An energy-absorbing threshold beam assembly and vehicle

Abstract

The application relates to the technical field of automobile design and manufacturing, in particular to an energy-absorbing door sill beam assembly and a vehicle. The energy-absorbing door sill beam assembly comprises a door sill outer plate, a door sill inner plate and a door sill reinforcing beam, wherein a cavity is arranged between the door sill outer plate and the door sill inner plate; the door sill reinforcing beam is arranged in the cavity, the door sill reinforcing beam comprises a plurality of collapse units arranged in sequence along a Y direction, the cross section of the collapse unit is in the shape of 8, the collapse unit comprises a first energy-absorbing cavity and a second energy-absorbing cavity, a buffer section is connected between the first energy-absorbing cavity and the second energy-absorbing cavity, the first energy-absorbing cavity comprises a first inclined plate, the second energy-absorbing cavity comprises a third inclined plate, the first inclined plate and the third inclined plate are respectively connected to two ends of the buffer section, the first inclined plate and the third inclined plate are located on the same side of the buffer section, and the ends of the first inclined plate and the third inclined plate, which are away from the buffer section, are arranged in directions away from each other. The application provides an energy-absorbing door sill beam assembly and a vehicle, so as to solve the problem of poor door sill beam crashworthiness in the related art.

Description

Technical Field

[0001] This application relates to the field of automotive design and manufacturing technology, and in particular to an energy-absorbing door sill beam assembly and a vehicle thereof. Background Technology

[0002] A door sill beam typically forms a cavity structure between the side door sill and the floor door sill. When the door sill beam is subjected to an impact force, the cavity collapses and deforms, absorbing the impact force and facilitating its dispersion and transmission, thereby reducing the deformation of the door sill beam and the amount of impact intrusion.

[0003] In related technologies, the door sill structure of traditional fuel vehicles usually consists of an inner door sill beam, a door sill beam reinforcement plate, and a side panel, with a support plate and a side impact reinforcement plate added in the middle, or a separate cavity. However, the structure of the door sill beam is relatively simple. In real vehicle crash tests, when used on large vehicles or electric vehicles with a weight much greater than that of fuel vehicles, it cannot withstand the high-speed instantaneous dynamic impact force during the collision, resulting in poor energy absorption and affecting the safety and reliability of the entire vehicle. Summary of the Invention

[0004] This application provides an energy-absorbing sill beam assembly and a vehicle to solve the problem of poor collision performance of sill beams in related technologies.

[0005] In a first aspect, an energy-absorbing sill beam assembly is provided, including an outer sill plate and an inner sill plate, wherein a cavity is provided between the outer sill plate and the inner sill plate;

[0006] A threshold reinforcement beam is disposed in the chamber. The threshold reinforcement beam includes multiple collapsible units arranged sequentially along the Y direction. The cross-section of each collapsible unit is figure-eight shaped and includes a first energy-absorbing cavity and a second energy-absorbing cavity. A buffer section connects the first energy-absorbing cavity and the second energy-absorbing cavity. The first energy-absorbing cavity includes a first inclined plate, and the second energy-absorbing cavity includes a third inclined plate. The first inclined plate and the third inclined plate are respectively connected to both ends of the buffer section, and the first inclined plate and the third inclined plate are located on the same side of the buffer section. The ends of the first inclined plate and the third inclined plate away from the buffer section are arranged in a direction away from each other.

[0007] In some embodiments, the collapse unit includes a first collapse unit and a second collapse unit, and a reinforcing surface is provided between the first collapse unit and the second collapse unit;

[0008] The threshold reinforcement beam is an integrally formed structure, including a welding start end and a welding end end, which are respectively welded to both sides of the reinforcement surface.

[0009] In some embodiments, the first collapse unit includes a first energy-absorbing cavity and a second energy-absorbing cavity. The first energy-absorbing cavity includes a force-bearing surface, a first inclined plate, and a second inclined plate. The force-bearing surface is connected to the outer sill plate. One end of the first inclined plate is connected to the force-bearing surface, and the other end is connected to the buffer section. One end of the second inclined plate is connected to the force-bearing surface, and the other end is connected to the buffer section.

[0010] The second energy-absorbing cavity includes a reinforcing surface, a third inclined plate, and a fourth inclined plate. One end of the third inclined plate is connected to the reinforcing surface, and the other end is connected to the buffer section. One end of the fourth inclined plate is connected to the reinforcing surface, and the other end is connected to the buffer section.

[0011] In some embodiments, an arc segment is provided at the junction of the first inclined plate and the force-bearing surface, and the radius of the arc segment is at least three times the thickness of the first inclined plate.

[0012] In some embodiments, the angle A between the first inclined plate and the horizontal plane is 30° to 75°, the angle B between the second inclined plate and the horizontal plane is 30° to 75°, and the angle A is greater than the angle B.

[0013] In some embodiments, the first collapse unit includes a first energy-absorbing cavity and a second energy-absorbing cavity, wherein the first energy-absorbing cavity is located at one end near the outer sill plate;

[0014] The second collapse unit includes a third energy-absorbing cavity and a fourth energy-absorbing cavity. The fourth energy-absorbing cavity is located at one end near the inner plate of the sill. The first energy-absorbing cavity, the second energy-absorbing cavity, the third energy-absorbing cavity and the fourth energy-absorbing cavity are arranged sequentially along the Y direction, and the reinforcing surface is located between the second energy-absorbing cavity and the third energy-absorbing cavity.

