This application is related to U.S. patent application Ser. No. 15/251,029, entitled “TWENTY-EIGHT-CORNERED STRENGTHENING MEMBER FOR VEHICLES,” and filed on a date even herewith; the entire contents of which is incorporated by reference herein.
The present disclosure relates generally to a strengthening member for a vehicle body or other structures. The present disclosure relates more specifically to a strengthening member having a twenty-eight-cornered cross section and to motor vehicles including a strengthening member having a twenty-eight-cornered cross section.
It is desirable, for vehicle strengthening members, to maximize impact energy absorption and bending resistance while minimizing mass per unit length of the strengthening member. Impact energy absorption may be maximized, for example, by assuring that the strengthening member compacts substantially along a longitudinal axis of the strengthening member upon experiencing an impact along this axis. Such longitudinal compaction may be referred to as a stable axial crush of the strengthening member.
When a compressive force is exerted on a strengthening member, for example, by a force due to a front impact load on a vehicle's front rail or other strengthening member in the engine compartment, the strengthening member can crush in a longitudinal direction to absorb the energy of the collision. In addition, when a bending force is exerted on a strengthening member, for example, by a force due to a side impact load on a vehicle's front side sill, B-pillar or other strengthening member, the strengthening member can bend to absorb the energy of the collision.
Conventional strengthening members rely on increasing the thickness and hardness of side and/or corner portions to improve crush strength. However, such increased thickness and hardness increases weight of the strengthening member and reduces manufacturing feasibility. It may be desirable to provide a strengthening assembly configured to achieve the same or similar strength increase as provided by the thickened sides and/or corners, while minimizing mass per unit length of the member, and maintaining a high manufacturing feasibility.
It may further be desirable to provide a strengthening member that can achieve increased energy absorption and a more stable axial collapse when forces such as front and side impact forces are exerted on the strengthening member, while also conserving mass to reduce vehicle weights and meet emission requirements. Also, it may be desirable to provide a strengthening member that can achieve improved energy absorption and bend when a bending force is exerted on the strengthening member. Additionally, it may be desirable to provide a strengthening member that possesses improved noise-vibration-harshness performance due to work hardening on its corners. In addition, it may be desirable, to provide a tunable strengthening member cross-section configured to achieve strength increases (i.e., load carrying and energy absorption) over basic polygonal designs, while also allowing flexibility in design to meet a range of vehicle applications.
In accordance with various exemplary embodiments of the present disclosure, a strengthening member is provided. The strengthening member has a cross section including twenty-eight corners and twenty-eight sides creating twenty internal angles and eight external angles, and at least one recessed area extending along a length of the strengthening member.
In accordance with another aspect of the present disclosure, a strengthening member for a motor vehicle is provided. The strengthening member has a cross section including twenty-eight corners and having twenty-eight sides arranged to create internal angles and external angles. The angles alternate in a pattern including five consecutive internal angles and two consecutive external angles.
In accordance with another aspect of the present disclosure, a vehicle is provided. The vehicle includes a strengthening member. The strengthening member has a cross section including twenty-eight corners and twenty-eight sides creating twenty internal angles and eight external angles, and at least one recessed portion extending along a length of the strengthening member.
In accordance with another aspect of the present disclosure, a strengthening member is provided. The strengthening member has twenty-eight sides and twenty-eight corners. A cross section of the strengthening member includes four lobe portions extending from a central portion defined by four of the twenty-eight sides.
Additional objects and advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present teachings. The objects and advantages of the present disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the claimed subject matter. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate exemplary embodiments of the present disclosure and together with the description, serve to explain principles of the present teachings.
At least some features and advantages of the present teachings will be apparent from the following detailed description of exemplary embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:
Although the following detailed description makes reference to exemplary illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.
Reference will now be made in detail to various exemplary embodiments, examples of which are illustrated in the accompanying drawings. The various exemplary embodiments are not intended to limit the disclosure. To the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents of the exemplary embodiments. In the drawings and the description, similar elements are provided with similar reference numerals. It is to be noted that the features explained individually in the description can be mutually combined in any technically expedient manner and disclose additional embodiments of the present disclosure.
