U.S. patent application number 16/391652 was filed with the patent office on 2019-08-15 for sixteen-cornered strengthening member for vehicles.
This patent application is currently assigned to FORD GLOBAL TECHNOLOGIES, LLC. The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to Yu-Kan HU, Leonard Anthony SHANER, Dana SUN, Tau TYAN.
Application Number | 20190248415 16/391652 |
Document ID | / |
Family ID | 57135462 |
Filed Date | 2019-08-15 |
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United States Patent
Application |
20190248415 |
Kind Code |
A1 |
TYAN; Tau ; et al. |
August 15, 2019 |
SIXTEEN-CORNERED STRENGTHENING MEMBER FOR VEHICLES
Abstract
A strengthening member for a motor vehicle, the strengthening
member has a cross section that comprises sixteen corners and
includes sides and corners creating eight internal angles and eight
external angles. Each internal angle ranges between about
90.degree. and about 145.degree. and each external angle ranges
between about 95.degree. and about 175.degree.. One or more tunable
parameters of a cross section can vary along a longitudinal axis of
the strengthening member.
Inventors: |
TYAN; Tau; (Northville,
MI) ; HU; Yu-Kan; (Ypsilanti, MI) ; SHANER;
Leonard Anthony; (New Baltimore, MI) ; SUN; Dana;
(Novi, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
FORD GLOBAL TECHNOLOGIES,
LLC
Dearborn
MI
|
Family ID: |
57135462 |
Appl. No.: |
16/391652 |
Filed: |
April 23, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14749426 |
Jun 24, 2015 |
10315698 |
|
|
16391652 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B62D 25/00 20130101;
B60R 19/34 20130101; B62D 21/15 20130101; B62D 21/02 20130101; F16F
7/12 20130101 |
International
Class: |
B62D 21/02 20060101
B62D021/02; B60R 19/34 20060101 B60R019/34; B62D 21/15 20060101
B62D021/15; B62D 25/00 20060101 B62D025/00; F16F 7/12 20060101
F16F007/12 |
Claims
1. A strengthening member for a motor vehicle, the strengthening
member comprising a sixteen-cornered cross section including
sixteen corners and including sides and corners creating eight
internal angles and eight external angles, wherein each internal
angle ranges between about 90.degree. and about 145.degree., and
wherein each external angle ranges between about 95.degree. and
about 175.degree..
2. The strengthening member of claim 1, wherein each of the eight
internal angles is substantially the same.
3. The strengthening member of claim 1, wherein each of the eight
external angles is substantially the same.
4. The strengthening member of claim 1, wherein at least one
internal angle is a right angle.
5. The strengthening member of claim 4, wherein each of the
internal angles is a right angle.
6. The strengthening member of claim 1, further comprising at least
one recessed portion.
7. The strengthening member of claim 6, wherein the at least one
recessed portion is defined by two internal angles and two external
angles of the strengthening member.
8. The strengthening member of claim 7, wherein the two external
angles defining the recessed portion are adjacent to one
another.
9. The strengthening member of claim 8, wherein the two external
angles defining the recessed portion are the same.
10. The strengthening member of claim 8, wherein the two internal
angles are each greater than 90 degrees.
11. The strengthening member of claim 6, wherein the at least one
recessed portion is defined by three sides of the strengthening
member.
12. The strengthening member of claim 11, wherein the three sides
of the strengthening member defining the at least one recessed
portion have the same length.
13. The strengthening member of claim 11, wherein two of the three
sides of the strengthening member defining the at least one
recessed portion have the same length and the other of the three
sides has a different length.
14. The strengthening member of claim 6, wherein the at least one
recessed portion comprises four recessed areas, wherein each
recessed area extends along a length of the strengthening member
from a first end of the strengthening member to a second end of the
strengthening member.
15. The strengthening member of claim 1, wherein the corners of the
cross section have substantially the same thickness as the sides of
the cross section.
16. A strengthening member for a motor vehicle, the strengthening
member comprising: a cross section comprising sixteen corners and
including sides and corners creating eight internal angles and
eight external angles; and a longitudinal axis, wherein the
strengthening member tapers along the longitudinal axis.
17. The strengthening member of claim 16, wherein each internal
angle is adjacent to another internal angle and an external
angle.
18. The strengthening member of claim 17, wherein the cross section
has more than two bisecting planes of symmetry.
19. The strengthening member of claim 18, wherein the cross section
has four bisecting planes of symmetry.
20. The strengthening member of claim 16, wherein at least one
internal angle of the cross section varies along at least a portion
of a length of the strengthening member.