[0015] In some embodiments, the third energy-absorbing cavity includes a fifth inclined plate, the fourth energy-absorbing cavity includes a seventh inclined plate, and a buffer section is connected between the third energy-absorbing cavity and the fourth energy-absorbing cavity. The fifth inclined plate and the seventh inclined plate are respectively connected to the buffer section and are located on the same side of the buffer section. The ends of the fifth inclined plate and the seventh inclined plate away from the buffer section are arranged in a direction away from each other.

[0016] The angle A between the first inclined plate and the horizontal plane is denoted as A, and the angle E between the fifth inclined plate and the horizontal plane is denoted as E. The angle A is greater than the angle E.

[0017] In some embodiments, the length of the first collapse unit in the Y direction is greater than the length of the second collapse unit in the Y direction.

[0018] In some embodiments, the length of the buffer segment is not less than 10 mm.

[0019] Secondly, a vehicle is provided, comprising:

[0020] One of the energy-absorbing sill beam assemblies described above;

[0021] The seat front crossbeam is connected to the seat front crossbeam via a front crossbeam force transmission component. The seat front crossbeam includes a front crossbeam lower plate, which includes a welded edge and a welded corner. The front crossbeam lower plate is welded to the sill inner plate, and the lower end of the sill reinforcing beam does not exceed the welded edge.

[0022] The beneficial effects of the technical solution provided in this application include:

[0023] This application provides an energy-absorbing sill beam assembly and a vehicle. Since a sill reinforcement beam is provided in the cavity between the outer sill plate and the inner sill plate, and along the Y direction of the vehicle coordinate system, the sill reinforcement beam includes multiple collapse units with a cross section of figure 8. Each collapse unit includes two energy-absorbing cavities, and a buffer section is provided between the two energy-absorbing cavities. The first inclined plate of the first energy-absorbing cavity and the third inclined plate of the second energy-absorbing cavity are inclined in a direction away from each other. When the sill beam assembly is subjected to an external lateral impact, the sill reinforcement beam collapses due to impact and compression, causing the first inclined plate and the third inclined plate to move towards each other. In this process, it is necessary to overcome the force of the first inclined plate and the third inclined plate that are far apart. Structurally, it can provide Y-direction support for the buffer and deformation on both sides of the sill. Based on the buffer section, the deformation resistance strength in the Y direction is enhanced.

[0024] In addition, there are multiple crumple zones arranged sequentially along the Y-axis of the vehicle. When subjected to an external lateral impact, the multiple energy-absorbing chambers in the crumple zone collapse and deform sequentially from the outside to the inside, thus achieving an energy absorption effect. Therefore, it can solve the problem of poor collision performance of door sill beams in related technologies. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 A schematic diagram of the assembly of the door sill beam with the vehicle provided in an embodiment of this application;

[0027] Figure 2 A plan view of the assembly of the sill beam with the vehicle provided in an embodiment of this application;

[0028] Figure 3 for Figure 2 Cross-sectional view at point MM;

[0029] Figure 4 A schematic diagram of the structure of the first and second collapsible units in the energy-absorbing sill beam assembly provided in this application embodiment;

[0030] Figure 5 A schematic diagram showing the dimensions of the first and second collapsible units in the energy-absorbing sill beam assembly provided in this embodiment of the application.

[0031] Figure 6 This is a partial schematic diagram of the second collapse unit provided in an embodiment of this application.

[0032] In the diagram: 1. Outer sill plate; 2. Inner sill plate; 3. Sill reinforcement beam; 31. First energy absorption cavity; 32. Second energy absorption cavity; 33. Third energy absorption cavity; 34. Fourth energy absorption cavity; 35. Welding start end; 36. Welding end; 37. Reinforcement surface; 38. Buffer section; 381. Upper buffer plate; 382. Lower buffer plate; 39. Force-bearing surface; 30. Force-transmitting surface; 4. Front crossbeam of the seat; 41. Force-transmitting component of the front crossbeam; 42. Lower plate of the front crossbeam; 42 1. Welding edge; 422. Welding corner; 5. Rear crossbeam of seat; 6. First crumple zone; 61. First inclined plate; 62. Second inclined plate; 63. Third inclined plate; 64. Fourth inclined plate; 7. Second crumple zone; 71. Fifth inclined plate; 72. Sixth inclined plate; 73. Seventh inclined plate; 74. Eighth inclined plate; 8. Fastener; 9. Impact-resistant component; 10. First welding point; 11. Second welding point; 12. Third welding point. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0034] This application provides an energy-absorbing sill beam assembly that can solve the problem of poor collision performance of sill beams in related technologies.

[0035] See Figures 1 to 6 As shown, this application embodiment provides an energy-absorbing sill beam assembly, including an outer sill plate 1, an inner sill plate 2, and a sill reinforcing beam 3, wherein a cavity is provided between the outer sill plate 1 and the inner sill plate 2;

[0036] Furthermore, the threshold reinforcement beam 3 is installed in the cavity, combined with... Figures 3 to 5 As shown, the threshold reinforcement beam 3 includes multiple collapsible elements arranged sequentially along the Y direction, and the cross-section of the collapsible element is "figure-eight".

