A combined multi-cell structure filled threshold beam assembly

Abstract

The application discloses a combined multi-cell structure filled door sill beam assembly. The combined multi-cell structure filled door sill beam assembly comprises two C-shaped plates and a combined multi-cell structure filled structure. The combined multi-cell structure filled structure comprises a front end out-of-plane vertex reinforced multi-cell honeycomb, a rear end coplanar vertex reinforced multi-cell honeycomb and a connecting plate. The front end out-of-plane vertex reinforced multi-cell honeycomb comprises a plurality of axial series reinforced cells with a hexagonal cross section distributed along the door sill beam axis. The rear end coplanar vertex reinforced multi-cell honeycomb comprises a plurality of thin-wall cells with a hexagonal cross section distributed along the door sill beam axis. The plurality of thin-wall cells are connected through overlapping boundaries to form a coplanar multi-cell honeycomb structure. The inner cross section of the hexagon is circular to form an arc-shaped reinforced cell wall at each vertex of the hexagon. The radius of the inner circle gradually increases from the middle to both sides. The application can transfer and absorb large collision energy when the vehicle faces a front small overlap offset collision and a side collision, and improve the impact resistance of the door sill beam structure.

Description

Technical Field

[0001] This invention belongs to the field of automotive collision safety technology, specifically relating to a combined multi-cell structure infill sill beam assembly. Background Technology

[0002] In frontal small overlap offset collisions and side impacts, the sill beam structure, as a crucial component for resisting impact and transferring loads, directly affects the degree of occupant injury due to its deformation and energy absorption characteristics. Multi-cell structures exhibit better stability and safety when bearing larger loads, and can reduce weight while improving mechanical performance. Applying multi-cell structures to sill beam design has significant practical implications for improving automotive crash safety.

[0003] Patent CN113998003A discloses a door sill beam assembly and an automobile, including a door sill beam body and a reinforcing structure. The door sill beam body is a hollow structure made of extruded metal material. Multiple body partition surfaces are provided inside the door sill beam body. The body partition surfaces are used to divide the door sill beam body into a first cavity and multiple second cavities along the radial direction of the door sill beam body. The reinforcing structure is a hollow structure made of extruded metal material. The reinforcing structure fills the first cavity. The radial cross-sectional shape of the reinforcing structure matches the radial cross-sectional shape of the first cavity.

[0004] Patent CN113978562A discloses a novel sill beam structure, comprising two outer plates. The inner walls of the outer plates are tightly fitted with a filling mechanism. The filling mechanism includes a main beam with an "I"-shaped cross-section, and energy-absorbing modules are provided on both sides of the main beam. One side of the energy-absorbing module has a locking groove, and the upper and lower ends of the energy-absorbing module are respectively provided with dovetail grooves. The other side of the energy-absorbing module has a first connecting groove longitudinally and a second connecting groove transversely. The upper and lower ends of the energy-absorbing module are respectively provided with reinforcing blocks. The bottom end of the reinforcing block is connected with a dovetail tenon, and the top end of the reinforcing block is provided with a third connecting groove.

[0005] The existing technical solutions of the aforementioned patents mainly improve the impact resistance of the sill beam by changing its cross-sectional shape, constructing a hollow structure inside the sill beam, adding a side impact support plate, or adding a hollow reinforcing structure with a matching shape. However, the structure is still a hollow beam or a thin-walled sheet metal structure. Although it has strong axial impact resistance, it is prone to bending deformation when subjected to lateral impact, resulting in a significant increase in peak impact force, concentrated crush deformation, and poor force transmission and diffusion capabilities, leading to poor energy absorption during side impacts. Summary of the Invention

[0006] The purpose of this invention is to overcome the problem that current door sill beam reinforcement structures have poor energy absorption performance when subjected to lateral impacts, and to provide a combined multi-cell structure filled door sill beam assembly. This assembly simultaneously improves the axial and lateral impact energy absorption characteristics of the door sill beam structure, meets the safety requirements of small overlap offset frontal collisions and side collisions, and also addresses issues such as improved body strength, lightweighting, and simplified manufacturing and assembly processes.

[0007] The technical solution to achieve the purpose of this invention is as follows: a combined multi-cell structure filled threshold beam assembly, comprising two C-shaped thin plates and a combined multi-cell structure filling structure filled in the cavity formed by the two C-shaped thin plates; the combined multi-cell structure filling structure comprises a front-end non-planar vertex reinforced multi-cell honeycomb, a rear-end coplanar vertex reinforced multi-cell honeycomb, and a connecting plate;

[0008] The front-end non-faceted vertex reinforced multi-cell honeycomb includes multiple axially connected reinforced cells with a regular hexagonal cross-section distributed along the axial direction of the threshold beam. Multiple identical cells form a non-faceted multi-cell honeycomb structure through overlapping boundaries. Each vertex of the regular hexagon is provided with an arc-shaped reinforced cell wall. Multiple cells are connected to each other at the vertices to form a reinforced region at the endpoints inside the multi-cell honeycomb structure. The thickness of the regular hexagonal matrix wall of each thin-walled cell remains unchanged from front to back, while the arc-shaped reinforced cell wall gradually increases.