21. The strengthening member of claim 16, wherein a thickness of at
least one side of the strengthening member varies along at least a
portion of a length of the strengthening member.
22. A vehicle comprising: a strengthening member comprising a
sixteen-cornered cross section including sixteen corners and
including sides and corners creating eight internal angle corners
and eight external angle corners.
23. The vehicle of claim 22, wherein the strengthening member is,
or is within, at least one vehicle structural member selected from
the group consisting of: a crush can, a front horn, a front rail, a
front side rail, a rear side rail, a rear rail, a frame cross
member, a shotgun, a hinge-pillar, an A-pillar, a B-pillar, a
C-pillar, a door beam, a cross car beam, a front header, a rear
header, a cow top, a roof rail, a lateral roof bow, longitudinal
roof bow, a body cross member, a back panel cross member, a rocker,
an underbody cross member, and an engine compartment cross member.
Description
RELATED APPLICATION
[0001] This application is a Divisional of U.S. patent application
Ser. No. 14/749,426, filed on Jun. 24, 2015 (currently pending),
the entire contents of which is incorporated by reference
herein.
TECHNICAL FIELD
[0002] 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 sixteen-cornered cross section and to motor vehicles
including a strengthening member having a sixteen-cornered cross
section.
BACKGROUND
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
SUMMARY
[0007] In accordance with various exemplary embodiments of the
present disclosure, a strengthening member for a motor vehicle is
provided. The strengthening member has a sixteen-cornered cross
section comprising sixteen corners and including sides and corners
creating eight internal angles and eight external angles. Each
internal angle ranges between about 90.degree. and about
145.degree.. Each external angle ranges between about 95.degree.
and about 175.degree..
[0008] In accordance with another aspect of the present disclosure,
a strengthening member for a motor vehicle comprises a cross
section comprising sixteen corners and including sides and corners
creating eight internal angles and eight external angles. The
strengthening member has a longitudinal axis, and the strengthening
member tapers along the longitudinal axis.
[0009] In accordance with a further aspect of the present
disclosure, a vehicle comprises a strengthening member. The
strengthening member comprises a sixteen-cornered cross section
including sixteen corners and including sides and corners creating
eight internal angle corners and eight external angle corners.
[0010] 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.
[0011] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] 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:
[0013] FIG. 1 illustrates an exemplary embodiment of a
sixteen-cornered cross section of a strengthening member, with the
strengthening member having eight internal angles and eight
external angles in accordance with the present teachings;
[0014] FIGS. 2A-2B illustrate top and perspective views of a first
exemplary embodiment of a strengthening member having a
sixteen-cornered cross section, with eight internal angles and
eight external angles, as shown in FIG. 1;
[0015] FIGS. 3A-3B illustrate top and perspective views of a second
exemplary embodiment of a strengthening member having
sixteen-cornered cross sections, with eight internal angles and
eight external angles in accordance with the present teachings;
[0016] FIGS. 4A-4B illustrate top and perspective views of a third
exemplary embodiment of a strengthening member having
sixteen-cornered cross sections, with eight internal angles and
eight external angles in accordance with the present teachings;
[0017] FIGS. 5A-5B illustrate top and perspective views of a fourth
exemplary embodiment of a strengthening member having
sixteen-cornered cross sections, with eight internal angles and
eight external angles in accordance with the present teachings;
[0018] FIGS. 6A-6B illustrate top and perspective views of a fifth
exemplary embodiment of a strengthening member having
sixteen-cornered cross sections, with eight internal angles and
eight external angles in accordance with the present teachings;
[0019] FIG. 7 illustrates strengthening members of various cross
sections having substantially the same thickness, substantially the
longitudinal length, and cross-sectional dimensions along
perpendicularly oriented transverse axes with substantially the
same lengths;
[0020] FIG. 8 illustrates an exemplary quasi-static axial collapse
of the strengthening members shown in FIG. 7;
[0021] FIG. 9 illustrates an exemplary dynamic crush of the
strengthening members shown in FIG. 7;
[0022] FIG. 10 is a graph of the dynamic crush force and associated
crush distance for the exemplary strengthening members shown in
FIG. 7;
[0023] FIG. 11 is a graph of the dynamic axial crush energy and
associated axial crush distance for the exemplary strengthening
members shown in FIG. 7;
[0024] FIG. 12 illustrates sixteen-cornered strengthening members
of varying cross-sectional shapes, each cross-section having sides
with substantially the same thickness, substantially the same
longitudinal length, and cross-sectional dimensions along
perpendicularly oriented transverse axes with substantially the
same lengths;
[0025] FIG. 13 illustrates an exemplary quasi-static axial collapse
of the strengthening members shown in FIG. 12;
[0026] FIG. 14 illustrates an exemplary dynamic crush of the
strengthening members shown in FIG. 12;
[0027] FIG. 15 is a graph of the dynamic crush force and associated
axial crush distance for exemplary strengthening members having the
cross sections shown in FIG. 12;
[0028] FIG. 16 is a graph of the dynamic axial crush energy and
associated axial crush distance for exemplary strengthening members
having the cross sections shown in FIG. 12;
[0029] FIG. 17 illustrates an exemplary embodiment of a vehicle
frame with several components for which a strengthening member
having sixteen-cornered cross sections, with eight internal angles
and eight external angles can be used; and
[0030] FIG. 18 illustrates an exemplary embodiment of a vehicle
upper body with several components for which a strengthening member
having sixteen-cornered cross sections, with eight internal angles
and eight external angles can be used.
