Stiffened vehicle side rail assembly

Abstract

A stiffness-reinforced vehicle side beam assembly includes a side beam inner, a side beam outer, and a reinforcing unit provided between the side beam inner and the side beam outer, wherein the reinforcing unit can include a plurality of unit members having upper and lower members joined to each other at intervals in a vertical direction and provided at intervals from each other in a longitudinal direction of a vehicle, and a connecting member joined to rear and front end portions of different unit members to connect the plurality of unit members to each other in the longitudinal direction of the vehicle.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Korean Patent Application No. 10-2021-0120466, filed on September 9, 2021, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] The present invention relates to a side beam assembly configured to support the lower side of a vehicle, and more specifically, to a rigid vehicle side beam assembly that can protect the high-voltage battery installed therein from impact in the event of a side collision, while achieving weight reduction. Background Technology

[0004] Side beams are installed to enhance the rigidity of the vehicle's lower sides.

[0005] Meanwhile, environmentally friendly vehicles, such as electric vehicles or hybrid electric vehicles, utilize the lower part of the vehicle's central floor as a mounting space for high-voltage batteries that supply power to the drive motor.

[0006] Recently, environmentally friendly vehicles are no longer sharing platforms with internal combustion engine vehicles, but instead are using platforms designed specifically for electric vehicles. This is because utilizing the space under the central floor allows for increased capacity of the high-voltage battery, thereby extending the vehicle's range.

[0007] However, in the event of a side collision, this structure poses a risk of damage to the high-voltage battery. A fire caused by a damaged high-voltage battery is unlike a typical fire; such fires are difficult to extinguish.

[0008] Therefore, the side beams must have sufficient rigidity to prevent impact energy from being transferred to the high-voltage battery in the event of a side collision.

[0009] Therefore, a reinforcing structure was applied inside the side beams, which include both the inner and outer components.

[0010] For example, there are side beam reinforcement structures that use extruded aluminum to manufacture reinforcing members and then apply them inside the side beams. While extruded aluminum can be lightweight, its high manufacturing cost reduces its price competitiveness.

[0011] At the same time, such as Figure 1 As shown, a steel-pressed structural reinforcement unit 130, comprising reinforcing members 131 to 134 made of steel, can be further manufactured and applied inside the side beam. While this reduces costs compared to aluminum extrusion, it results in increased weight.

[0012] The content contained in this background section is only intended to enhance the understanding of the overall background of the present invention, and does not acknowledge or imply in any way that such content constitutes prior art known to those skilled in the art. Summary of the Invention

[0013] Various aspects of the present invention aim to provide a stiffened vehicle side beam assembly that utilizes inexpensive materials but provides sufficient stiffness performance even while keeping the weight down to the level of aluminum materials, thereby reducing deformation due to impact in the event of a side collision.

[0014] To achieve this objective, a stiffened vehicle side beam assembly according to various exemplary embodiments of the present invention includes a side beam inner member, a side beam outer member, and a reinforcing unit disposed between the side beam inner member and the side beam outer member. The reinforcing unit may include: a plurality of unit members having upper and lower members that are spaced apart from each other in the vertical direction and spaced apart from each other in the longitudinal direction of the vehicle; and connectors that engage with the rear and front ends of the different unit members to connect the plurality of unit members to each other in the longitudinal direction of the vehicle.

[0015] The unit component can be configured such that its width in the longitudinal direction of the vehicle increases from the lower end to the upper end, and the connector can be configured such that its width in the longitudinal direction of the vehicle increases from the upper end to the lower end.

[0016] The unit component may include: an upper component having at least one stage in the longitudinal direction of the vehicle; and a lower component that accommodates the upper component and engages with the front and rear ends of the upper component.

[0017] The lower surface of the upper component can be set to be separated from the bottom of the lower component by a predetermined interval.

[0018] The upper component may include: a lower surface; and an upper surface positioned above the lower surface and disposed together with the lower surface in the longitudinal direction of the vehicle.

