Six-cavity rolling threshold beam profile structure

Abstract

The utility model provides a six-cavity rolling doorsill beam section bar structure which comprises a section bar body, the section bar body is integrally formed through a steel belt rolling forming technology, the strength of the steel belt is not lower than 500 MPa, the section bar is divided into six cavities, the upper half portion of the section bar is sequentially provided with a second cavity 2, a sixth cavity 6 and a fourth cavity 4 from left to right, and the second cavity 2, the sixth cavity 6 and the fourth cavity 4 are arranged in the middle of the section bar body. And the lower half part of the sectional material is sequentially provided with a third cavity 3, a first cavity 1 and a fifth cavity 5 from left to right. When in use, the steel belt with the strength of more than or equal to 500MPa is rolled and integrally formed, so that the types of materials and the purchase cost are reduced, the working procedures of tailor welding, laser hole cutting and the like are omitted, the investment of personnel and equipment and the energy consumption are reduced, the production efficiency is improved, and the process is lower in carbon.

Description

Technical Field

[0001] This utility model belongs to the field of automotive parts technology, specifically, it relates to a six-cavity roll-formed profile structure for reinforcing automotive door sills. Background Technology

[0002] In the automotive body structure design system, the door sill beam, as a core safety barrier, not only plays a crucial role in the conduction and dispersion of collision energy, but is also a core component for the safety protection of new energy vehicle batteries. When a vehicle suffers a side collision, the door sill beam must effectively withstand external impact forces to prevent catastrophic consequences such as short circuits, fires, or even explosions caused by compression deformation of the chassis battery pack. Simultaneously, its precise connection to the vehicle body frame plays a decisive role in improving the vehicle's torsional rigidity and rollover resistance.

[0003] Current mainstream automotive door sill anti-collision beam technologies have revealed significant technical bottlenecks and cost disadvantages in practical applications, as detailed below:

[0004] I. Technical Limitations of Aluminum Extruded Door Sill Anti-collision Beams

[0005] This technology uses aluminum extrusion profiles as the core manufacturing process, but it is constrained by both material properties and processing technology, resulting in multiple technical shortcomings:

[0006] The contradiction between material strength and cost: The tensile strength of conventional aluminum profiles is only about 260 MPa, which is insufficient to meet stringent collision safety standards. To improve structural strength, the design needs to be strengthened by increasing the number of profile layers and thickening the wall panels. This not only significantly increases the structural complexity and causes the weight of components to exceed the limit, but also, the high cost of aluminum ingots, which is about 20,000 yuan / ton, further exacerbates the manufacturing cost pressure.

[0007] Low processing efficiency: During hot extrusion molding, the complex profile structure design limits the extrusion speed, making it difficult to improve production efficiency. Simultaneously, under high temperature and pressure conditions, the molds are prone to wear, deformation, and other failures. To maintain continuous production, at least three sets of molds need to be used alternately. Although the purchase cost of a single mold set is low, the maintenance and debugging costs resulting from frequent replacements significantly increase the overall cost of mold use throughout its lifecycle.

[0008] High subsequent processing costs: To achieve precise assembly with the vehicle body, the aluminum extruded door sill beams require numerous mounting holes, positioning holes, and other structural features to be machined using CNC equipment. The complex machining processes not only extend the production cycle but also significantly increase equipment depreciation, energy consumption, and labor costs.

[0009] II. Technical Bottlenecks of Steel Welded Composite Threshold Anti-collision Beams

[0010] This solution manufactures rectangular, hat-shaped, and C-shaped modular components using sheet metal stamping, and then assembles them into a multi-cavity composite structure via laser welding. Its main technical limitations are:

[0011] The complex process chain leads to efficiency and precision issues: the need for collaborative processing of multiple materials necessitates multiple steps in the production process, including stamping, laser welding, and shaping, resulting in a lengthy production cycle. Thermal deformation during welding is difficult to control effectively, causing dimensional deviations in finished products to exceed tolerance limits, making quality consistency control extremely challenging.

[0012] High equipment and labor costs: The high fixed asset investment in stamping and welding equipment, coupled with problems such as high manual labor participation and low production efficiency, results in high unit processing costs, making it difficult to meet the cost control requirements of large-scale production in the automotive industry.