[0031] 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.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0032] 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.
[0033] The present teachings contemplate strengthening members with
sixteen-cornered cross sections having substantially increased
stiffness throughout the sides and corners without increasing
thickness within the corners as done in 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.
[0034] 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. The shape also improves moisture shedding abilities of the
strengthening member and permits a more customized fit with other
vehicle components.
[0035] 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, and/or other known manufacturing
processes. Thus-formed sections can be joined via welding, brazing,
soldering, adhesive bonding, fastening, press fitting or other
known joining technologies.
[0036] Strengthening members in accordance with the present
teachings can comprise, for example, traditional steels, advanced
high strength steels (AHSS), ultra high strength steels (UHSS),
new/next generation high strength steels (NGHSS), titanium alloys,
aluminum alloys, magnesium alloys, nylons, plastics, composites,
hybrid materials 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.
[0037] An exemplary embodiment of a sixteen-cornered cross section
of a strengthening member 100 in accordance with the present
teachings is illustrated in FIG. 1. The strengthening member 100
has sixteen sides. The illustrated cross section of the
strengthening member 100 comprises sixteen sides having lengths
S.sub.1-S.sub.16 and thicknesses T.sub.1-T.sub.16, eight internal
corners with angles and eight external corners with angles .sub.e1-
.sub.e8.
[0038] The perimeter of the sixteen-sided cross section generally
forms a polygon comprising a plurality of internal and external
corners. As embodied herein and shown in FIG. 1, the polygon may be
formed of alternating internal and external angles, and in
particular, may be formed by alternating two consecutive internal
corners/angles with two consecutive external corners/angles. This
repeating pattern, which alternates between two consecutive
internal corners/angles and two consecutive external corners/angles
(i.e., an alternating two-in-two-out configuration), results in a
cross section with up to four bisecting planes of symmetry. Under
an axial and symmetric loading condition, strengthening members
with symmetrical, polygonal cross sections, including the various
embodiments of the present teachings, may have better load carrying
capabilities and energy absorbing capabilities than those with
asymmetrical, polygonal cross sections with an equivalent number of
corners and sides. Furthermore, strengthening members with
symmetrical, polygonal cross sections with more than two bisecting
planes of symmetry (e.g., three bisecting planes of symmetry, or
four-or-more bisecting planes of symmetry), including the various
embodiments of the present teachings, may have better load carrying
capabilities and energy absorbing capabilities than those with
symmetrical, polygonal cross sections with two or fewer bisecting
planes of symmetry and an equivalent number of corners and sides.
However, as those of skill in the art will understand, use of
asymmetrical cross-sections may offer other benefits that provide
advantages that cannot be realized using a symmetrical
cross-section. The present disclosure contemplates that a
sixteen-sided, sixteen-cornered cross-section, in accordance with
the present teachings, may be either symmetrical or
asymmetrical.
[0039] Depending upon the particular application and/or the desired
features of the strengthening member, the lengths of the sides and
the thicknesses of the sides of the sixteen-sided, sixteen-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) compared to conventional
strengthening member cross sections. Varying these features of the
sixteen-sided, sixteen-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
lengths of sides S.sub.1-S.sub.16, the thicknesses T.sub.1-T.sub.16
of the sides as well as the internal angles .sub.i1- .sub.i8 and
external angles .sub.e1- .sub.e8 of the corner angles 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.
