Vehicle Side Impact Structure Using Sandwiched Pipe and Stamped Members
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Solution Overview
Problem
Current vehicle body structures face challenges in effectively absorbing side impacts while minimizing intrusion into the occupant space, particularly in light trucks where the impact location is lower due to increased height, and in maintaining crash performance standards set by regulatory bodies like NHTSA and IIHS.
Innovation Solution
A vehicle body structure that includes a pipe member sandwiched between lower and upper stamped members, which extends laterally across the vehicle frame, providing axial loading through MIG welding and integration with bulkheads and stiffeners to enhance structural integrity and crash absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional sheet metal stampings and steel tubes are used for side crash structure, then structural strength and crash absorption are improved, but vehicle weight and manufacturing cost increase
Solution Approach 1:
The patent employs a composite structure combining a steel pipe member with aluminum alloy stamped members (upper and lower side stamped members). This composite material approach allows the structure to achieve high strength and crash absorption performance while reducing overall weight compared to traditional all-steel constructions. The steel pipe provides core structural strength, while the aluminum stamped members reduce weight and facilitate integration with the vehicle body.
Solution Approach 2:
The side crash structure is divided into distinct functional segments: the pipe member extending laterally across the vehicle frame, the upper stamped member, and the lower stamped member. This segmentation allows each component to be optimized independently for its specific function while collectively achieving the desired crash absorption performance with reduced weight.
2Strength
If traditional sheet metal stampings and steel tubes are used for side crash structure, then structural strength and crash absorption are improved, but manufacturing cost increases
Solution Approach 1:
By using aluminum alloy stamped members in combination with the pipe member, the patent reduces manufacturing complexity and cost. The stamped members can be produced using conventional stamping processes, and the overall structure requires fewer components and assembly steps compared to traditional multi-piece steel tube constructions, thereby lowering manufacturing costs while maintaining crash absorption performance.
Solution Approach 2:
The upper and lower stamped members are integrated with the pipe member to form a unified structural assembly. This merging of components simplifies the overall structure, reduces the number of separate parts, and facilitates easier manufacturing and assembly compared to traditional designs that require multiple discrete steel tubes and brackets.
3Strength
If the pipe member is enclosed between stamped members, then structural integrity and crash absorption are improved, but device complexity increases
Solution Approach 1:
The pipe member is enclosed between the upper and lower stamped members to form an integrated structural assembly. This merging approach enhances structural integrity by creating a unified load-bearing system that effectively absorbs side crash forces, while the modular nature of the components keeps the overall complexity manageable.
Solution Approach 2:
The structure is segmented into three main components (pipe member, upper stamped member, lower stamped member) that can be manufactured and assembled separately. This segmentation allows for optimized design of each component while maintaining relatively simple individual structures, avoiding the need for complex monolithic designs.
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 configuration reduces weight and cost while maintaining side impact crash characteristics, effectively absorbing side impacts and minimizing intrusion into the occupant space, thus meeting regulatory standards.
Implementation Method 1
The pipe member is MIG welded to the stamped members to axially load the pipe member for side impact collisions
Data Source
AI summary
A vehicle body structure for absorbing side impacts includes a pipe member extending laterally from a first lateral side of a vehicle frame to a second lateral side of the vehicle frame. The vehicle body structure also includes a lower stamped member or assembly and an upper stamped member. The lower stamped member or assembly is disposed on an underside of the pipe member and extends laterally from the first lateral side of the vehicle to the second lateral side of the vehicle. The upper side stamped member is disposed over the pipe member to sandwich the pipe member between the lower side and the upper side stamped members. The upper side stamped member extends laterally from the first lateral side of the vehicle frame to the second lateral side of the vehicle frame.