[0013] In summary, the aluminum extrusion method is trapped in a vicious cycle of "insufficient strength → structural reinforcement → cost increase," while the steel welding method faces the technical dilemma of "complex processes → low efficiency → loss of precision control." Furthermore, the electrochemical corrosion risk caused by the metal potential difference when connecting aluminum extruded profiles to the steel body further shortens the vehicle's service life. Therefore, there is an urgent need for a door sill beam profile structure and processing technology that balances high strength, low cost, and high forming precision. Utility Model Content

[0014] In view of the deficiencies in the existing technology, the purpose of this utility model is to provide a six-cavity roll-formed door sill beam profile structure.

[0015] According to the present invention, a six-cavity roll-formed door sill beam profile structure is provided, comprising a profile, wherein the profile is integrally formed by a steel strip roll forming process, and the steel strip has a strength of not less than 500MPa. The profile is divided into six cavities, the upper half of the profile being the second cavity, the sixth cavity and the fourth cavity from left to right, and the lower half of the profile being the third cavity, the first cavity and the fifth cavity from left to right.

[0016] The steel strip is divided into a left section, a middle section, and a right section. The left section, after being rolled, is further divided into a first connecting plate segment, a first arc-shaped structure, a second connecting plate segment, a second arc-shaped structure, a third connecting plate segment, a third arc-shaped structure, a fourth connecting plate segment, a fourth arc-shaped structure, a fifth connecting plate segment, and a fifth arc-shaped structure. The left section of the steel strip is rolled to form a P-shaped structure. The middle section of the steel strip, after being rolled, is further divided into a sixth connecting plate segment, a sixth arc-shaped structure, a seventh connecting plate segment, a seventh arc-shaped structure, an eighth connecting plate segment, an eighth arc-shaped structure, a ninth connecting plate segment, a ninth arc-shaped structure, and a tenth connecting plate segment. The middle section of the steel strip is rolled to form... The steel strip has a U-shaped structure. After being rolled, the right section is divided into the tenth arc-shaped structure, the eleventh connecting plate section, the eleventh arc-shaped structure, the twelfth connecting plate section, the twelfth arc-shaped structure, the thirteenth connecting plate section, the thirteenth arc-shaped structure, the fourteenth connecting plate section, the fourteenth arc-shaped structure, the fifteenth connecting plate section, the fifteenth arc-shaped structure, and the sixteenth connecting plate section. The right section of the steel strip is rolled to form a Z-shaped structure. The joints between the connecting walls of each cavity are connected by laser welding. The left and right sections of the steel strip are rolled and welded to form a profile with a supporting structure distributed in the middle. The supporting structure is used to separate the various cavities.

[0017] In a preferred embodiment: the first cavity is a rectangular closed structure formed by the left half of the second connecting plate segment, the third connecting plate segment, the fourth connecting plate segment, and the fifth connecting plate segment. The second connecting plate segment serves as the left wall of the first cavity and is connected to the third connecting plate segment via a second arc-shaped structure. The third connecting plate segment serves as the bottom wall of the first cavity and is connected to the fourth connecting plate segment via a third arc-shaped structure. The fourth connecting plate segment serves as the right wall of the first cavity and is connected to the fifth connecting plate segment via a fourth arc-shaped structure. The left half of the fifth connecting plate segment serves as the top wall of the first cavity. The second connecting plate segment is connected to the first connecting plate segment via a first arc-shaped structure. The first connecting plate segment extends into the third cavity and is laser-welded to the right half of the fifth connecting plate segment.

[0018] In a preferred embodiment: the second cavity is a rectangular closed structure formed by the right section of the ninth connecting plate segment, the tenth connecting plate segment, the eleventh connecting plate segment, and the twelfth connecting plate segment. The right section of the ninth connecting plate segment serves as the top wall of the second cavity. The ninth connecting plate segment is connected to the tenth connecting plate segment through a ninth arc-shaped structure. The tenth connecting plate segment serves as the left wall of the second cavity. The tenth connecting plate segment is connected to the eleventh connecting plate segment through a tenth arc-shaped structure. The eleventh connecting plate segment serves as the bottom wall of the second cavity. The eleventh connecting plate segment is laser-welded to the fifth connecting plate segment. The eleventh connecting plate segment is connected to the twelfth connecting plate segment through an eleventh arc-shaped structure. The twelfth connecting plate segment serves as the right wall of the second cavity. The twelfth connecting plate segment is connected to the thirteenth connecting plate segment through a twelfth arc-shaped structure. The thirteenth connecting plate segment is laser-welded to the ninth connecting plate segment.