[0040] In addition, in a strengthening member in accordance with
the present teachings, each internal corner angle .sub.i1- .sub.i8
of the strengthening member can range from about 90.degree. to
about 145.degree., and each external corner angle .sub.e1- .sub.e8
of the strengthening member can range from about 95.degree. to
about 175.degree.. In accordance with the present teachings, the
internal angles .sub.i1- .sub.i8 of the strengthening member may
all be substantially the same, and similarly, the external angles
.sub.e1- .sub.e8 of the strengthening member may all be
substantially the same. Additionally, the present teachings
contemplate embodiments for which one, some, or all of the internal
angle(s) .sub.i1- .sub.i8 are right angles. Additionally or
alternatively, the present disclosure contemplates embodiments in
which at least some of the internal angles .sub.i1- .sub.i8 of the
strengthening member differ from one another, and similarly, at
least some of the external angles .sub.e1- .sub.e8 of the
strengthening member differ from one another. FIG. 1 illustrates an
exemplary embodiment in which all of the internal angles .sub.i1-
.sub.i8 are about 90.degree., all of the external corner angles
.sub.e1- .sub.e8 are about 135.degree., and the aspect ratio is
1:1.
[0041] In certain exemplary embodiments of the present disclosure,
such as in an automotive application, for example, a length of each
side S.sub.1-S.sub.16 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 length of each side S.sub.1-S.sub.16 of the
strengthening member may be larger.
[0042] In certain exemplary embodiments of the present disclosure,
such as in an automotive application, for example, a thickness
T.sub.1-T.sub.16 of the sides 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
T.sub.1-T.sub.16 of the sides of the strengthening member may be
larger. In one exemplary embodiment, a thickness T.sub.1-T.sub.16
of each of the sides of the strengthening member may be about 3.3
mm. In another exemplary embodiment, a thickness T.sub.1-T.sub.16
of each of the sides may be about 2.3 mm. In another exemplary
embodiment, a thickness T.sub.1-T.sub.16 of each of the sides may
be about 2.2 mm. In some exemplary embodiments, the thickness
T.sub.1-T.sub.16 of the sides is substantially the same as the
thickness of the corners for each side. In some exemplary
embodiments the thickness T.sub.1-T.sub.16 of each side wall,
(e.g., side walls 202A-202P (see FIG. 2A)), can vary with respect
to each other side wall. Alternatively or concurrently, the
thickness T.sub.1-T.sub.16 can vary within each length of the sides
S.sub.1-S.sub.16.
[0043] Top and perspective views of a first exemplary embodiment of
a strengthening member 200 having a sixteen-cornered cross section,
with eight internal angles and eight external angles are
illustrated in FIGS. 2A-2B. Strengthening member 200 has sixteen
corners 204A-H and 206A-H and sixteen side walls 202A-202P. Eight
of the corners are internal angle corners 204A-204H and eight of
the corners are external angle corners 206A-206H. Strengthening
member 200 also has a first transverse axis 208, a second
transverse axis 210, and a longitudinal axis 212. Although shown
with its longitudinal axis 212 positioned substantially vertically,
when strengthening member 200 (as well as all of the other various
embodiments in accordance with the present teachings) is installed
within a vehicle, the longitudinal axis 212 of the strengthening
member may be oriented substantially horizontally. When installed
in such a position, the shape of strengthening member 200
facilitates reducing or preventing moisture collecting or pooling
along portions of the walls of the strengthening member. For
example, certain conventional strengthening members whose walls
form adjacent external angles of 90 degrees or form rectangular,
square, or u-shaped recesses or depressions may collect moisture or
permit moisture to pool in the recesses, increasing the possibility
of weakening of the strengthening member via rusting, stripping,
cracking, etc. (i.e., any form of oxidation or other chemical or
physical distortion which the material of manufacture of the
strengthening member may be more susceptible to due to the presence
of moisture).
[0044] In contrast, a strengthening member formed in accordance
with the present teachings does not include a recessed portion in
which liquids or moisture remain for a long period of time. In
particular, the walls of the strengthening member are angled
relative to one another to promote shedding of any moisture or
fluid that falls within any recessed portion of the strengthening
member. For example, as shown in FIGS. 2A and 2B, strengthening
member 200 includes a first recessed portion 214 between side walls
202A and 202C. However, side walls 202A and 202C are connected by a
sloped/angled side wall 202B in such a manner that fluid impinging
or collecting on side wall 202B will run off side wall 202B and
toward the ends of side wall 202A or 202C. Similarly, for example,
as shown in FIGS. 2A and 2B, strengthening member 200 includes
second recessed portion 215 between side walls 202E and 202G, third
recessed portion 216 between side walls 2021 and 202K, and fourth
recessed portion 217 between side walls 202M and 2020.