[0037] Specifically, in combination Figure 4 As shown, the collapse unit includes a first energy-absorbing chamber 31 and a second energy-absorbing chamber 32, with a buffer section 38 connecting the first energy-absorbing chamber 31 and the second energy-absorbing chamber 32. Figure 4 As shown, the first energy-absorbing cavity 31 includes a first inclined plate 61, and the second energy-absorbing cavity 32 includes a third inclined plate 63. The first inclined plate 61 and the third inclined plate 63 are respectively connected to the two ends of the buffer section 38, and the first inclined plate 61 and the third inclined plate 63 are located on the same side of the buffer section 38. The ends of the first inclined plate 61 and the third inclined plate 63 away from the buffer section 38 are arranged in a direction away from each other.

[0038] When the energy-absorbing sill beam assembly is subjected to a high-speed side impact, the first inclined plate 61 and the third inclined plate 63 move towards each other, that is, in the opposite direction of their orientation, in order to compress the first energy-absorbing cavity 31 and the second energy-absorbing cavity 32, providing Y-axis support for energy-absorbing deformation, thus achieving sufficient energy absorption; on the other hand, the buffer section 38, as Figures 3 to 5 As shown, the energy-absorbing chamber is positioned between the first energy-absorbing chamber 31 and the second energy-absorbing chamber 32 along the Y-direction parallel to the vehicle coordinate system, which also strengthens the Y-direction support of the energy-absorbing sill beam assembly.

[0039] This application provides an energy-absorbing sill beam assembly. A sill reinforcement beam 3 is installed in the first chamber of the outer sill plate 1 and the inner sill plate 2. Along the Y-direction of the vehicle coordinate system, the sill reinforcement beam 3 includes multiple "8"-shaped collapsible units. Each collapsible unit includes two energy-absorbing chambers, with a buffer section 38 between them. The first inclined plate 61 of the first energy-absorbing chamber 31 and the third inclined plate 63 of the second energy-absorbing chamber 32 are inclined in directions away from each other. When the sill beam assembly is subjected to an external lateral impact, the sill reinforcement beam 3 collapses due to impact and compression, causing the first inclined plate 61 and the third inclined plate 63 to move towards each other. This process requires overcoming the forces of the far-away first inclined plate 61 and the third inclined plate 63. Structurally, this provides Y-direction support for buffering and deformation on both sides of the sill. Based on the buffer section 38, the deformation resistance strength in the Y direction is enhanced. Therefore, it can solve the problem of poor collision performance of sill beams in related technologies.

[0040] In some optional embodiments, the sill reinforcement beam 3 is a one-piece molded structure, see [link to relevant documentation]. Figure 3 As shown, the threshold reinforcement beam 3 includes a welding start end 35 and a welding end end 36, which are then combined with... Figure 3 As shown, the collapse unit includes a first collapse unit 6 and a second collapse unit 7, and a reinforcing surface 37 is provided between the first collapse unit 6 and the second collapse unit 7. The welding start end 35 and welding end end 36 of the threshold reinforcing beam 3 are respectively welded to both sides of the reinforcing surface 37.

[0041] Furthermore, combined Figure 3 and Figure 4 As shown, the first collapse unit 6 includes a first inclined plate 61, a second inclined plate 62, a third inclined plate 63, and a fourth inclined plate 64. The first inclined plate 61 and the third inclined plate 63 are located on the same side of the buffer section 38, while the second inclined plate 62 and the fourth inclined plate 64 are located on the other side of the buffer section 38. The buffer section 38 has a double-layer structure, with the upper and lower plates welded together, dividing the first collapse unit 6 into a first energy-absorbing cavity 31 and a second energy-absorbing cavity 32. Therefore, the cross-section of the first collapse unit 6 is figure-eight shaped.

[0042] Furthermore, combined Figures 3 to 5 As shown, the cross-section of the second collapse unit 7 is the same as that of the first collapse unit 6, which is also "figure-eight" shaped, forming a closed cross-section of "double figure-eight" shape, generating four cavities, which can provide Y-direction support for the buffering and deformation of the two sides of the threshold beam that tends to deform due to impact.

[0043] Furthermore, since the threshold reinforcement beam 3 is an integrally formed structure, specifically the welding start end 35 and welding end end 36 are welded to both sides of the reinforcement surface 37, the threshold reinforcement beam 3 has a complete structure and can directly form a complete weld nugget. This avoids the risk of weld point breakage due to column collision and side collision impacts that would occur during segmented welding, which would lead to the failure of the entire cross-section's resistance and energy absorption.

[0044] On the other hand, combining Figures 3 to 5 As shown, the welding positions of the welding start end 35, welding end end 36, and reinforcing surface 37 are R-angle lap joint welds. Specifically, this type of weld position does not experience direct impact force when subjected to high-speed impacts from column and side collisions. Even in the latter half of the deformation process, it mainly bears shear force rather than tensile force. The risk of cross-sectional energy absorption collapse due to weld failure is extremely small, reducing the risk of easy weld failure due to the force direction at the laser weld start and end.

[0045] Furthermore, the threshold reinforcement beam 3, while having four cavities and multiple inclined plates opposite to the direction of collision deformation, becomes a complete closed structure after roll forming. It retains the collision deformation induction characteristics and will not easily deform under actual side and pole impacts. It can adapt to medium and large vehicles or electric vehicles with large overall vehicle weight and has a wide range of applications.

[0046] Furthermore, the threshold reinforcement beam 3 has a "double figure-eight" shaped section, and under the same material thickness, its Z-direction bending section modulus is at least twice that of the embodiment with a section that is only a cavity.