[0019] In a preferred embodiment: the third cavity is a rectangular closed structure formed by the second connecting plate segment, the right half of the fifth connecting plate segment, the sixth connecting plate segment, and the left segment of the seventh connecting plate segment. The second connecting plate segment serves as the right wall of the third cavity, the left half of the fifth connecting plate segment serves as the top wall of the third cavity, the fifth connecting plate segment is connected to the sixth connecting plate segment through a fifth arc-shaped structure, the sixth connecting plate segment serves as the left wall of the third cavity, the sixth connecting plate segment is connected to the seventh connecting plate segment through a sixth arc-shaped structure, the left segment of the seventh connecting plate segment serves as the bottom wall of the third cavity, and the middle segment of the seventh connecting plate segment is laser welded to the third connecting plate segment.

[0020] In a preferred embodiment: the fourth cavity is a rectangular closed structure formed by an eighth connecting plate segment, a ninth connecting plate segment, a fourteenth connecting plate segment, and a fifteenth connecting plate segment. The right half of the eighth connecting plate segment serves as the right wall of the fourth cavity. The eighth connecting plate segment is connected to the ninth connecting plate segment via an eighth arc-shaped structure. The left half of the ninth connecting plate segment serves as the top wall of the fourth cavity. The thirteenth connecting plate segment is connected to the fourteenth connecting plate segment via a thirteenth arc-shaped structure. The fourteenth connecting plate segment serves as the left wall of the fourth cavity. The fourteenth connecting plate segment is connected to the fifteenth connecting plate segment via a fourteenth arc-shaped structure. The fifteenth connecting plate segment serves as the bottom wall of the fourth cavity. The bottom left side of the fifteenth connecting plate segment is laser-welded to the top right side of the fifth connecting plate segment. The fifteenth connecting plate segment is connected to the sixteenth connecting plate segment via a fifteenth arc-shaped structure. The sixteenth connecting plate segment extends into the fifth cavity and is laser-welded to the eighth connecting plate segment.

[0021] In a preferred embodiment: the fifth cavity is a rectangular closed structure formed by the fourth connecting plate segment, the right segment of the seventh connecting plate segment, the left half of the eighth connecting plate segment, and the fifteenth connecting plate segment. The fourth connecting plate segment serves as the left wall of the fifth cavity, the right segment of the seventh connecting plate segment serves as the bottom wall of the fifth cavity, the fourth connecting plate segment serves as the left wall of the fifth cavity, the seventh connecting plate segment is fixedly connected to the eighth connecting plate segment through a seventh arc-shaped structure, the left half of the eighth connecting plate segment serves as the right wall of the fifth cavity, and the fifteenth connecting plate segment serves as the top wall of the fifth cavity.

[0022] In a preferred embodiment: the sixth cavity is a rectangular closed structure formed by the fifth connecting plate segment, the twelfth connecting plate segment, the thirteenth connecting plate segment and the fourteenth connecting plate segment. The fifth connecting plate segment serves as the bottom wall of the sixth cavity, the twelfth connecting plate segment serves as the left wall of the sixth cavity, the thirteenth connecting plate segment serves as the top wall of the sixth cavity, and the fourteenth connecting plate segment serves as the right wall of the sixth cavity.

[0023] In a preferred embodiment: the fifth connecting plate segment is divided into a first segment, a second segment, and a sixteenth arc-shaped structure after being rolled. The first segment is laser-welded to the eleventh connecting plate segment. The first segment is connected to the second segment through the sixteenth arc-shaped structure, making the fifth connecting plate segment Z-shaped. The first cavity is a rectangular closed structure composed of the second, third, fourth, and second segments of the fifth connecting plate segment. The second connecting plate segment serves as the top wall of the first cavity. The right side of the second connecting plate segment is laser-welded to the left side of the fifteenth connecting plate segment. The third connecting plate segment serves as the right wall of the first cavity. The fourth connecting plate segment serves as the bottom wall of the first cavity. The fourth connecting plate segment is laser-welded to the seventh connecting plate segment. The second segment of the fifth connecting plate segment serves as the left wall of the first cavity. The first connecting plate segment extends into the first cavity and is laser-welded to the second segment of the fifth connecting plate segment.