[0045] The strengthening member 200 of FIGS. 2A-2B also has a
uniform cross section along a length of the strengthening member
200, from a first end 218 to a second end 220 of the strengthening
member 200. Additionally, the length of each side S.sub.1-S.sub.16
is approximately the same as illustrated in FIGS. 2A-2B. As also
illustrated, each of the internal angles is substantially the same
and each of the external angles is substantially the same. In
particular, each internal angle is about 90.degree. and each
external angle is about 135.degree.. The thicknesses of each
sidewall 202A-202P are also substantially the same.
[0046] Top and perspective views of an alternative exemplary
embodiment of a strengthening member 300 having a sixteen-cornered
cross section, with eight internal angles and eight external
angles, are illustrated in FIGS. 3A-3B. Strengthening member 300
differs from strengthening member 200 in several aspects. For
example, as shown in FIGS. 3A and 3B, one or more of the side walls
of the strengthening member may be angled with respect to the
longitudinal axis 312 of the strengthening member to provide a
taper to at least a portion of the shape of the strengthening
member 300. As shown in FIGS. 3A-3B, strengthening member 300 is
tapered along its length, from a first end 318 of the strengthening
member 300 to a second end 320 of the strengthening member. The
strengthening member 300 tapers along its length at an angle
.alpha., which can range from about 1.degree. to about 65.degree..
The degree of taper of each side wall may be substantially the
same, or different side walls may exhibit differing degrees of
taper. Tapering may be required due to component packaging
constraints and/or to effectively couple, attach or otherwise bond
other components to a strengthening member.
[0047] In the exemplary embodiment of FIGS. 3A-3B, all of the
internal angles .sub.i are about 90.degree. and all of the external
angles .sub.e are about 135.degree.. Also, as shown in FIGS. 3A-3B,
strengthening member 300 includes recessed areas 314, 315, 316 and
317. Each recessed area 314, 315, 316 and 317 extends along the
length of the strengthening member 300 from first end 318 to second
end 320. In the disclosed exemplary embodiment of FIGS. 3A-3B, the
lengths of the sides S.sub.1-S.sub.16 are each approximately the
same as the other sides when taken at any cross section along the
longitudinal length of the strengthening member 300. However, the
length of each side gradually/incrementally increases along the
longitudinal axis 312 of the strengthening member 300 from first
end 318 to second end 320 to provide the tapered shape. As noted
above, the embodiment of FIGS. 3A-3B is exemplary, and therefore
all of the contemplated embodiments with variations to the lengths
and thicknesses of the sides and to the angles of the internal and
external corner angles of the sixteen-cornered cross sections, with
eight internal angles and eight external angles, of the
strengthening members in accordance with the present teachings are
not shown in the figures, but based on the teachings herein, will
be apparent to those of skill in the art.
[0048] Top and perspective views of an alternative exemplary
embodiment of a strengthening member 400 having the
sixteen-cornered cross section, with eight internal angles and
eight external angles, are illustrated in FIGS. 4A-4B. Similar to
the strengthening member 300, strengthening member 400 tapers along
its longitudinal axis 412 from a first end 418 of the strengthening
member to a second end 420 of the strengthening member. However, as
shown in FIGS. 4A-4B, strengthening member 400 differs from
strengthening members 200 and 300 in that the
dimension-to-dimension ratio of the cross section of the
strengthening member, taken along transverse axes 408, 410 is not
1:1; rather, the aspect ratio is about 6.5:10.0. FIGS. 4A-4B
illustrate a strengthening member that has a first length 422 along
a first (minor) transverse axis 408 and a second length 424 along a
second (major) transverse axis 410, where the second transverse
axis is perpendicular to the first transverse axis. The aspect
ratio of a strengthening member may be defined as [first length
422]:[second length 424]. In the exemplary embodiment of FIGS.
4A-4B, all of the internal corner angles are about the same, e.g.,
about 90.degree.. In contrast, the external angles are not all
same. In particular, as shown in FIG. 4A, external angles each of
the external angles .sub.e1, .sub.e4, .sub.e5, and .sub.e8 have a
first measurement, for example, about 123.5.degree., while external
angles .sub.e2, .sub.e3, .sub.e6, and .sub.e7 have a second
measurement, for example, about 145.5.degree.. As also shown, the
sides of the strengthening member 400 have differing lengths. Also,
the strengthening member 400 of the exemplary embodiment shown in
FIGS. 4A-4B includes recessed areas 414, 415, 416 and 417 spaced
around the perimeter of the strengthening member and extending
along the length of the strengthening member 400, each recessed
area 414-417 extending from first end 418 to second end 420 of
strengthening member 400. As noted above, the embodiment of FIGS.
4A-4B is exemplary, and therefore all of the contemplated
embodiments with variations to the lengths of the sides,
thicknesses of the sides, the angles of the internal and external
corner angles, and the aspect ratio of the of the sixteen-cornered
cross sections, with eight internal angles and eight external
angles, of the strengthening members in accordance with the present
teachings are not shown in the figures.