The present teachings contemplate strengthening members with twenty-eight-cornered cross sections. The cross-sectional configuration of these strengthening members provides increased stiffness throughout the sides and corners of the strengthening members when compared to conventional strengthening members. Such conventional strengthening members must rely on increasing thickness within the corners to achieve increases in strength, which result in increases in the weight of the conventional strengthening members. The strengthening members of the present disclosure are designed based in part on, for example, a variety of tunable parameters configured to achieve strength increases (i.e., load carrying and energy absorption) over basic polygonal designs (e.g., polygonal strengthening member cross sections having less or the same number of sides), while also allowing design flexibility to meet a range of vehicle applications.
In accordance with the present teachings, the shape of the strengthening members disclosed herein provides the strengthening member with stabilized folding, reduced crush distance, and increased energy absorption in response to an axially applied crash force when compared to conventional strengthening members. In at least some embodiments, the shape also improves moisture shedding abilities of the strengthening member and permits a more customized fit with other vehicle components.
The strengthening members in accordance with the present teachings can achieve increased energy absorption and a more stable axial collapse when forces such as front and side impact forces are exerted on the strengthening member. Furthermore, the side lengths and configurations, and/or degrees of the internal and external angles, of the strengthening members in accordance with the present teachings can achieve a similar, if not greater, strength increase as thickened corners, while minimizing mass per unit length of the member and maintaining a high manufacturing feasibility because the member can be formed by stamping, bending, press forming, hydro-forming, molding, casting, extrusion, uniform or non-uniform roll forming, machining, forging, 3-D printing, and/or other known suitable manufacturing processes. Thus-formed sections can be joined via welding, brazing, soldering, adhesive bonding, fastening, press fitting or other known joining technologies.
Strengthening members in accordance with the present teachings may be made, for example, of steel alloys, titanium alloys, aluminum alloys, magnesium alloys, nylons, plastics, polymers, composites, fiber-reinforced composites, silicone, semiconductor, papers, hybrid materials (i.e., multiple dissimilar materials), shape-memory materials, foams, gels or any other suitable materials. Those of ordinary skill in the art would understand, for example, that the material used for a strengthening member may be chosen based at least in part on intended application, strength/weight considerations, cost, packaging space, and/or other design factors.
Turning to the drawings, an exemplary embodiment of a cross section of a strengthening member 100 having twenty-eight corners in accordance with the present teachings is illustrated in
As labeled in
The perimeter of the twenty-eight-sided cross section generally forms a polygon comprising a plurality of internal and external corners. As embodied herein and shown in
Depending upon the particular application and/or the desired features of the strengthening member, the cross-sectional lengths of the sides of the strengthening member and the cross-sectional thicknesses of the sides of the twenty-eight-sided, twenty-eight-cornered strengthening member as well as the internal and external corner angles of the strengthening member can be varied (i.e., can be tuned) to achieve improved strength and other performance features (e.g., stability of folding pattern) of the strengthening member when compared to conventional strengthening members. Varying these features of the twenty-eight-sided, twenty-eight-cornered strengthening member may obviate the need for increased side and/or corner thickness. In accordance with various exemplary embodiments of the present teachings, the cross-sectional lengths L1-L28 of sides S1-S28, the cross-sectional thicknesses T1-T28 of the sides as well as the cross-sectional internal angles i1-i20 of the internal corners and external angles e1-e8 of the external corners can be varied to a certain degree, as would be understood by one skilled in the art, for example in accordance with available packaging space within a vehicle.
In addition, in a strengthening member in accordance with the present teachings, each internal corner angle i1-i20 of a cross-section of the strengthening member can range from about 30° to about 175°, and each external corner angle e1-e8 of a cross section of the strengthening member can range from about 45° to about 175°. In accordance with the present teachings, the internal angles i1-i20 of a cross section of the strengthening member may all be substantially the same, and/or, the external angles e1-e8 of a cross-section of the strengthening member may all be substantially the same. Additionally or alternatively, the present disclosure contemplates embodiments in which at least some of the internal angles i1-i20 of a cross section of the strengthening member differ from one another, and/or similarly, at least some of the external angles of e1-e8 a cross-section of the strengthening member differ from one another.