[0009] The rear coplanar vertex-reinforced multicell honeycomb consists of multiple thin-walled cells with hexagonal cross-sections distributed laterally along the threshold beam. These thin-walled cells form a coplanar multicell honeycomb structure by overlapping boundaries. The inner cross-section of the hexagon is circular, thus forming arc-shaped reinforced cell walls at each vertex of the hexagon. The multiple thin-walled cells are interconnected at the vertices, thus forming reinforced regions at the inner endpoints of the multicell honeycomb structure. The radius of the inner circle gradually increases from the middle to both sides.

[0010] The front-end non-planar vertex reinforced multicell and the back-end coplanar vertex reinforced multicell are connected by a connecting plate.

[0011] Furthermore, the C-shaped sheet is made of stamped metal material, and the C-shaped sheet is connected by spot welding on both sides and forms a cavity in the middle of the C-shape.

[0012] Furthermore, the front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell are made of CBS plastic or nylon.

[0013] Furthermore, the length ratio along the sill beam of the front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell is 1:2.

[0014] Furthermore, the front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell are connected to the connecting plate by adhesive.

[0015] Furthermore, in the front-end skew-vertex reinforced multicell cell, the radius r of the arc-shaped reinforced cell wall gradually transitions from L1 to L2 in the axially tandem reinforced cell from front to back. Where L1 is the inner side length of the axially tandem reinforced cell, and the matrix thickness t1 of the axially tandem reinforced cell remains unchanged.

[0016] Furthermore, the external shape of the cross-section of the rear coplanar vertex-reinforced multicell honeycomb transverse parallel-reinforced cell is a regular hexagon, and the internal shape is circular. All cell cross-sections have the same external dimensions, and the radius of the inner circle gradually increases from the center to the sides. The radius of the inner circle of the cell increases from the center... Gradually transitioning to the outermost edge Where L2 is the transversely parallel reinforced cell and t2 is the transversely parallel reinforced cell wall thickness.

[0017] Compared with the prior art, the significant advantages of this invention are:

[0018] In the case of a small overlap frontal offset collision, the front-end eccentric vertex reinforced multi-cell honeycomb structure of this invention absorbs energy through cell wall buckling and in-plane deformation, while simultaneously providing internal support and reinforcement to the wrinkled sill beam, thus improving the safety of the vehicle in small offset collisions. In the case of a side impact, the rear-end coplanar vertex reinforced multi-cell honeycomb structure enhances the overall strength of the sill beam through its overall coplanar load-bearing capacity, preventing local bending deformation and dispersing the impact force through overall deformation. This better achieves load transfer and energy absorption, improving the safety of the vehicle in side impacts. Traditional thin-walled structures, when subjected to impact, mainly exhibit folding failure deformation concentrated at the cell wall connection points.

[0019] This invention designs arc-shaped reinforced cell walls at each vertex of thin-walled cells, thereby forming reinforced regions at the internal endpoints of multi-cell honeycomb structures. This helps to form an ideal energy-absorbing axisymmetric progressive buckling deformation mode. At the same time, by changing the thickness of the arc-shaped cell walls of thin-walled cells, the honeycomb structure can be reinforced through axial series, lateral parallel, and three-dimensional hybrid reinforcement designs. This allows for the guided design of impact resistance without changing the macroscopic dimensions of the honeycomb structure, resulting in filled reinforced structures with different energy absorption characteristics.

[0020] The multi-cell structure of this invention can be injection molded using CBS plastic or nylon, resulting in a high level of lightweight structure. It can be filled into the internal cavity of the door sill beam by means of adhesive bonding, and the manufacturing and assembly process is simple. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the combined multi-cell structure filled threshold beam assembly of the present invention; wherein (a) is a three-dimensional schematic diagram and (b) is an exploded view.

[0022] Figure 2This is a schematic diagram of the combined multi-cell filling structure of the present invention.

[0023] Figure 3 This is a schematic diagram of the front-end eccentric vertex-enhanced multicellular honeycomb structure of the present invention.

[0024] Figure 4 This is a schematic diagram of the coplanar vertex-reinforced multicell honeycomb structure at the rear end of the present invention.

[0025] Figure 5 This is a schematic diagram of the axially tandem reinforced cell (taking a regular hexagonal cross section as an example) of the present invention; wherein (a) is a three-dimensional schematic diagram, (b) is a front view, and (c) is a rear view.