[0047] In some alternative embodiments, taking the first collapse unit 6 as an example, combined with Figures 3 to 4As shown, the first collapse unit 6 includes a first energy-absorbing cavity 31 and a second energy-absorbing cavity 32. The first energy-absorbing cavity 31 includes a force-bearing surface 39, a first inclined plate 61 and a second inclined plate 62. The force-bearing surface 39 is connected to the outer sill plate 1. One end of the first inclined plate 61 is connected to the force-bearing surface 39 and the other end is connected to the buffer section 38. One end of the second inclined plate 62 is connected to the force-bearing surface 39 and the other end is connected to the buffer section 38.

[0048] The second energy-absorbing cavity 32 includes a reinforcing surface 37, a third inclined plate 63, and a fourth inclined plate 64. One end of the third inclined plate 63 is connected to the reinforcing surface 37, and the other end is connected to the buffer section. One end of the fourth inclined plate 64 is connected to the reinforcing surface 37, and the other end is connected to the buffer section 38. Figure 3 As shown, the buffer section 38 in the first collapse unit 6 has a double-layer structure. Specifically, in combination with... Figure 6 As shown, the buffer section 38 includes an upper buffer plate 381 and a lower buffer plate 382. The two ends of the upper buffer plate 381 are respectively connected to the fifth inclined plate 71 and the seventh inclined plate 73, and the two ends of the lower buffer plate 382 are respectively connected to the sixth inclined plate 72 and the eighth inclined plate 74. The upper buffer plate 381 and the lower buffer plate 382 are connected by welding. The welding point is the first welding point 10. The welding method can be roller spot welding, ordinary spot welding or laser fusion welding.

[0049] Similarly, the second collapse unit 7 includes a fifth inclined plate 71, a sixth inclined plate 72, a seventh inclined plate 73, and an eighth inclined plate 74, combined with Figure 4 As shown, a buffer section 38 is also connected between the fifth inclined plate 71 and the seventh inclined plate 73, and the ends of the fifth inclined plate 71 and the seventh inclined plate 73 that are not connected to the buffer section 38 are far apart from each other. Furthermore, the ends of the sixth inclined plate 72 and the eighth inclined plate 74 that are not connected to the buffer section 38 are also far apart from each other.

[0050] Combination Figure 3 and Figure 4 As shown, from the outer sill plate 1 to the inner sill plate 2, the sill reinforcing beam 3 sequentially includes a first energy-absorbing section a1, a second energy-absorbing section a2, a third energy-absorbing section a3, a fourth energy-absorbing section a4, a fifth energy-absorbing section a5, and a sixth energy-absorbing section a6, wherein the dividing line between the third energy-absorbing section a3 and the fourth energy-absorbing section a4 is at the reinforcing surface 37.

[0051] Optionally, combined Figures 3 to 5 As shown, an arc segment is provided at the junction of the first inclined plate 61 and the force-bearing surface 39. The radius of the arc segment is preferably at least three times the thickness of the first inclined plate 61. That is, when the overall thickness of the threshold reinforcing beam 3 is 1 mm, the radius of the arc segment is preferably 3 mm.

[0052] Furthermore, the side of the first energy-absorbing cavity 31 that contacts the outer sill plate 1 is the force-bearing surface 39. The first energy-absorbing cavity 31 includes the force-bearing surface 39, a first inclined plate 61, a second inclined plate 62, and as shown in the figure. Figure 5 The first energy-absorbing cavity has an upper fillet R1 and a lower fillet R2. Preferably, the maximum values ​​of R1 and R2 are not less than three times the thickness of the first inclined plate 61, but a thickness of 5 mm can also be selected.

[0053] Furthermore, the larger the radii of R1 and R2, the greater the resistance to deformation. The specific values ​​can be adjusted according to the crushing deformation mode and crushing force of the simulation model.

[0054] Optionally, the angle A between the first inclined plate 61 and the horizontal plane is 30° to 75°, and the angle B between the second inclined plate 62 and the horizontal plane is 30° to 75°, with angle A being greater than angle B. The smaller the angles A and B, the greater the deformation resistance of the first energy-absorbing cavity 31, and the more impact energy the first energy-absorbing interval a1 absorbs during the extrusion deformation process. It should be noted that the horizontal plane refers to the XY plane of the vehicle coordinate system.

[0055] Furthermore, the first inclined plate 61, the second inclined plate 62, the third inclined plate 63, and the fourth inclined plate 64, together with the first welding point 10 between the upper buffer plate 381 and the lower buffer plate 382, ​​form a special X-shaped strong support structure, namely as shown in the figure. Figure 3 The second energy absorption interval segment a2 is shown.

[0056] Optionally, the width L1 of the buffer segment 38 is as follows: Figure 5 As shown, the thickness is not less than 10mm, preferably more than 12mm; similarly, the angle C between the third inclined plate 63 and the horizontal plane is 30° to 75°, and the angle D between the fourth inclined plate 64 and the horizontal plane is 30° to 75°. The smaller the angle, the greater the deformation resistance, and the more impact energy is absorbed during the deformation of the second energy absorption interval a2.

[0057] Furthermore, the second energy-absorbing cavity 32 includes a third inclined plate 63, a fourth inclined plate 64, an upper rounded corner R3, a lower rounded corner R4, a reinforcing surface 37, and a third welding point 12 where the welding start end 35 is welded to the reinforcing surface 37, forming the third energy-absorbing interval segment a3.