[0049] Top and perspective views of an alternative exemplary
embodiment of a strengthening member 500 having the
sixteen-cornered cross section, with eight internal angles and
eight external angles, are illustrated in FIGS. 5A-5B. In the
exemplary embodiment of FIGS. 5A-5B, each of the internal angles is
about 90.degree. and each of the external angles is about
135.degree.. As illustrated in FIG. 5A, the lengths of side walls
502B, 502F, 502J, and 502N are greater in comparison to the lengths
of side walls 502A, 502C-E, 502G-I, 502K-M, 502O and 502P. This
difference in the lengths of the sides provides recessed areas 514,
515, 516 and 517, each of which extends along the length of the
strengthening member 500 from first end 518 to second end 520 of
the strengthening member. These recessed areas 514-517 each have a
depth .delta..sub.514-.delta..sub.517, which is reduced (and may be
considered relatively shallow) in comparison to the recessed areas
shown in the strengthening members illustrated in FIGS. 2A-4B. This
type of parameter tuning, i.e., changing the lengths of the sides
to reduce the depth of the recess areas 514-517, can further
improve the moisture shedding ability of the strengthening member
500. In particular, the combination of the decreased depth of the
recessed area and the increased length of the sloped wall (floor)
of the recessed area work together to direct moisture out of the
recessed areas 514-517.
[0050] Top and perspective views of an alternative exemplary
embodiment of a strengthening member 600 having the
sixteen-cornered cross section, with eight internal angles and
eight external angles, are illustrated in FIGS. 6A-6B. The
strengthening member 600 of FIGS. 2A-2B has a uniform cross section
along a longitudinal axis 612 of the strengthening member 600, from
a first end 618 to a second end 620 of the strengthening member
200. The thickness of each sidewall 602A-602P is also substantially
the same to each other side wall 602A-602P and throughout the
longitudinal length of each side wall 602A-602P. However, the
lengths of each side S.sub.1-S.sub.16 of each side wall 602A-602P
are not all the same. For example, as shown in FIG. 6A, the
cross-sectional lengths S.sub.j of side walls 602A, 602C, 602E,
602G, 602I, 602K, 602M and 602O are all substantially the same,
however, they are different than the cross-sectional lengths
S.sub.j of side walls 602B, 602F, 602J and 602N. Further, 602B,
602F, 602J and 602N are all substantially the same cross sectional
length S.sub.j, however the cross sectional lengths S; are
different than those of 602D, 602H, 602L and 602P. The
strengthening member 600 includes eight internal angles .sub.i1-
.sub.i8 and eight external angles .sub.e1- .sub.e8. As shown in
FIGS. 6A-6B, each of the internal angles is about 105.degree. and
each of the external angles is about 150.degree.. In addition, and
in contrast to the strengthening member 500 shown in FIGS. 5A-5B,
the lengths of side walls 602B, 602F, 602J, and 602N are shorter in
comparison to the lengths of side walls 602A, 602C-E, 602G-I,
602K-M, 602O and 602P. This difference in the lengths of the sides
provides recessed areas 614-617, each of which extends along the
length of the strengthening member 600 from first end 618 to second
end 620 of the strengthening member 600. These recessed areas
614-617 have a depth .delta..sub.614-.delta..sub.617, respectively,
which is increased (and may be considered relatively deep) in
comparison to the recessed areas shown in the strengthening members
illustrated in FIGS. 5A-5B. However, the increased depth of the
recessed areas 614-617 may be compensated for by varying the
internal and external angles of the strengthening member cross
section. For example, as shown in FIGS. 6A-6B, increasing the
internal angles to larger than 90 degrees results in a recessed
area 614 in which all walls of the recessed portion are sloped.
This configuration increases the ability of the recessed areas
614-617 of the strengthening member to shed moisture.
[0051] 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.
[0052] As discussed and embodied herein, the lengths
S.sub.1-S.sub.16 and thicknesses T.sub.1-T.sub.16 of the sides of
the strengthening member are tunable parameters of the
strengthening member. The lengths S.sub.1-S.sub.16 and thicknesses
T.sub.1-T.sub.16 of the sides may be tuned to provide desired
characteristics in the strengthening member. For example, in the
embodiment of FIGS. 3A-3B, these parameters are tuned to provide a
strengthening member 300 with side walls and corners that are
tapered along the longitudinal length of the strengthening member
300.