[0019] The front and rear ends of the upper component may be respectively formed with a first front flange and a first rear flange that extend in the height direction of the vehicle to contact the inner surface of the lower component.

[0020] The lower member may include: a bottom, an inclined surface that engages with the inner surface of the side beam inner member; a second front flange that extends upward from the front end of the bottom; a second rear flange that extends upward from the rear end of the bottom; and a second side flange that extends upward from the inside of the bottom in the vehicle width direction and is formed on the lower member, the second side flange engaging with the vertical surface of the inner surface of the side beam inner member.

[0021] The upper and lower surfaces of the upper member may have a first side flange portion that contacts the second side flange portion of the lower member on the inner side in the vehicle width direction.

[0022] The upper surface of the upper component can be at the same height as the upper end of the lower component.

[0023] The connector may include: an upper surface portion; a third front flange portion extending downward from the front end of the upper surface portion and engaging with the rear end of the unit member located in front of it; and a third rear flange portion extending downward from the rear end of the upper surface portion and engaging with the front end of the unit member located behind it.

[0024] The connector may further include a third side flange that extends downward from the inside of the upper surface portion in the width direction of the vehicle and engages with the vertical surface of the inner surface of the side beam inner member.

[0025] The upper surface may have a lower surface formed at the front and rear parts respectively, and a welding hole may be formed in either of the lower surfaces. A welding tool for joining the unit component to the inclined surface of the inner surface of the side beam internals passes through the welding hole.

[0026] The lower end of the battery mounting nut for mounting the battery can engage with the bottom of the lower member, and a through hole through which the battery mounting nut passes is formed in any lower surface of the upper member.

[0027] The battery mounting nut can be joined to the lower surface of the upper component by CO2 welding or projection welding.

[0028] The outer circumference of the battery mounting nut can be joined to the inner circumference of the through hole by CO2 welding.

[0029] Unit components and connectors can be joined together by spot welding.

[0030] Unit components and connectors can be spot welded to the internal components of the side beam.

[0031] According to various exemplary embodiments of the invention, a stiffened vehicle side beam assembly having the above-described structure can utilize inexpensive materials such as steel and provide corresponding stiffness at a weight equivalent to that of expensive aluminum extrusion materials, thereby achieving side impact performance and saving costs.

[0032] As mentioned above, the ability to resist side impacts in vehicles using high-voltage batteries can be improved, preventing fires caused by damage to the high-voltage batteries due to side impacts.

[0033] The methods and apparatus of the present invention have other features and advantages, which will become apparent from the accompanying drawings and the following detailed description, which together serve to explain certain principles of the invention, or will be set forth in more detail in the drawings and detailed description. Attached Figure Description

[0034] Figure 1 These are exploded perspective views and perspective views showing the side beam reinforcement members of a steel pressure structure according to the prior art.

[0035] Figure 2 These are exploded perspective views and perspective views illustrating the reinforcing unit of a stiffening vehicle side beam assembly according to various exemplary embodiments of the present invention.

[0036] Figure 3 This is an exploded perspective view showing the connection relationship between unit members and connectors in a stiffening unit of a rigid vehicle side beam assembly according to various exemplary embodiments of the present invention.

[0037] Figure 4 This is an exploded perspective view showing the connection relationship between the upper and lower members constituting the unit members in a stiffening unit of a rigid vehicle side beam assembly according to various exemplary embodiments of the present invention.

[0038] Figure 5 This is an enlarged perspective view of the main part of the reinforcing unit of a stiffening vehicle side beam assembly according to various exemplary embodiments of the present invention.

[0039] Figure 6A and Figure 6B These are schematic diagrams and perspective views illustrating the state in which a stiffened vehicle side beam assembly according to various exemplary embodiments of the present invention connects a reinforcing unit to the side beam and the high-voltage battery.

[0040] It is understood that the accompanying drawings are not necessarily drawn to scale, but rather present slightly simplified representations of various features illustrating the basic principles of the invention. Specific design features of the invention disclosed herein, including, for example, particular dimensions, orientations, positions, and shapes, will be determined in part by the particular intended application and environment of use.