[0058] Optionally, the maximum values ​​of R3 and R4 are not less than three times the thickness of the third inclined plate 63, or they can be selected as 5 mm. The specific values ​​can also be adjusted according to the crushing deformation mode and crushing force of the simulation model. The larger the R angle, the greater the deformation resistance. The larger the angle C between the third inclined plate 63 and the horizontal plane, and the larger the angle D between the fourth inclined plate 64 and the horizontal plane, the greater the deformation resistance and the more impact energy absorbed during the deformation of the third energy absorption interval a3.

[0059] Furthermore, the third energy-absorbing cavity 33 includes a fifth inclined plate 71, a sixth inclined plate 72, a reinforcing surface 37, and upper fillet R5 of the third energy-absorbing cavity and upper fillet R3 of the second energy-absorbing cavity, which, together with the second welding point 11 between the welding start end 35 and the reinforcing surface 37, constitute the fourth energy-absorbing interval segment a4.

[0060] Optionally, the maximum values ​​of R3 and R5 should not be less than three times the thickness of the fifth inclined plate 71, and 5mm or more is recommended. The specific values ​​can also be adjusted according to the crushing deformation mode and crushing force of the simulation model. The larger the R angle, the greater the deformation resistance. The angle E between the fifth inclined plate 71 and the horizontal plane, and the angle F between the sixth inclined plate 72 and the horizontal plane are recommended to be adjusted between 30° and 75°. The smaller the angle, the greater the deformation resistance, and the more impact energy absorbed during the deformation of the fourth energy absorption interval a4.

[0061] Furthermore, the fifth inclined plate 71, the sixth inclined plate 72, the seventh inclined plate 73, and the eighth inclined plate 74, together with the first welding point 10 between the upper buffer plate 381 and the lower buffer plate 382, ​​form a special X-shaped strong support structure, namely as shown in the figure. Figure 3 The fifth energy absorption interval segment a5 is shown.

[0062] Optionally, the width L1 of the buffer segment 38 is as follows: Figure 5 As shown, the thickness is not less than 10mm, preferably more than 12mm; similarly, the included angles E between the fifth inclined plate 71 and the horizontal plane, F between the sixth inclined plate 72 and the horizontal plane, G between the seventh inclined plate 73 and the horizontal plane, and K between the eighth inclined plate 74 and the horizontal plane are in the range of 30° to 75°. The smaller the angle, the greater the deformation resistance, and the more impact energy is absorbed during the deformation of the fifth energy absorption interval a5.

[0063] Furthermore, the fourth energy-absorbing cavity 34 includes a seventh inclined plate 73, an eighth inclined plate 74, a force-transmitting surface 30, and an upper fillet R7 and a lower fillet R8 of the fourth energy-absorbing cavity. The force-transmitting surface 30 is located at the end of the fourth energy-absorbing cavity 34 facing the inner sill plate 2. Figure 5 As shown, at least a portion of the fourth energy-absorbing cavity 34 is the sixth energy-absorbing interval segment a6.

[0064] Optionally, the maximum values ​​of R7 and R8 should not be less than three times that of the seventh inclined plate 73, and 5mm or more is recommended. The specific values ​​can also be adjusted according to the crushing deformation mode and crushing force of the simulation model. The larger the R angle, the greater the deformation resistance. The angle G between the seventh inclined plate 73 and the horizontal plane and the angle K between the eighth inclined plate 74 and the horizontal plane are both recommended to be adjusted between 30° and 75°. The smaller the angle, the greater the deformation resistance, and the more impact energy absorbed during the deformation of the sixth energy absorption interval a6.

[0065] Optionally, the door sill reinforcement beam 3 is manufactured using a roll forming process. The material can be a cold-stamped steel sheet with a mechanical strength of less than 1700MPa. Through continuous rolling and folding of the roll forming line, a beam structure with a "double figure-eight" cross section is gradually formed. Subsequently, two roll spot welds (or laser welding and ordinary spot welding) and two laser welds are used to form four closed and independent deformable energy-absorbing cavities and two figure-eight intersecting deformable energy-absorbing sections. Through the sequential deformation of up to six independent energy-absorbing sections, the impact force of pole collisions and side collisions transmitted from the outside of the vehicle is gradually absorbed by the structural collapse deformation. At the same time, the Y-axis impact energy is transferred to the door sill and the front floor seat crossbeam, ensuring that external impact objects do not excessively intrude into the passenger compartment. It also prevents spontaneous combustion accidents caused by excessive deformation of the battery pack frame and excessive compression of the battery cells.

[0066] In some optional embodiments, to ensure that the vehicle achieves progressive and stable crumple deformation from the outside to the inside during pole and side impacts, thereby absorbing energy step by step and inducing deflection of the upper part of the side pole to protect the battery pack, the following design requirements are also required: The angle A between the first inclined plate 61 and the horizontal plane is set to the largest of several angles, and each angle is set as follows:

[0067] AB≧5°, CD≧5°, EF≧5°, GK≧5°;

[0068] AC≧7°, EG≧7°, AE≧7°, CG≧8°.

[0069] Furthermore, this specification also provides an implementable example regarding the fillet radius data for the energy-absorbing cavity:

[0070] For the first collapsible unit 6: R1-R3≧3mm, and R2-R4≧3mm;

[0071] For the second collapsing unit 7: R5-R7≧3mm, and R6-R8≧3mm.