[0053] As discussed and embodied herein, the aspect ratio of a
cross section of the strengthening member is a tunable parameter 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 FIGS. 4A-4B, these parameters are tuned to provide a
strengthening member 400 having two cross-sectional dimensions
along perpendicularly oriented transverse axes that are
substantially different in length the longitudinal length of the
strengthening member 400.
[0054] As discussed and embodied herein, the lengths of the sides
S.sub.1-S.sub.16 of the cross section is a tunable parameter in
accordance with the present teachings. The lengths of the sides
S.sub.1-S.sub.16 of a strengthening member may be tuned to provide
desired characteristics in the strengthening member. For example,
in the embodiment of FIGS. 5A-5B this parameter is tuned to provide
a strengthening member 500 with recess areas 514-517 having
particular depths .delta..sub.514-.delta..sub.517 that extend along
the longitudinal length of the strengthening member 500.
[0055] As discussed and embodied herein, the eight internal angles
.sub.i1- .sub.i8 and eight external angles .sub.e1 .sub.e8 are
tunable parameters of the strengthening member. The internal angles
.sub.i1- .sub.i8 and external angles .sub.e1- .sub.e8 may be tuned
to provide desired characteristics in the strengthening member. For
example, in the embodiment of FIGS. 6A-6B, these parameters are
tuned to provide a strengthening member 600 with sloped recessed
areas 614-617 having a particular depths
.delta..sub.614-.delta..sub.617 that extend along the longitudinal
length of the strengthening member 600.
[0056] As discussed and embodied herein, multiple tunable
parameters--including but not limited to the lengths
S.sub.1-S.sub.16 and thicknesses T.sub.1-T.sub.16 of the sides of
the strengthening member, the aspect ratio of a cross section of
the strengthening member, the internal angles .sub.i1- .sub.i8 and
external angles .sub.e1 .sub.e8 of the corners, and the depths
.delta..sub.j14-j17 of the recess areas--may all be tuned within
the same strengthening member. These parameters all may be tuned
within the same strengthening member to provide desired
characteristics in the strengthening member.
[0057] In the illustrated embodiments of FIGS. 2A-6B, the
strengthening members may have a one-piece construction. As stated
above, the one-piece constructions shown in FIGS. 2A through 6B are
exemplary only and the present teachings contemplate strengthening
members of other constructions such as two-piece construction or
even three-or-more piece construction.
[0058] To demonstrate the improved strength and performance
features of a sixteen-cornered cross section having eight 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 FIGS. 7-11.
[0059] Strengthening members of varying shapes (i.e., cross
sections) having the same mass, thickness, longitudinal length and
the same cross-sectional lengths along perpendicular transverse
axes were modeled as illustrated in FIG. 7. Crash simulations were
then run for each member to simulate an impact with the same rigid
mass (e.g., an impactor), impact speed, and initial kinetic
energy.
[0060] FIG. 8 shows cross members which have undergone a simulated
quasi-static crush. During each quasi-static crush the impact speed
is slow (e.g., 1 in/min). An impactor compresses the members with a
controlled displacement. Therefore, all members reach the same
crush distance with the same crush time. Thus, subjecting multiple
strengthening members to a quasi-static crush provides a comparison
of the folding length and the crush stability of the strengthening
members. As shown in FIG. 8, the sixteen-cornered cross section in
accordance with the present teachings demonstrated the most stable
axial collapse and the smallest folding length.
[0061] FIG. 9 shows cross members which have undergone a simulated
dynamic crush. During each dynamic crush, the impactor is propelled
by a gas gun with a designated mass and initial impact velocity
which creates a designated initial kinetic energy. The initial
kinetic energy crushes the members. Performance of each
strengthening member can be compared by measuring the crush
distance and specific energy absorption of each strengthening
member. As shown in FIG. 9, the sixteen-cornered cross section in
accordance with the present teachings also demonstrated the
shortest crush distance.
[0062] FIG. 10 illustrates the dynamic crush force (in kN) and
associated axial crush distance (in mm) for the simulated dynamic
crush, exerted axially on the exemplary strengthening members
having the cross sections shown in FIG. 7. As shown in FIG. 10, the
strengthening member having a sixteen-cornered cross section could
sustain a much higher crushing force for a given resulting crushing
distance as compared with the square, hexagonal, circular,
octagonal, and twelve-cornered cross sections. Specifically, the
sixteen-cornered cross section in accordance with the present
teachings achieved about a 65% increase in averaged crush force
and/or crash energy absorption as compared with the octagon.