In various exemplary embodiments according to the present disclosure, the internal angles i1-i5, i6-i10, i11-i15, and i16-i20 that at least partially define each lobe portion 141-144 may or may not all be substantially the same, and/or, the internal angles e1-e8 that at least partially define the central portion may or may not all be substantially the same, and/or the external angles e1-e8 may all be substantially the same. For example,
In certain exemplary embodiments of the present disclosure, such as in an automotive application, for example, a cross-sectional length L1-L28 of each side S1-S28 of a cross section of the strengthening member can range from about 10 mm to about 250 mm. In other exemplary embodiments, such as in an aircraft, spacecraft, watercraft, or building application, for example, a cross-sectional length L1-L28 of each side S1-S28 of the cross section of the strengthening member may be longer.
In certain exemplary embodiments of the present disclosure, such as in an automotive application, for example, a thickness T1-T28 of the sides of the cross section of the strengthening member can range from about 0.6 mm to about 6.0 mm. In other exemplary embodiments of the strengthening member, such as in an aircraft, spacecraft, watercraft, or building application, for example, a thickness T1-T28 of the sides of a cross section of the strengthening member may be greater. In one exemplary embodiment, a cross-sectional thickness T1-T28 of each of the sides of the strengthening member may be about 3.3 mm. In another exemplary embodiment, a cross-sectional thickness T1-T28 of each of the sides may be about 2.3 mm. In another exemplary embodiment, a cross-sectional thickness T1-T28 of each of the sides may be about 2.0 mm. In some exemplary embodiments, the cross-sectional thickness T1-T28 of the sides is substantially the same as the thickness of the corners for each side. In some exemplary embodiments the cross-sectional thickness T1-T28 of each side wall, (e.g., side walls S201-S228, respectively (see
Top and perspective views of a first exemplary embodiment of a strengthening member 200 having a twenty-eight-cornered cross section, with twenty internal angles and eight external angles are illustrated in
Also, as shown in
Strengthening member 200 also has a first transverse axis 230, a second transverse axis 240, and a longitudinal axis 250. Although shown with its longitudinal axis 250 positioned substantially vertically (in
The strengthening member 200 of
Top and perspective views of an alternative exemplary embodiment of a strengthening member 300 having a twenty-eight-cornered cross section, with twenty internal angles and eight external angles, are illustrated in
Strengthening member 300 may differ from strengthening member 200 in several aspects. For example, as shown in
In the exemplary embodiment of
In the disclosed exemplary embodiment of
Top and perspective views of an alternative exemplary embodiment of a strengthening member 400 having the twenty-eight-cornered cross section, with twenty internal angles and eight external angles, are illustrated in
Similar to the strengthening member 200, strengthening member 400 has a uniform cross section along a length LL1400 of the strengthening member 400, from a first end 460 to a second end 470 of the strengthening member 400. However, as shown in
In the exemplary embodiment of
Additionally, in the exemplary embodiment of
As also shown in
Top and perspective views of an alternative exemplary embodiment of a strengthening member 500 having the twenty-eight-cornered cross section, with twenty internal angles and eight external angles, are illustrated in
Similar to the strengthening member 300, strengthening member 500 tapers along its longitudinal axis 550 from first end 560 of strengthening member to second end 570 of strengthening member 500. Strengthening member 500 tapers along its length at an angle α, which may range from about 1° to about 65°. In the exemplary embodiment of
As illustrated in
Top and perspective views of an alternative exemplary embodiment of a strengthening member 600 having the twenty-eight-cornered cross section, with twenty internal angles and eight external angles, are illustrated in
Similar to strengthening members 300 and 500, strengthening member 600 tapers along its longitudinal axis 650 from first end 660 of strengthening member 600 to second end 670 of strengthening member 600. Strengthening member 600 tapers along its length LL600 at an angle α, which may range from about 1° to about 65°. In the exemplary embodiment of
In addition, strengthening member 600 of the exemplary embodiment shown in
Top and perspective views of an alternative exemplary embodiment of a strengthening member 700 having a twenty-eight-cornered cross-section, with twenty internal angles and eight external angles, are illustrated in