[0072] Furthermore, it is recommended that the length of the first energy absorption interval a1 + the second energy absorption interval a2 + the third energy absorption interval a3 ≥ the fourth energy absorption interval a4 + the fifth energy absorption interval a5 + the sixth energy absorption interval a6 be greater than that of the second energy absorption interval a6 located on the inner side. That is, the length of the first collapsing unit 6 located on the outer side in the Y direction should be greater than the length of the second collapsing unit 7 located on the inner side.

[0073] Since the sill beam is usually subjected to impacts from the outside, i.e. the side of the outer sill plate 1, the first crumple unit 6 located on the outside is the first to come into contact with the impact and undergo crumple deformation. By appropriately extending the first crumple unit 6 to be longer than the second crumple unit 7, it is beneficial for the first crumple unit 6 to absorb the impact energy from the outside. The impact force of the pole impact and side impact transmitted from the outside of the vehicle is gradually absorbed by the crumple deformation of the sill reinforcement 3 itself, so as to achieve the effect of energy absorption by the successive crumple deformation.

[0074] In some alternative embodiments, see Figures 3 to 5 As shown, the sill reinforcement beam 3 is fixed in the cavity formed by the outer sill plate 1 and the inner sill plate 2 by a fastener 8. Specifically, the fastener 8 includes a bolt and a nut. The bolt passes through both the outer sill plate 1 and the force-bearing surface 39 of the sill reinforcement beam 3, and the nut is fixed in the first energy-absorbing cavity 31. This ensures that the sill reinforcement beam 3 will not overturn due to compression and impact during external lateral impacts. Furthermore, the nut + bolt configuration eliminates the need for specialized equipment such as FDS, resulting in low cost and stable connection.

[0075] Further, see Figure 3 and Figure 4 As shown, the sill inner plate 2 and the sill reinforcing beam 3 are designed with a gap structure, the gap of which can be controlled within 1mm, with a recommended design of 0.5mm; optionally, an impact-resistant component 9 is provided to fill the gap, preferably a whole strip of impact-resistant structural adhesive, to ensure the stability of the impact-resistant component 9 during the entire deformation process of the sill. Further, the impact-resistant structural adhesive is adhered between the sill inner plate 2 and the force transmission surface 30.

[0076] This application provides an embodiment of a vehicle, which includes:

[0077] An energy-absorbing sill beam assembly as described above, and as... Figure 1 and Figure 2 The front crossbeam 4 of the seat shown is specifically as follows: Figure 3 As shown in the cross-sectional view, the inner sill plate 2 is connected to the front crossbeam 4 of the seat via the front crossbeam force transmission component 41. When the vehicle is subjected to a pole impact and a side impact, the impact energy is transmitted from the outer sill plate 1 to the sill reinforcement beam 3 through the force-bearing surface 39, and then to the front crossbeam force transmission component 41 and the front crossbeam 4 of the seat via the force transmission surface 30 of the sill reinforcement beam 3.

[0078] Furthermore, such as Figures 3 to 5 As shown, the front crossbeam 4 of the seat includes a lower front crossbeam plate 42, which is welded to the inner door sill plate 2. The lower front crossbeam plate 42 includes a welding edge 421 and a welding corner 422. The part of the lower front crossbeam plate 42 that is actually welded to the inner door sill plate 2 is the part from the welding edge 421 to the welding corner 422.

[0079] Specifically, to ensure that the external impact energy is transmitted along the path of outer sill plate 1 → sill reinforcement beam 3 → inner sill plate 2 → front seat crossbeam 4 during pole and side impacts, such as... Figure 5 The second height difference H between the bottom end of the sill reinforcement beam 3 and the front crossbeam 4 of the seat should be as small as possible.

[0080] Optionally, the lower end of the sill reinforcement beam 3 does not exceed the weld edge 421. Since the inner sill plate 2 needs to be supported by the front crossbeam 4 of the seat when energy is transferred from the outer sill plate 1 to the inner sill plate 2, and the weld edge 421 is the welding endpoint between the lower plate 42 of the front crossbeam and the inner sill plate 2, if it continues to extend downward, the sill reinforcement beam 3 will abut against the single-layer plate of the inner sill plate 2, which is not conducive to transferring the impact energy to the front crossbeam 4 of the seat.

[0081] Because the impact force needs to be transferred to the front crossbeam 4 of the seat, the upper end of the sill reinforcement beam 3 must be lower than the front crossbeam 4 of the seat when the front crossbeam force transmission component 41 is set. Therefore, the lower end of the sill reinforcement beam 3 is preferably flush with the lower end of the front crossbeam 4 of the seat (i.e., flush with the welded corner 422) so that the force on the sill reinforcement beam 3 can be completely transferred to the front crossbeam 4 of the seat, so that the "double figure-eight" cross section of the sill reinforcement beam 3 can play a greater role.

[0082] Furthermore, the height difference h between the rounded corner of the fourth energy-absorbing cavity 34 of the threshold reinforcement beam 3 on the side away from the outer threshold plate 1 and the upper rounded corner on the inner side of the threshold inner plate 2 is not less than 3mm, so as to prevent interference between the two rounded corners of the inner threshold plate 2 and the threshold reinforcement beam 3 when errors occur due to the separate manufacturing of the inner threshold plate 2 and the threshold reinforcement beam 3.