[0041] In the accompanying drawings, reference numerals in several figures refer to the same or equivalent parts of the invention. Detailed Implementation

[0042] Reference will now be made in detail to various exemplary embodiments of the invention illustrated in the accompanying drawings and described below. Although the invention will be described in conjunction with exemplary embodiments thereof, it should be understood that this description is not intended to limit the invention to those exemplary embodiments. On the other hand, the invention is intended to cover not only the exemplary embodiments thereof, but also various alternatives, modifications, equivalents and other embodiments that may be included within the spirit and scope of the invention as defined in the appended claims.

[0043] In the following, a stiffened vehicle side beam assembly according to various exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0044] According to various exemplary embodiments of the present invention, a stiffened vehicle side beam assembly includes a side beam inner member 10, a side beam outer member 20, and a reinforcing unit 30 disposed between the side beam inner member 10 and the side beam outer member 20. The reinforcing unit 30 may include: a plurality of unit members 31 having an upper member 31a and a lower member 31b that are spaced apart from each other in the vertical direction and are spaced apart from each other in the longitudinal direction of the vehicle; and a connector 32 that engages with the rear and front ends of the different unit members 31 to connect the unit members 31 to each other in the longitudinal direction of the vehicle.

[0045] In the side beam assembly 1, the inner side beam 10 and the outer side beam 20, which are disposed on the lower side of the vehicle along the longitudinal direction of the vehicle, are joined to each other, and a side beam reinforcing unit 30 (hereinafter referred to as "reinforcing unit") configured to enhance the rigidity of the side beam assembly 1 is disposed between the inner side beam 10 and the outer side beam 20.

[0046] The upper and lower parts of the inner side beam 10 and the outer side beam 20 may be respectively formed with upper joints 11 and 21 and lower joints 12 and 22 for joining, and the middle parts of the inner side beam 10 and the outer side beam 20 protrude in opposite directions to form a space inside.

[0047] The reinforcing unit 30 can be disposed in the space formed between the inner part 10 of the side beam and the outer part 20 of the side beam, so as to enhance the rigidity of the side beam assembly 1.

[0048] Therefore, the reinforcing unit 30 may include: a plurality of unit members 31 having upper members 31a and lower members 31b that are spaced apart from each other in the vertical direction and are spaced apart from each other in the longitudinal direction of the vehicle; and a connector 32 that connects the unit members 31 to each other.

[0049] The unit component 31 and the connector 32 can be alternately arranged in the longitudinal direction of the vehicle, and the unit component 31 and the connector 32 can be spot welded together to form a reinforcing unit 30. Since the unit component 31 and the connector 32 can be alternately arranged, the front end of any connector 32 can engage with the rear end of the unit component 31 located in front, and the rear end can engage with the front end of another unit component 31 located behind.

[0050] The unit member 31 and the reinforcing unit 30 can be configured such that the width in the longitudinal direction of the vehicle can increase in the height direction of the vehicle. For example, the unit member 31 can be configured such that the width in the longitudinal direction of the vehicle can increase from the lower end to the upper end, and the connector 32 can be configured such that the width in the longitudinal direction of the vehicle can increase from the upper end to the lower end.

[0051] The unit member 31 may include an upper member 31a formed in a multi-level shape in the longitudinal direction of the vehicle, and a lower member 31b that accommodates the upper member 31a and is joined to the front and rear ends of the upper member 31a. In other words, the lower member 31b may have a cross-section with an upper opening, the upper member 31a is accommodated in the lower member 31b, and the periphery of the upper member 31a may be joined to the inner surface of the lower member 31b.

[0052] The upper component 31a may have a lower surface 31ab and an upper surface 31aa higher than the lower surface 31ab, with the lower surface 31ab and the upper surface 31aa arranged along the longitudinal direction of the vehicle. Multiple upper surfaces 31aa and multiple lower surfaces 31ab may be alternately arranged along the longitudinal direction of the vehicle. For example, as... Figure 4 As shown, the upper member 31a may have a lower surface 31ab that can be respectively disposed at the front and rear of the upper surface 31aa.