[0026] Figure 6 This is a schematic cross-sectional view of the axially tandem reinforced cell structure of the present invention.

[0027] Figure 7 This is a schematic diagram of the transversely parallel reinforced honeycomb structure of the present invention.

[0028] Figure 8 This is a schematic diagram of the cross-section of the transversely parallel reinforced honeycomb structure of the present invention. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings.

[0030] The outer and inner plates of the threshold beam of this invention are both C-shaped thin plate structures formed by stamping metal materials, and the two ends of the thin plate cross-section have bent welded edges. Figure 1 As shown, the cavity is formed by spot welding at the welding edge.

[0031] The composite multi-cell structure filling structure consists of a front-end skew-vertex reinforced multi-cell honeycomb, a rear-end coplanar-vertex reinforced multi-cell honeycomb, and a connecting plate. Figure 2 (As shown).

[0032] The front-end skew-vertex reinforced multicellular cell comprises multiple thin-walled cell structures with a regular hexagonal shape distributed along the axial direction of the threshold beam. Figure 3 As shown, multiple thin-walled cells form an irregular multi-cell honeycomb structure through overlapping boundaries. Each vertex of the regular hexagon has an arc-shaped reinforcing cell wall with increased thickness. Multiple thin-walled cells connect at the vertices, forming a reinforced region at the endpoints within the multi-cell honeycomb structure. In a small overlap frontal offset collision, the front-end irregular vertex-reinforced multi-cell honeycomb exhibits a progressive crumpling deformation mode from the impact end to the rear end. It absorbs energy through cell wall buckling and in-plane deformation, while simultaneously providing internal support and reinforcement to the wrinkled sill beam, thus improving the vehicle's small overlap collision safety.

[0033] The rear coplanar vertex-reinforced multicellular cell consists of multiple thin-walled cell structures with regular hexagonal shapes distributed laterally along the threshold beam. Figure 4 As shown, multiple thin-walled cells form a coplanar multi-cell honeycomb structure through overlapping boundaries. Each vertex of the regular hexagon has an arc-shaped reinforcing cell wall with increased thickness. Multiple thin-walled cells connect at the vertices, forming reinforced regions at the endpoints within the multi-cell honeycomb structure. When a vehicle experiences a side impact, the rear-end coplanar vertex-reinforced multi-cell honeycomb structure enhances the overall strength of the sill beam through its overall coplanar load-bearing capacity, preventing localized bending deformation of the sill beam. The overall deformation disperses the impact force, better achieving load transfer and energy absorption. The multi-cell structure itself stably absorbs energy through layer-by-layer collapse, thus improving the overall side-impact safety of the vehicle.

[0034] Vertex reinforcement design can significantly improve the load-bearing capacity of thin-walled cell structures at joints, and helps multi-cell structures form a progressive buckling deformation and collapse mode, thereby improving the impact energy absorption characteristics of multi-cell infill sill beams. The honeycomb structure formed by combining front-end non-planar vertex-reinforced multi-cell honeycombs with rear-end coplanar vertex-reinforced multi-cell honeycombs can simultaneously improve the axial and lateral impact resistance of sill beams.

[0035] Regular hexagonal axially tandem reinforced cell ( Figure 5-6 The cell shown has an inner side length of L1, a wall thickness of t1 on its six sides, and an arc-shaped cell wall radius of r1. The thickness of the arc-shaped reinforced cell wall at the vertices of the thin-walled cell can be designed by changing the arc radius. The arc-shaped cell wall radius r1 has a certain range; according to the properties of a regular hexagon, r... 1min The distance from the center point to the center of any side is... r max Let r be the distance from the center point of the regular hexagon to its vertex. 1max =L1, therefore the range of r1 is When the radius of the arc r1 is small, the reinforced wall thickness at the cell vertex is large; conversely, when the radius of the arc r1 is large, the reinforced wall thickness at the cell vertex is small. The reinforced wall thickness at the cell vertex gradually decreases as the radius of the arc increases.

[0036] By varying the thickness of the arc-shaped cell wall in thin-walled cells, a gradient design is achieved to obtain better impact energy absorption properties. Specifically, the thickness of the arc-shaped cell wall in the thin-walled cells varies continuously along the axial direction, i.e., the value of the arc-shaped cell wall radius r1... Uniform variation, thereby forming axially tandem reinforced cells ( Figure 6 As shown in the figure, multiple thin-walled cells form an axially tandem reinforced honeycomb through overlapping boundaries.