[0083] Because the door sill reinforcement beam 3 is a beam structure with a "double figure-eight" cross section, it is subsequently combined with two round spot welding (or laser welding and ordinary spot welding) and two laser welding to form four closed and independent deformable energy-absorbing cavities (i.e., the first energy-absorbing cavity 31, the second energy-absorbing cavity 32, the third energy-absorbing cavity 33, and the fourth energy-absorbing cavity 34) and two figure-eight intersecting deformable energy-absorbing sections (i.e., the second energy-absorbing section a2 and the fifth energy-absorbing section a5). Through the sequential deformation of up to six independent energy-absorbing sections, the pole impact and side impact impact forces transmitted from the outside of the vehicle are gradually absorbed by the structural collapse deformation. At the same time, the Y-axis impact energy is transferred to the door sill and the front crossbeam 4 of the seat, which avoids excessive intrusion of external impact objects into the passenger compartment and prevents spontaneous combustion accidents caused by excessive deformation of the battery pack frame and excessive compression of the battery cells.

[0084] Optionally, it also includes a rear seat crossbeam 5, which, like the front seat crossbeam 4, is connected to the inner door sill panel 2.

[0085] This application provides an energy-absorbing door sill beam assembly and a vehicle, which have the following advantages:

[0086] (1) Both the upper buffer plate 381 and the lower buffer plate 382 are complete surfaces without any end connection. They are connected by the first welding point 10, which can directly form a complete weld nugget. As the key connection part of the second energy absorption section a2, there will be no defect that all the welding is half spot welding. This can avoid the risk of the weld point breaking due to the Y-direction impact of the column and side impact, which would lead to the failure of the entire cross section's resistance and energy absorption.

[0087] (2) The second welding point 11 between the lower fillet R4 of the second energy absorption cavity and the lower fillet R6 of the third energy absorption cavity, and the third welding point 12 between the upper fillet R5 of the third energy absorption cavity and the upper fillet R3 of the second energy absorption cavity are all Y-direction fitting welds with R-angles. The force on the weld when subjected to Y-direction impact force is not in the direct impact direction, and it mainly bears shear force rather than tensile force. The risk of cross-sectional energy absorption collapse due to weld failure is extremely small.

[0088] (3) Both the second energy absorption section a2 and the fifth energy absorption section a5 are X-shaped strong support structures that can provide support in both directions at the same time. They can provide Y-direction support for the buffering and deformation on both sides of the threshold strengthening beam 3, avoiding the defect that the first and second energy absorption vertical plates above and below the traditional threshold beam energy absorption section are ordinary upright forms and have no resistance strength to Y-direction deformation.

[0089] (4) The first energy absorption cavity 31, the second energy absorption cavity 32, the third energy absorption cavity 33, and the fourth energy absorption cavity 34 are all complete and relatively independent cavities, and respectively form the first energy absorption interval segment a1, the third energy absorption interval segment a3, the fourth energy absorption interval segment a4, and the sixth energy absorption interval segment a6. Together with the second energy absorption interval segment a2 and the fifth energy absorption interval segment a5, they form a total of 6 deformation buffer features, forming a “double 8” shaped structure. Each cavity and each deformation feature is a deformation point. The actual collision deformation mode is stable, and it is not easy to have defects such as random cavity deformation or insufficient deformation energy absorption.

[0090] (5) The threshold reinforcement beam 3 can be formed by multiple continuous forming of steel plate through special roll forming process. Under the same weight or size of parts, the cost per piece is more than half that of aluminum extrusion parts. Welding, screwing, riveting, riveting + screwing are all possible, and the connection cost is lower than that of FDS.

[0091] (6) The first energy-absorbing cavity 31, the second energy-absorbing cavity 32, the third energy-absorbing cavity 33, the fourth energy-absorbing cavity 34, and the first energy-absorbing interval a1, the second energy-absorbing interval a2, the third energy-absorbing interval a3, the fourth energy-absorbing interval a4, the fifth energy-absorbing interval a5, and the sixth energy-absorbing interval a6, although they are 4 cavities and 6 deformation buffer features, are a complete closed structure after rolling. They retain the collision deformation induction features and will not easily deform under actual side collision and pole collision impacts. This avoids the defect that the vehicle cannot be adapted to the large weight of medium and large fuel vehicles or electric vehicles, which result in large collision kinetic energy and cannot buffer and absorb energy.

[0092] (7) The height difference H between the door sill reinforcement beam 3 and the front crossbeam of the seat tends to be 0. The height difference h between the inner rounded corner of the door sill reinforcement beam and the upper rounded corner of the inner side of the door sill is not less than 3mm. That is, the height of the door sill reinforcement beam 3 in the Z direction is close to the height of the front crossbeam of the seat in the Z direction. During the process of energy absorption by its own structural deformation, the door sill reinforcement beam 3 can transmit the impact force of external side collision and pole collision to the lower body of the vehicle body to the maximum extent according to the force transmission path of door sill outer panel 1 → door sill reinforcement beam 3 → door sill inner panel 2 → front crossbeam of the seat. This not only prevents the external intrusion into the vehicle body from being too large, but also protects the battery pack from being squeezed.

[0093] (8) The cross section of the threshold reinforcement beam 3 is a “double figure-eight” shaped resistance structure of a complete cavity. For the second energy absorption section a2 and the fifth energy absorption section a5, under the same material thickness, its Z-direction bending section modulus is at least twice that of the scheme of setting the threshold reinforcement beam 3 as multiple continuous cavities.