[0053] Here, the lower surface 31ab can be spaced apart from the bottom 31ba of the lower member 31b, and the upper member 31a can have a multi-level structure, thereby improving the stiffness against side impacts.

[0054] For engagement with the lower member 31b, the upper member 31a may have a first front flange portion 31ac and a first rear flange portion 31ad formed on its front and rear ends, respectively. The first front flange portion 31ac and the first rear flange portion 31ad extend in the vehicle height direction and contact the inner surface of the lower member 31b. Furthermore, a first side flange portion 31ae may also be formed on the inner end of the upper member 31a in the vehicle width direction to contact the inner surface of the lower member 31b.

[0055] The lower member 31b may include: a bottom 31ba, an inclined surface that engages with the inner surface of the side beam inner member 10; a second front flange 31bb that extends upward from the front end of the bottom 31ba; a second rear flange 31bc that extends upward from the rear end of the bottom 31ba; and a second side flange 31bd that extends upward from the inner side of the bottom 31ba in the vehicle width direction and is formed on the lower member 31b, and engages with the vertical surface of the inner surface of the side beam inner member 10.

[0056] The bottom 31ba can form the lower part of the lower member 31b, and a portion thereof can be joined to the horizontally inclined surface of the inner surface of the side beam inner member 10. Figure 6B (The part indicated by "w7"). The upper member 31a may be disposed in the lower member 31b, and the lower surface 31ab of the upper member 31a is separated from the bottom 31ba by a predetermined interval.

[0057] The second front flange portion 31bb and the second rear flange portion 31bc can be formed by extending upward from the front end and the rear end of the bottom portion 31ba, respectively. The inner surfaces of the second front flange portion 31bb and the second rear flange portion 31bc can be welded to the first front flange portion 31ac and the first rear flange portion 31ad, respectively. Figure 5 (The part represented by "w1" in the middle).

[0058] Furthermore, a second side flange 31bd can be formed extending upward from the inner end of the bottom 31ba in the width direction of the vehicle. The inner surface of the second side flange 31bd can be spot-welded to the first side flange 31ae, and the outer surface can be spot-welded to the vertical surface of the inner surface of the side beam inner member 10. Figure 5 (The part represented by "w2" in the middle).

[0059] The lower member 31b may have a form in which the upper surface and the surface other than the outer surface in the width direction of the vehicle can be connected to each other.

[0060] The upper surface of the upper member 31a and the upper end of the lower member 31b can be at the same height.

[0061] The upper component 31a and the lower component 31b in unit component 31 can be joined together by spot welding.

[0062] The cross-sectional structure of the unit member 31, formed by joining the upper member 31a and the lower member 31b, provides stiffness to resist side impacts.

[0063] Simultaneously, lower surfaces 31ab are formed at the front and rear portions of the upper surface 31aa, respectively. A welding hole 31ag is formed in either of the lower surfaces 31ab, through which a welding tool for joining the unit member 31 to the inclined surface of the inner side surface of the side beam inner member 10 passes. With the upper member 31a and lower member 31b joined, it is difficult for the welding tool for joining the lower member 31b to the side beam inner member 10 to enter the space between the upper member 31a and lower member 31b. Therefore, the welding hole 31ag can be formed in the lower surface 31ab, and the welding tool can enter through the welding hole 31ag, allowing the lower member 31b to be joined to the side beam inner member 10.

[0064] In addition, the lower surface 31ab of the upper member 31a may be formed with a through hole 31af through which the battery mounting nut 33 passes and a welding hole 31ag for joining the lower member 31b to the inner surface of the side beam inner member 10.

