the shotgun beam components away from the hinge pillar components upon deformation, thereby inhibiting impact force transfer to the occupant cabin, using fasteners, adhesive materials, or welds with a deformation threshold that facilitates controlled energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vehicle frame components are fixed to one another at robust joints to achieve sufficient stiffness, then structural stiffness is improved, but the ability to selectively manage load transfers is worsened
Solution Approach 1:
The bracket incorporates a deformation feature that transitions from a rigid state during normal operation to a deformable state during impact events. This dynamic behavior allows the joint to maintain stiffness under normal conditions while enabling controlled load transfer management during collisions, resolving the contradiction between structural rigidity and adaptive load management.
Solution Approach 2:
The bracket's deformation feature changes its mechanical parameters (stiffness, strength) based on the magnitude of applied loads. Under normal operating conditions, the bracket maintains high stiffness through its robust construction, but under impact conditions exceeding a threshold, the deformation feature yields to allow load transfer management. This parameter change enables both robust stiffness and selective load management.
2Stability of the object's composition
If robust joints are used to maintain structural stiffness, then frame rigidity is improved, but impact force transfer to occupant cabin is worsened
Solution Approach 1:
The bracket serves as an intermediary element between the shotgun beam component and the hinge pillar component. It includes a deformation feature that acts as a controlled weak point, allowing impact forces to be absorbed and managed in a predetermined manner. This intermediary structure protects the overall frame rigidity while preventing harmful force transfer to the occupant cabin during impacts.
Solution Approach 2:
The bracket is designed with a predetermined deformation feature that is configured to yield under impact conditions before forces can propagate to the occupant cabin. This beforehand cushioning mechanism ensures that impact energy is absorbed at the bracket level, protecting critical frame components and the cabin from harmful force transfers while maintaining normal structural rigidity.
3Adaptability or versatility
If deformation features are designed into the bracket, then load transfer management is improved, but manufacturing complexity is worsened
Solution Approach 1:
The bracket is segmented into distinct functional zones: a robust connection portion for maintaining structural integrity and a deformation feature portion for load transfer management. This segmentation allows each zone to be optimized independently - the connection portion for strength and the deformation feature for controlled yielding - while simplifying the overall design by clearly defining functional boundaries.
Solution Approach 2:
The bracket applies local quality by concentrating the deformation feature at specific strategic locations where load transfer management is most needed, while maintaining robust construction in other areas. This localized approach to deformation allows the bracket to achieve adaptive load management without requiring complex features throughout the entire structure, thereby reducing overall manufacturing complexity.
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 solution effectively manages load transfer and deformation in vehicle frames, enhancing safety by reducing the impact force transmitted to the occupant cabin while maintaining structural stiffness and durability.
Implementation Method 1
the bracket (200) includes a deformation feature (280) configured to deform upon application of a load exceeding a predetermined threshold
Data Source
AI summary
A frame portion for a vehicle includes a pillar component extending along a first direction and a beam component at least partially extending along a second direction substantially orthogonal to the first direction. The beam component has a rear end proximate the pillar component. The frame portion further includes a bracket coupled between the pillar component and the rear end of the beam component. The bracket spaces the beam component from the pillar component.