[0094] (9) The sill reinforcement beam 3 and the outer sill plate 1 are connected by bolts and rivets, and the sill beam and the inner sill plate are connected by impact-resistant structural adhesive. This avoids the problem of the sill beam completely reversing and failing when hit by a real vehicle pillar, and the deformation is stable.

[0095] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0096] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0097] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. An energy-absorbing sill beam assembly, characterized in that, It includes: A sill outer panel (1) and a sill inner panel (2) are provided, and a chamber is provided between the sill outer panel (1) and the sill inner panel (2); A threshold reinforcement beam (3) is disposed in the chamber. The threshold reinforcement beam (3) includes a plurality of collapse units arranged sequentially along the Y direction. The collapse unit has a figure-eight cross section and includes a first energy absorption cavity (31) and a second energy absorption cavity (32). A buffer section (38) is connected between the first energy absorption cavity (31) and the second energy absorption cavity (32). The first energy absorption cavity (31) includes a first inclined plate (61), and the second energy absorption cavity (32) includes a third inclined plate (63). The first inclined plate (61) and the third inclined plate (63) are respectively connected to the two ends of the buffer section (38), and the first inclined plate (61) and the third inclined plate (63) are located on the same side of the buffer section (38). The ends of the first inclined plate (61) and the third inclined plate (63) away from the buffer section (38) are arranged in a direction away from each other. The first energy-absorbing cavity (31) includes a force-bearing surface (39), a first inclined plate (61), and a second inclined plate (62). The force-bearing surface (39) is connected to the outer door sill plate (1). One end of the first inclined plate (61) is connected to the force-bearing surface (39), and the other end is connected to the buffer section (38). One end of the second inclined plate (62) is connected to the force-bearing surface (39), and the other end is connected to the buffer section (38). The angle A between the first inclined plate (61) and the horizontal plane is 30°~75°, and the angle B between the second inclined plate (62) and the horizontal plane is 30°~75°, and the angle A is greater than the angle B.

2. The energy-absorbing sill beam assembly as described in claim 1, characterized in that: The collapse unit includes a first collapse unit (6) and a second collapse unit (7), and a reinforcing surface (37) is provided between the first collapse unit (6) and the second collapse unit (7). The threshold reinforcement beam (3) is an integrally formed structure, including a welding start end (35) and a welding end end (36), which are respectively welded to both sides of the reinforcement surface (37).

3. The energy-absorbing sill beam assembly as described in claim 2, characterized in that: The first collapse unit (6) includes the first energy absorption chamber (31) and the second energy absorption chamber (32); The second energy-absorbing cavity (32) includes a reinforcing surface (37), a third inclined plate (63) and a fourth inclined plate (64). One end of the third inclined plate (63) is connected to the reinforcing surface (37) and the other end is connected to the buffer section. One end of the fourth inclined plate (64) is connected to the reinforcing surface (37) and the other end is connected to the buffer section (38).

4. The energy-absorbing sill beam assembly as described in claim 3, characterized in that: An arc segment is provided at the junction of the first inclined plate (61) and the force-bearing surface (39), and the radius of the arc segment is at least three times the thickness of the first inclined plate (61).

5. The energy-absorbing sill beam assembly as described in claim 2, characterized in that: The first collapse unit (6) includes a first energy absorption cavity (31) and a second energy absorption cavity (32), wherein the first energy absorption cavity (31) is located at one end near the outer sill plate (1); The second collapse unit (7) includes a third energy-absorbing cavity (33) and a fourth energy-absorbing cavity (34). The fourth energy-absorbing cavity (34) is located at one end near the inner sill plate (2). The first energy-absorbing cavity (31), the second energy-absorbing cavity (32), the third energy-absorbing cavity (33) and the fourth energy-absorbing cavity (34) are arranged sequentially along the Y direction, and the reinforcing surface (37) is located between the second energy-absorbing cavity (32) and the third energy-absorbing cavity (33).

6. The energy-absorbing sill beam assembly as described in claim 5, characterized in that: The third energy-absorbing cavity (33) includes a fifth inclined plate (71), the fourth energy-absorbing cavity (34) includes a seventh inclined plate (73), and a buffer section (38) is connected between the third energy-absorbing cavity (33) and the fourth energy-absorbing cavity (34). The fifth inclined plate (71) and the seventh inclined plate (73) are respectively connected to the buffer section (38) and are located on the same side of the buffer section (38). The ends of the fifth inclined plate (71) and the seventh inclined plate (73) away from the buffer section (38) are arranged in a direction away from each other. The angle A between the first inclined plate (61) and the horizontal plane is E, and the angle A is greater than the angle E.

7. The energy-absorbing sill beam assembly as described in claim 2, characterized in that: The length of the first collapse unit (6) in the Y direction is greater than the length of the second collapse unit (7) in the Y direction.

8. The energy-absorbing sill beam assembly as described in claim 2, characterized in that: The length of the buffer section is not less than 10 mm.

9. A vehicle, characterized in that, It includes: An energy-absorbing sill beam assembly as described in any one of claims 1-8; The front crossbeam (4) of the seat is connected to the front crossbeam (4) of the seat via the front crossbeam force transmission member (41). The front crossbeam (4) of the seat includes a lower plate (42) of the front crossbeam. The lower plate (42) of the front crossbeam includes a welded edge (421) and a welded corner (422). The lower plate (42) of the front crossbeam is welded to the inner plate (2) of the sill. The lower end of the sill reinforcing beam (3) does not exceed the welded edge (421).

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