[0065] A nut mounting surface 31be can be formed on the bottom 31ba of the lower member 31b, such that the lower end of a battery mounting nut 33 configured to mount a high-voltage battery 40 to the nut mounting surface 31be can be engaged. Figure 5 (The part indicated by "w4" in the middle). Furthermore, a through hole 31af can be formed in either of the lower surfaces 31ab of the upper member 31a, through which the battery mounting nut 33 passes. In this case, the battery mounting nut 33 can be joined to the lower surface 31ab by CO2 welding or projection welding, and the outer circumference of the battery mounting nut 33 ( Figure 5 The portion indicated by "w5" can be joined to the inner circumference of the through hole 31af via CO2 welding. Therefore, a structure can be formed to mount the high-voltage battery 40 to the reinforcing unit 30.

[0066] Here, the through hole 31af and the weld hole 31ag can be formed by changing their positions. In other words, Figure 4 The diagram shows that the through hole 31af is formed on the left side and the welding hole 31ag is formed on the right side. Conversely, the through hole 31af can be formed on the right side and the welding hole 31ag can be formed on the left side.

[0067] The connector 32 may include: an upper surface portion 32a; a third front flange portion 32b extending downward from the front end of the upper surface portion 32a and engaging with the rear end of the unit member 31 located in front of it; and a third rear flange portion 32c extending downward from the rear end of the upper surface portion 32a and engaging with the front end of the unit member 31 located behind it.

[0068] The connector 32 can utilize the upper surface portion 32a as a base, and the third front flange portion 32b and the third rear flange portion 32c can be welded to the rear or front end of the adjacent unit member 31. Figure 5 (The part represented by "w3") allows the unit component 31 and the connector 32 to be connected in the longitudinal direction of the vehicle.

[0069] Furthermore, the connector 32 may further include a third side flange 32d, which extends downward from the inside of the upper surface portion 32a in the vehicle width direction and engages with the vertical surface of the inner surface of the side beam inner member 10. The connector 32 is engaged to the side beam inner member 10 by spot welding the third side flange 32d. Figure 6B (The part indicated by "w6"), which allows the reinforcing unit 30 to be securely attached to the side beam inner member 10.

[0070] According to various exemplary embodiments of the present invention, the stiffness-enhanced vehicle side beam assembly having the above-described structure, the stiffening unit 30 enhances the stiffness of the side beam assembly 1 against lateral input loads, thereby improving stability against side impacts.

[0071] The side beam assembly 1, including the inner side beam 10 and the outer side beam 20, can have Figure 6A The surfaces shown in ① to ⑥. In other words, in the event of a side collision, the side beam assembly 1 may have surfaces that directly form the sidewall (①, ②), surfaces that connect to the sidewall (③, ④), and internal and external surfaces (⑤, ⑥) for assembling the side beam with parts. Here, in the case of a side collision between the vehicle and a utility pole (P), it is best to directly connect the surfaces (①, ②) to improve side collision performance; if not, the surfaces (③, ④) can be connected. However, conventional aluminum extrusion structures and steel pressure welded structures have structures that only connect the surfaces (⑤, ⑥).

[0072] However, when the reinforcing unit 30 is applied, such as Figure 6B As shown, surface (①) can be directly connected to the upper member 31a, the lower member 31b, and the connector 32 by spot welding, and surface (④) can be directly connected to the bottom 31ba of the lower member 31b by spot welding. The present invention has the same number of matching surfaces as the conventional steel pressure welded structure, but the present invention provides a surface (①) with the greatest resistance to side impacts, thereby improving side impact performance.

[0073] In addition, steel, as a relatively inexpensive material, can be used to achieve lightweight structures and improved stiffness.

[0074] Furthermore, compared to conventional steel pressure welded structures, the present invention requires less material, thus reducing the weight and cost of the side beam assembly.

[0075] For ease of interpretation and precise definition of the appended claims, the features are described using the terms “upper,” “lower,” “inner,” “outer,” “up,” “lower,” “upward,” “downward,” “front,” “back,” “rear,” “inner side,” “outer side,” “inward,” “outer,” “within,” “outside,” “forward,” and “backward”, with reference to the locations shown in the figures for exemplary embodiments. It will be further understood that the term “connection” or its derivatives refer to both direct and indirect connections.