[0037] The thickness of the thin-walled cells can vary in a gradient along one or more directions on the transverse surface of the honeycomb structure in a modular form, thereby forming a transversely parallel reinforced honeycomb. Figure 7-8 As shown), Figure 7 In the transversely parallel-strengthened thin-walled cells, the thickness of the arc-shaped thin walls decreases from the center to the sides, while the radius r2 of the arc-shaped cell walls increases from the center to the sides, ultimately forming a symmetrical honeycomb structure. This facilitates the formation of an ideal energy-absorbing axisymmetric progressive buckling deformation mode. In the rear-end coplanar vertex-strengthened multi-cell honeycomb transversely parallel-strengthened cells, the external shape of the cross-section is a regular hexagon, and the internal shape is circular. All cell cross-sections have the same external dimensions, and the radius of the inner circle gradually increases from the center to the sides. Furthermore, the radius of the inner circle of the cell increases from the center... Gradually transitioning to the outermost edge Where L2 is the outer side length of the transversely parallel reinforced cell, and t2 is the wall thickness of the transversely parallel reinforced cell.

[0038] In transverse parallel honeycomb structures, the thickness of the arc-shaped thin wall of the cell can also vary along the axial direction, thus forming a three-dimensional hybrid reinforced honeycomb. By changing the thickness of the reinforcing thin wall at the apex of the thin-walled cell and using different periodic expansion forms for series, parallel, and hybrid honeycomb reinforcement design, it is possible to achieve the guiding design of collision force and energy absorption curve without changing the structural mass and macroscopic dimensions, thereby obtaining filled structures with different energy absorption characteristics.

Claims

1. A composite multi-cell structure infilled sill beam assembly, characterized in that, It includes two C-shaped thin plates and a combined multi-cell filling structure filled in the cavity formed by the two C-shaped thin plates; The combined multi-cell structure filling structure consists of a front-end skew-vertex reinforced multi-cell honeycomb, a rear-end coplanar vertex reinforced multi-cell honeycomb, and a connecting plate. The front-end non-faceted vertex reinforced multi-cell honeycomb includes multiple axially connected reinforced cells with a regular hexagonal cross-section distributed along the axial direction of the threshold beam. Multiple identical cells form a non-faceted multi-cell honeycomb structure through overlapping boundaries. Each vertex of the regular hexagon is provided with an arc-shaped reinforced cell wall. Multiple cells are connected to each other at the vertices to form a reinforced region at the endpoints inside the multi-cell honeycomb structure. The thickness of the regular hexagonal matrix wall of each thin-walled cell remains unchanged from front to back, while the arc-shaped reinforced cell wall gradually increases. The rear coplanar vertex-reinforced multicell honeycomb consists of multiple thin-walled cells with hexagonal cross-sections distributed laterally along the threshold beam. These thin-walled cells form a coplanar multicell honeycomb structure by overlapping boundaries. The inner cross-section of the hexagon is circular, thus forming arc-shaped reinforced cell walls at each vertex of the hexagon. The multiple thin-walled cells are interconnected at the vertices, thus forming reinforced regions at the inner endpoints of the multicell honeycomb structure. The radius of the inner circle gradually increases from the middle to both sides. The front-end non-planar vertex reinforced multicell and the back-end coplanar vertex reinforced multicell are connected by a connecting plate.

2. The combined multi-cell structure infill sill beam assembly according to claim 1, characterized in that, The C-shaped sheet is made of stamped metal material. The C-shaped sheet is connected by spot welding on both sides and forms a cavity in the middle of the C-shape.

3. The combined multi-cell structure infill sill beam assembly according to claim 1, characterized in that, The front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell are made of CBS plastic or nylon.

4. The combined multi-cell structure infilled sill beam assembly according to claim 1, characterized in that, The length ratio of the front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell along the sill beam axis is 1:

2.

5. The combined multi-cell structure infilled sill beam assembly according to claim 1, characterized in that, The front-end non-planar vertex reinforced multicell and the rear-end coplanar vertex reinforced multicell are connected to the connecting plate by adhesive.

6. The combined multi-cell structure infilled sill beam assembly according to claim 1, characterized in that, In the front-end skew-vertex reinforced multicell cell, the axially tandem reinforced cell wall radius r of the arc-shaped reinforced cell gradually transitions from L1 to L2 from front to back. Where L1 is the inner side length of the axially tandem reinforced cell, and the matrix thickness t1 of the axially tandem reinforced cell remains unchanged.

7. The combined multi-cell structure infill sill beam assembly according to claim 1, characterized in that, The rear-end coplanar vertex-reinforced multi-cell honeycomb, with lateral parallel reinforcement, features a hexagonal external shape and a circular internal shape for each cell section. All cell sections have the same external dimensions, while the radius of the inner circle gradually increases from the center to the sides. Furthermore, the radius of the inner circle within each cell decreases from the center... Gradually transitioning to the outermost edge Where L2 is the transversely parallel reinforced cell and t2 is the transversely parallel reinforced cell wall thickness.

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