[0063] FIG. 11 illustrates the dynamic axial crush energy (in
kN-mm) and associated axial crush distance (in mm) for a simulated
dynamic crush exerted on the exemplary strengthening members having
the cross sections shown in FIG. 7. As shown in FIG. 11, the
strengthening member having a sixteen-cornered cross section could
absorb the same total kinetic energy of the impact over a much
shorter distance as compared with the square, hexagonal, circular
and octagonal cross sections. In particular, a sixteen-cornered
cross section in accordance with the present teachings absorbed the
full axial crush energy in about 60% of the axial crush distance as
the basic octagonal cross section.
[0064] To further demonstrate the improved strength and performance
features of a sixteen-cornered cross section in accordance with the
present teachings compared to basic sixteen-sided cross section
designs, exemplary strengthening members were modeled and crash
simulation runs were conducted, as shown and described below with
reference to FIGS. 12-16.
[0065] Strengthening members of varying shapes (i.e., sixteen-sided
cross sections) having the same thickness, longitudinal length and
the same cross-sectional lengths along perpendicular transverse
axes were modeled as illustrated in FIG. 12. As above, tests were
then run for each member to simulate a quasi-static collapse and a
dynamic crush with the same rigid mass (e.g. an impactor), impact
speed, and initial kinetic energy. As shown in FIG. 13 for the
quasi-static collapse, the sixteen-cornered cross section in
accordance with the present teachings demonstrated the most stable
axial collapse and smallest folding length. Furthermore, as shown
in FIG. 14 for the dynamic crush, the sixteen-cornered cross
section in accordance with the present teachings also demonstrated
the shortest crush distance.
[0066] FIG. 15 illustrates the dynamic crush force (in kN) and
associated axial crush distance (in mm) for the simulated dynamic
crush, exerted axially on the exemplary strengthening members
having the cross sections shown in FIG. 12. As shown in FIG. 15,
once again, the strengthening member having a sixteen-cornered
cross section in accordance with the present teachings could
sustain a much higher crushing force for a given resulting crushing
distance as compared with the other sixteen-sided cross sections
(i.e., the basic sixteen-sided polygon (hexadecagon) and
sixteen-sided corrugated polygon). In fact, the sixteen-cornered
cross section in accordance with the present teachings achieved
about a 75% increase in averaged crush force and/or crash energy
absorption as compared with the hexadecagon.
[0067] FIG. 16 illustrates the axial crush energy (in kN-mm) and
associated axial crush distance (in mm) for a simulated dynamic
crush exerted on the exemplary strengthening members having the
cross sections shown in FIG. 12. As shown in FIG. 16, once again,
the strengthening member having a sixteen-cornered cross section in
accordance with the present teachings could absorb the same total
kinetic energy of the impact over a much shorter crush distance as
compared with the other sixteen-sided cross sections. In fact, the
sixteen-cornered cross section in accordance with the present
teachings absorbed the full axial crush energy in about 57% of the
axial crush distance as the hexadecagon.
[0068] Sixteen-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, including basic sixteen-sided polygonal cross
sections, while minimizing mass per unit length, provides mass
saving solutions that reduce vehicle weight and meet new CAFE and
emission standards.
[0069] Beyond the increased load carrying and energy absorption
capabilities, 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).
[0070] In addition, a sixteen-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 sixteen cornered cross 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.
[0071] Sixteen-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.
[0072] For example, as shown in FIGS. 17 and 18, sixteen-cornered
strengthening members with eight internal angles and eight external
angles in accordance with the present disclosure can be used to
form part of or within a vehicle frame and/or a vehicle upper body.
FIG. 17 illustrates an exemplary embodiment of a vehicle frame 1700
with several components for which the strengthening can be used.
For example, the strengthening members in accordance with the
present invention may form or be used as a part of a front horn
1702, a front rail 1704, a front side rail 1706, a rear side rail
1708, a rear rail 1710, and/or as one or more cross members 1712.
Likewise, FIG. 18 illustrates an exemplary embodiment of a vehicle
upper body 1800 with several components for which the strengthening
can be used. For example, the strengthening members in accordance
with the present disclosure may be formed or be used as a part of a
shotgun 1802, a hinge-pillar 1804, an A-pillar 1806, a B-pillar
1808, a C-pillar 1810, one or more door beams 1812, a cross car
beam 1814, a front header 1816, a rear header 1818, a cow top 1820,
a roof rail 1822, a lateral roof bow 1824, longitudinal roof bow
1826, one or more body cross members 1828, and/or a body cross
member 1830.
[0073] Moreover, the strengthening members in accordance with the
present disclosure may be used as or form a part of vehicle
underbody components, for example, as 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.
[0074] 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.
[0075] Although various exemplary embodiments described herein have
been described as configured to be used with automotive vehicles,
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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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.
* * * * *