[0076] For illustrative and descriptive purposes, the foregoing description of specific exemplary embodiments of the invention has been disclosed. These descriptions are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and it will be apparent that many modifications and variations are possible in light of the foregoing teachings. The selected exemplary embodiments are intended to explain certain principles of the invention and its practical application, enabling those skilled in the art to implement and utilize the various exemplary embodiments of the invention and their various alternatives and modifications. The scope of the invention is intended to be defined by the appended claims and their equivalents.

Claims

1. A stiffened vehicle side beam assembly, comprising: Side beam inner component, side beam outer component, and reinforcing unit disposed between the side beam inner component and the side beam outer component. The reinforcing unit includes: Multiple unit components, having upper and lower components that are spaced apart from each other in the vertical direction, and arranged spaced apart from each other in the longitudinal direction of the vehicle; and Connectors are engaged with the rear and front ends of different unit components to connect the plurality of unit components to each other in the longitudinal direction of the vehicle.

2. The side beam assembly according to claim 1, wherein, The plurality of unit components are formed such that their width in the longitudinal direction of the vehicle increases from the lower end toward the upper end, and The connector is configured such that its width in the longitudinal direction of the vehicle increases from the upper end toward the lower end.

3. The side beam assembly according to claim 1, wherein, Each of the unit components includes: The upper component has at least one stage in the longitudinal direction of the vehicle; and The lower component accommodates the upper component and engages with the front and rear ends of the upper component.

4. The side beam assembly according to claim 3, wherein, The lower member has a cross-section with an upper opening, the upper member is housed within the lower member, and the periphery of the upper member is joined to the inner surface of the lower member.

5. The side beam assembly according to claim 3, wherein, The lower surface of the upper component is configured to be spaced apart from the bottom of the lower component by a predetermined interval.

6. The side beam assembly according to claim 5, wherein, The upper component includes: The lower surface; and The upper surface is positioned above the lower surface and is disposed together with the lower surface in the longitudinal direction of the vehicle.

7. The side beam assembly according to claim 6, wherein, The upper component has a first front flange and a first rear flange that extend in the height direction of the vehicle to contact the inner surface of the lower component.

8. The side beam assembly according to claim 6, wherein, The lower component includes: The bottom surface is an inclined surface that engages with the inner surface of the side beam internals; The second front flange extends upward from the front end of the bottom; The second rear flange extends upward from the rear end of the bottom; and The second side flange is engaged with the vertical surface of the inner surface of the side beam inner component.

9. The side beam assembly of claim 8, wherein, The second side flange extends upward from the inside in the width direction of the vehicle, and The upper and lower surfaces of the upper member have a first side flange portion formed on the inner side in the vehicle width direction, which contacts the second side flange portion of the lower member.

10. The side beam assembly according to claim 6, wherein, The upper surface of the upper component is at the same height as the upper end of the lower component.

11. The side beam assembly according to claim 1, wherein, The connector includes: upper surface part; The third front flange extends downward from the front end of the upper surface portion and joins the rear end of the unit member located in front of it; and The third rear flange extends downward from the rear end of the upper surface portion and joins the front end of the unit member located behind it.

12. The side beam assembly of claim 11, wherein, The connector further includes a third side flange that extends downward from the inside of the upper surface portion in the width direction of the vehicle and engages with the vertical surface of the inner surface of the side beam inner member.

13. The side beam assembly according to claim 6, wherein, At least one welding hole is formed in the lower surface at the front or rear of the upper surface, through which a welding tool for joining the unit component to the inclined surface of the inner side surface of the side beam internals passes.

14. The side beam assembly of claim 13, wherein, The lower end of the battery mounting nut for mounting the battery engages with the bottom of the lower component, and A through hole through which the battery mounting nut passes is formed in the lower surface of the front or rear portion of the upper surface.

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