[0024] In a preferred embodiment: the first segment of the fifth connecting plate is divided into a long segment, a short segment, and a seventeenth arc-shaped structure after being rolled and bent. The long segment of the fifth connecting plate is connected to the short segment of the fifth connecting plate through the seventeenth arc-shaped structure. The long segment of the fifth connecting plate is laser-welded to the eleventh connecting plate segment. The short segment of the fifth connecting plate and the eleventh connecting plate segment are spaced apart, thereby causing the first segment of the fifth connecting plate to sink and bend to form a step shape. The first connecting plate segment is straight and connected to the second connecting plate segment. The first connecting plate segment extends into the gap between the short segment of the fifth connecting plate and the eleventh connecting plate segment and is laser-welded.

[0025] In a preferred embodiment: the ninth connecting plate segment is divided into a right segment, an eighteenth arc-shaped structure, a middle segment, a nineteenth arc-shaped structure, and a left segment after being rolled and bent twice. The right segment of the ninth connecting plate is connected to the middle segment of the ninth connecting plate through the eighteenth arc-shaped structure. The middle segment of the ninth connecting plate is laser-welded to the thirteenth connecting plate segment. The middle segment of the ninth connecting plate is connected to the left segment of the ninth connecting plate through the nineteenth arc-shaped structure. The left segment of the ninth connecting plate is connected to the tenth connecting plate segment through the ninth arc-shaped structure. The right segment of the ninth connecting plate is laser-welded to the sixteenth connecting plate segment. The second cavity is formed by the tenth, eleventh, twelfth, and left segments of the ninth connecting plate to form a trapezoidal closed structure. The fourth cavity is formed by the fourteenth, fifteenth, and right segments of the ninth connecting plate to form a triangular closed structure. The fifth cavity is formed by the upper right corner of the original rectangular closed structure being cut off to form a pentagonal closed structure, so that the second, fourth, and fifth cavities are adapted to the automotive assembly contour.

[0026] Compared with the prior art, the present invention has the following beneficial effects.

[0027] 1. When using this utility model, steel strips with a strength of not less than 500MPa are rolled and integrally formed, which reduces the types of materials and procurement costs, eliminates processes such as welding and laser cutting, reduces personnel and equipment investment and energy consumption, improves production efficiency and makes the process more carbon-efficient.

[0028] 2. When this utility model is used, the six-cavity "honeycomb" structure disperses the collision load through the coordinated deformation of multiple cavities, the supporting structure guides energy conduction to protect the battery pack, the connection does not require punching, the forming precision is high, the overall strength and rigidity are excellent, and the anti-collision performance is significantly improved. Attached Figure Description

[0029] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0030] Figure 1 This is a schematic diagram of the structure of this utility model;

[0031] Figure 2 This is a cross-sectional view of Embodiment 1 of the present invention;

[0032] Figure 3 This is a schematic diagram of the structure of Embodiment 2 of this utility model;

[0033] Figure 4 This is a schematic diagram of the structure of Embodiment 3 of this utility model;

[0034] Figure 5 This is a structural schematic diagram of Embodiment 4 of the present invention;

[0035] In the picture:

[0036]

[0037] Detailed Implementation

[0038] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0039] Example 1

[0040] like Figure 1-2As shown, this embodiment discloses a six-cavity roll-formed door sill beam profile structure, including a profile body. The profile is integrally formed by a steel strip roll forming process, and the steel strip strength is not less than 500MPa. The profile is divided into six cavities. The upper half of the profile is, from left to right, the second cavity 2, the sixth cavity 6, and the fourth cavity 4. The lower half of the profile is, from left to right, the third cavity 3, the first cavity 1, and the fifth cavity 5.