In contrast, strengthening member 700 does not include a recessed portion in which liquids or moisture can remain for a long period of time. In particular, each of internal angles i701-i720 and external angles e701-e708 have been selected such that walls S701-S728 of strengthening member 700 are angled relative to one another to promote shedding of any moisture or fluid that falls within any recessed portion of strengthening member 700. For example, as shown in
In the exemplary embodiment of
Recessed portions 731-734 are relatively shallow compared to the depth the recessed areas 831-834 shown in strengthening member 800, illustrated in
Top and perspective views of an alternative exemplary embodiment of a strengthening member 800 having the twenty-eight-cornered cross-section, with twenty internal angles and eight external angles, are illustrated in
In the exemplary embodiment of
The cross-sectional lengths L801-L828 of the sides S801-S828, respectively, have each been selected such that recessed areas 831-834 have a depth δ831-δ834, respectively. This depth is relatively greater than the depth the recessed areas 731-734 shown in strengthening member 700, illustrated in
More generally, the various exemplary embodiments of the present teachings contemplate, for example, strengthening members with corners having different bend radii, with non-uniform cross sections, having non-symmetrical shapes, with sides having variable thicknesses, and/or having variable tapered sides. Various additional exemplary embodiments contemplate strengthening members that are bent and/or curved. Moreover, to further adjust a member's folding pattern and/or peak load capacity, various additional exemplary embodiments also contemplate strengthening members having trigger holes, flanges, and/or convolutions as would be understood by those of ordinary skill in the art. Combinations of one or more of the above described variations are also contemplated.
As discussed and embodied herein, the cross-sectional lengths L1-L28 and thicknesses T1-T28 of the sides of a strengthening member are tunable parameters of the strengthening member. The cross-sectional lengths L1-L28 and thicknesses T1-T28 of the sides may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of
As discussed and embodied herein, the aspect ratio of a cross section of a strengthening member is a tunable parameter of the strengthening member in accordance with the present teachings. The aspect ratio of a cross section of a strengthening member may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of
As discussed and embodied herein, the cross sectional lengths L1-L28 of the sides S1-S28 of the cross section of a strengthening member is a tunable parameter in accordance with the present teachings. The lengths L1-L28 of the sides S1-S28 of a strengthening member may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of
As discussed and embodied herein, the twenty internal angles i1-i20 and eight external angles e1-e8 are tunable parameters of the strengthening member. The internal angles i1-i20 and external angles e1-e8 may be tuned to provide desired characteristics in the strengthening member. For example, in the embodiment of
As discussed and embodied herein, multiple tunable parameters—including but not limited to the cross-sectional lengths L1-L28 and thicknesses T1-T28 of the sides of a strengthening member, the aspect ratio of a cross section of the strengthening member, the internal angles i1-i20 and external angles e1-e8 of the corners, the size of the recessed areas, and the size of the lobe portions—may all be tuned within the same strengthening member to provide desired characteristics in the strengthening member.
In the various illustrated exemplary embodiments of
To demonstrate the improved strength and performance features of a twenty-eight-cornered cross section having twenty internal angles and eight external angles in accordance with the present teachings, the inventors compared various existing and conventional strengthening member cross section designs to cross sections based on the designs disclosed herein. Exemplary strengthening members were modeled and crash simulation runs were conducted, as shown and described below with reference to
Strengthening members having varying cross-sectional shapes and having the same mass, thickness, and longitudinal length were modeled as illustrated in
Twenty-eight-cornered cross sections in accordance with the present teachings may, therefore, allow improved impact energy management over, for example, basic polygonal strengthening member cross sections, by minimizing mass per unit length, thereby providing mass saving solutions that reduce vehicle weight and meet new corporate average fuel economy (CAFE) and emission standards.
Beyond the increased load carrying and energy absorption efficiency, strengthening members in accordance with the present teachings may provide additional advantages or benefits such as improved moisture shedding abilities (as noted above), increased bending energy absorption capacity, improved manufacturing feasibility, and better fitting of the shape amongst the other components of the complete device (e.g., vehicle, as noted above).