[0041] The steel strip is divided into a left section, a middle section, and a right section. The left section, after being rolled, is further divided into the first connecting plate section 7, the first arc-shaped structure 23, the second connecting plate section 8, the second arc-shaped structure 24, the third connecting plate section 9, the third arc-shaped structure 25, the fourth connecting plate section 10, the fourth arc-shaped structure 26, the fifth connecting plate section 11, and the fifth arc-shaped structure 27. The left section of the steel strip is rolled to form a P-shaped structure. The middle section of the steel strip, after being rolled, is further divided into the sixth connecting plate section 12, the sixth arc-shaped structure 28, the seventh connecting plate section 13, the seventh arc-shaped structure 29, the eighth connecting plate section 14, the eighth arc-shaped structure 30, the ninth connecting plate section 15, the ninth arc-shaped structure 31, and the tenth connecting plate section 16. The middle section of the steel strip is rolled to form a square shape. The right section of the steel strip, after being rolled, is divided into the tenth arc-shaped structure 32, the eleventh connecting plate section 17, the eleventh arc-shaped structure 33, the twelfth connecting plate section 18, the twelfth arc-shaped structure 34, the thirteenth connecting plate section 19, the thirteenth arc-shaped structure 35, the fourteenth connecting plate section 20, the fourteenth arc-shaped structure 36, the fifteenth connecting plate section 21, the fifteenth arc-shaped structure 37, and the sixteenth connecting plate section 22. The right section of the steel strip is rolled to form a Z-shaped structure. The joints between the connecting walls of each cavity are all connected by laser welding. The left and right sections of the steel strip are rolled and welded to form a support structure distributed in the middle of the profile. The support structure is used to separate the various cavities and to ensure the pressure-bearing capacity of the profile.

[0042] The first cavity 1 is a rectangular closed structure formed by the left half of the second connecting plate segment 8, the third connecting plate segment 9, the fourth connecting plate segment 10, and the fifth connecting plate segment 11. The second connecting plate segment 8 serves as the left wall of the first cavity 1. The second connecting plate segment 8 is connected to the third connecting plate segment 9 through the second arc structure 24. The third connecting plate segment 9 serves as the bottom wall of the first cavity 1. The third connecting plate segment 9 is connected to the fourth connecting plate segment 10 through the third arc structure 25. The fourth connecting plate segment 10 serves as the right wall of the first cavity 1. The fourth connecting plate segment 10 is connected to the fifth connecting plate segment 11 through the fourth arc structure 26. The left half of the fifth connecting plate segment 11 serves as the top wall of the first cavity 1. The second connecting plate segment 8 is connected to the first connecting plate segment 7 through the first arc structure 23. The first connecting plate segment 7 extends into the third cavity 3 and is laser-welded to the right half of the fifth connecting plate segment 11.

[0043] The second cavity 2 is a rectangular closed structure formed by the right section of the ninth connecting plate segment 15, the tenth connecting plate segment 16, the eleventh connecting plate segment 17, and the twelfth connecting plate segment 18. The right section of the ninth connecting plate segment 15 serves as the top wall of the second cavity 2. The ninth connecting plate segment 15 is connected to the tenth connecting plate segment 16 through the ninth arc-shaped structure 31. The tenth connecting plate segment 16 serves as the left wall of the second cavity 2. The tenth connecting plate segment 16 is connected to the eleventh connecting plate segment 17 through the tenth arc-shaped structure 32. The eleventh connecting plate segment 17 serves as the bottom wall of the second cavity 2. The eleventh connecting plate segment 17 is laser-welded to the fifth connecting plate segment 11. The eleventh connecting plate segment 17 is connected to the twelfth connecting plate segment 18 through the eleventh arc-shaped structure 33. The twelfth connecting plate segment 18 serves as the right wall of the second cavity 2. The twelfth connecting plate segment 18 is connected to the thirteenth connecting plate segment 19 through the twelfth arc-shaped structure 34. The thirteenth connecting plate segment 19 is laser-welded to the ninth connecting plate segment 15.

[0044] The third cavity 3 is a rectangular closed structure consisting of the second connecting plate segment 8, the right half of the fifth connecting plate segment 11, the sixth connecting plate segment 12, and the left segment of the seventh connecting plate segment 13. The second connecting plate segment 8 serves as the right wall of the third cavity 3, the left half of the fifth connecting plate segment 11 serves as the top wall of the third cavity 3, the fifth connecting plate segment 11 is connected to the sixth connecting plate segment 12 through the fifth arc structure 27, the sixth connecting plate segment 12 serves as the left wall of the third cavity 3, the sixth connecting plate segment 12 is connected to the seventh connecting plate segment 13 through the sixth arc structure 28, the left segment of the seventh connecting plate segment 13 serves as the bottom wall of the third cavity 3, and the middle segment of the seventh connecting plate segment 13 is laser welded to the third connecting plate segment 9.

[0045] The fourth cavity 4 is a rectangular closed structure formed by the eighth connecting plate segment 14, the ninth connecting plate segment 15, the fourteenth connecting plate segment 20, and the fifteenth connecting plate segment 21. The right half of the eighth connecting plate segment 14 serves as the right wall of the fourth cavity 4. The eighth connecting plate segment 14 is connected to the ninth connecting plate segment 15 through the eighth arc-shaped structure 30. The left half of the ninth connecting plate segment 15 serves as the top wall of the fourth cavity 4. The thirteenth connecting plate segment 19 is connected to the fourteenth connecting plate segment 20 through the thirteenth arc-shaped structure 35. Plate segment 20 serves as the left wall of the fourth cavity 4. The fourteenth connecting plate segment 20 is connected to the fifteenth connecting plate segment 21 through the fourteenth arc structure 36. The fifteenth connecting plate segment 21 serves as the bottom wall of the fourth cavity 4. The bottom left side of the fifteenth connecting plate segment 21 is laser-welded to the top right side of the fifth connecting plate segment 11. The fifteenth connecting plate segment 21 is connected to the sixteenth connecting plate segment 22 through the fifteenth arc structure 37. The sixteenth connecting plate segment 22 extends into the fifth cavity 5 and is laser-welded to the eighth connecting plate segment 14.

[0046] The fifth cavity 5 is a rectangular closed structure composed of the fourth connecting plate segment 10, the right segment of the seventh connecting plate segment 13, the left half of the eighth connecting plate segment 14, and the fifteenth connecting plate segment 21. The fourth connecting plate segment 10 serves as the left wall of the fifth cavity 5, the right segment of the seventh connecting plate segment 13 serves as the bottom wall of the fifth cavity 5, the seventh connecting plate segment 13 is fixedly connected to the eighth connecting plate segment 14 through the seventh arc-shaped structure 29, the left half of the eighth connecting plate segment 14 serves as the right wall of the fifth cavity 5, and the fifteenth connecting plate segment 21 serves as the top wall of the fifth cavity 5.

[0047] The sixth cavity 6 is a rectangular closed structure composed of the fifth connecting plate segment 11, the twelfth connecting plate segment 18, the thirteenth connecting plate segment 19 and the fourteenth connecting plate segment 20. The fifth connecting plate segment 11 serves as the bottom wall of the sixth cavity 6, the twelfth connecting plate segment 18 serves as the left wall of the sixth cavity 6, the thirteenth connecting plate segment 19 serves as the top wall of the sixth cavity 6, and the fourteenth connecting plate segment 20 serves as the right wall of the sixth cavity 6.

[0048] Example 2

[0049] like Figure 3 As shown, the position of the forming cavity structure in this embodiment is the same as in embodiment 1. The main improvement is that when the left section of the steel strip is formed into the first cavity 1 by roll forming, the left section of the steel strip that is bent by five roll forming replaces the left section of the steel strip that is bent by four roll forming. The fifth connecting plate section 11 is further bent at a right angle. After roll forming, the fifth connecting plate section 11 is divided into the first section 111 of the fifth connecting plate, the second section 112 of the fifth connecting plate, and the sixteenth arc structure 113. The first section 111 of the fifth connecting plate is laser welded to the eleventh connecting plate section 17. The first section 111 of the fifth connecting plate is connected to the second section 112 of the fifth connecting plate through the sixteenth arc structure 113, so that the fifth connecting plate section 11 is in a Z-shaped right angle.

[0050] The first cavity 1 is a rectangular closed structure composed of the second connecting plate segment 8, the third connecting plate segment 9, the fourth connecting plate segment 10, and the fifth connecting plate second segment 112. The second connecting plate segment 8 serves as the top wall of the first cavity 1. The right side of the second connecting plate segment 8 is laser-welded to the left side of the fifteenth connecting plate segment 21. The third connecting plate segment 9 serves as the right wall of the first cavity 1. The fourth connecting plate segment 10 serves as the bottom wall of the first cavity 1. The fourth connecting plate segment 10 is laser-welded to the seventh connecting plate segment 13. The fifth connecting plate second segment 112 serves as the left wall of the first cavity 1. The first connecting plate segment 7 extends into the first cavity 1 and is laser-welded to the fifth connecting plate second segment 112.

[0051] By adding a bend, the top connecting wall can be bent, increasing the strength of the outer wall support structure. This allows for a more even distribution of the load on the profile, improving the compression resistance of the top of the cavity and making it less prone to deformation under impact loads. The first connecting plate segment 7 extends into the first cavity 1, enhancing the integrity of the support structure and the cavity, reducing local stress concentration, and improving the torsional stiffness of the profile.