In addition, a twenty-eight-cornered strengthening member in accordance with the present teachings also may be tuned to accommodate unique packaging requirements for use in various vehicles. By virtue of the particular shape of the cross section of at least some of the twenty-eight-cornered strengthening members, it may be easier to couple, bond, attach, or otherwise affix other device components to the strengthening member. Other device components can include, but are not limited to, engine mounts or transmission mounts.
Twenty-eight-cornered strengthening members in accordance with the present teachings are contemplated for use as structural members in a number of environments. For example, in a motor vehicle, a strengthening member as disclosed herein may be used, for example, as one or more of crush cans, front rails, mid-rails, rear rails, side rails, shotguns, cross members, roof structures, beltline tubes, door beams, pillars, internal reinforcements, and other components that can benefit from increased crash energy absorption or the other advantages described herein. In addition, the present teachings can be applied to both body-on-frame and unitized vehicles, or other types of structures.
For example, as shown in
Moreover, the strengthening members in accordance with the present disclosure may be used as, or form a part of, a vehicle underbody component, for example, a rocker and/or one or more underbody cross members. Also, the strengthening members in accordance with the present disclosure may be used as or form a part of vehicle engine compartment components, for example, as one or more engine compartment cross members.
Depending on the application, embodiments of the present teachings will have varied shapes (i.e. various cross sections) to accommodate specific member space constraints. When used as a vehicle front rail, for example, to achieve optimized axial crush performance, the lengths and thicknesses of the sides and/or angles of the corners can all be adjusted (tuned) to provide optimal strength, size and shape to meet engine compartment constraints.
Although various exemplary embodiments described herein have been described as configured to be used with automotive vehicles (e.g., car, truck, van, ATV, RV, motorcycle, etc.), it is envisioned that the various strengthening members in accordance with the present teachings may be configured for use with other types of vehicles (e.g. aircrafts, spacecrafts and watercrafts) and/or structures, for which it may be desirable to provide increased crash energy absorption. Thus, it will be appreciated by those of ordinary skill in the art having the benefit of this disclosure that the present teachings provide strengthening members for various applications. Further modifications and alternative embodiments of various aspects of the present teachings will be apparent to those skilled in the art in view of this description.
It is to be understood that the particular examples and embodiments set forth herein are non-limiting, and modifications to structure, dimensions, materials, and methodologies may be made without departing from the scope of the present teachings.
In particular, those skilled in the art will appreciate that a strengthening member may include more than one longitudinal section or portion, with each section or portion having one or more of the variations taught in accordance with the present disclosure. Said variation(s) can be made continuously or intermittently along the length of each longitudinal section. In other words, strengthening members that embody combinations of one or more of the above variations to the disclosed tunable parameters, which have not been illustrated or explicitly described, are also contemplated.
For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the written description and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present teachings are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein.
It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
It will be apparent to those skilled in the art that various modifications and variations can be made to the devices and methods of the present disclosure without departing from the scope of its teachings. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only.
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104443039 | Mar 2015 | CN |
104763772 | Jul 2015 | CN |
104890308 | Sep 2015 | CN |
105235616 | Jan 2016 | CN |
102005037055 | Feb 2007 | DE |
102009035782 | Mar 2010 | DE |
0856681 | Aug 1998 | EP |
2375496 | Jul 1978 | FR |
1123337 | Aug 1968 | GB |
08-337183 | Dec 1996 | JP |
3897542 | Jan 2007 | JP |
2007-023661 | Feb 2007 | JP |
2008-0168745 | Jul 2008 | JP |
2008261493 | Oct 2008 | JP |
2009184417 | Aug 2009 | JP |
04-371059 | Nov 2009 | JP |
2011051581 | Mar 2011 | JP |
2012107660 | Jun 2012 | JP |
2013-159132 | Aug 2013 | JP |
5348910 | Aug 2013 | JP |
2014004973 | Jan 2014 | JP |
2015124784 | Jul 2015 | JP |
2246646 | Oct 2004 | RU |
9209766 | Jun 1992 | WO |
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Number | Date | Country | |
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20180057058 A1 | Mar 2018 | US |