[0052] Example 3

[0053] like Figure 4 As shown, the position of the forming cavity structure in this embodiment is the same as in embodiment 1. The main improvement is that when the left section of the steel strip is formed into the first cavity 1 by roll forming, the left section of the steel strip bent by five roll formings replaces the left section of the steel strip bent by four roll formings. The first section 111 of the fifth connecting plate is divided into a long section 1111, a short section 1113, and a seventeenth arc-shaped structure 1112. The long section 1111 of the fifth connecting plate is connected to the short section 1113 of the fifth connecting plate through the seventeenth arc-shaped structure 1112. The long section 1111 of the fifth connecting plate is laser welded to the eleventh connecting plate section 17. The short section 1111 of the fifth connecting plate is... The 113 and the eleventh connecting plate segment 17 are spaced apart, so that the first segment 111 of the fifth connecting plate sinks and bends to form a step shape; the first connecting plate segment 7 and the second connecting plate segment 8 are connected in a straight line, and the first connecting plate segment 7 extends into the gap between the short segment 1113 of the fifth connecting plate and the eleventh connecting plate segment 17 and is laser welded; by keeping the left end of the steel strip in a straight state, the complex positioning of the end extending into the cavity is avoided. When the car suffers an oblique collision, the left end can directly bear the lateral load, and the force is transmitted to the second cavity 2 through the top of the sinking third cavity 3, reducing the lateral deformation of the first cavity 1.

[0054] Example 4

[0055] like Figure 5 As shown, the molding cavity structure in this embodiment is the same as in embodiment 1. The main improvement is that after the ninth connecting plate segment 15 is bent twice by roller pressing, it is divided into the right segment 151, the eighteenth arc structure 152, the middle segment 153, the nineteenth arc structure 154, and the left segment 155. The right segment 151 is connected to the middle segment 153 through the eighteenth arc structure 152. The middle segment 153 is laser-welded to the thirteenth connecting plate segment 19. The middle segment 153 is connected to the left segment 155 through the nineteenth arc structure 154. The left segment 155 is connected to the tenth connecting plate segment 16 through the ninth arc structure 31. The right segment 151 is laser-welded to the sixteenth connecting plate segment 22.

[0056] The second cavity 2 is a trapezoidal closed structure formed by the tenth connecting plate segment 16, the eleventh connecting plate segment 17, the twelfth connecting plate segment 18, and the left segment 155 of the ninth connecting plate. The fourth cavity 4 is a triangular closed structure formed by the fourteenth connecting plate segment 20, the fifteenth connecting plate segment 21, and the right segment 151 of the ninth connecting plate. The fifth cavity 5 is a pentagonal closed structure formed by missing the upper right corner of the original rectangular closed structure. This allows the second cavity 2, the fourth cavity 4, and the fifth cavity 5 to fit the automotive assembly contour. By improving the matching degree between the non-rectangular cavity contour and the arc structure of the automotive door sill, the installation gap is reduced, thereby reducing secondary processing caused by contour mismatch and improving assembly efficiency.

[0057] Working principle

[0058] This utility model uses a single automotive steel with a strength of ≥500MPa, which is processed by roll forming technology. This process reduces the types of materials, shortens the procurement cycle and reduces costs, while meeting the strength requirements under collision scenarios. The production process only requires simple roll forming operation, without the need for subsequent steel structure welding and laser cutting processes, which significantly reduces personnel and equipment investment and does not increase production energy consumption.

[0059] The profiles are bent and rolled at multiple angles according to customer requirements to form six closed cavities of different shapes. A "honeycomb" support system is constructed by welding. The closed section of each cavity can independently resist extrusion deformation. When connected to the car body, there is no need to punch holes in the door sill beam. The connection is directly fixed by reducing the number of connections and using welding technology. This design eliminates offline welding process, reduces welding workload, and improves forming accuracy. The structural integrity ensures overall strength and rigidity and enhances anti-collision performance.

[0060] When a collision load is applied to the shell of the profile, the concentrated load will be dispersed into a multi-directional distributed force. Energy is absorbed through the coordinated deformation between the cavities, and the load is transferred layer by layer between the cavities to avoid damage to a single cavity due to excessive stress. In addition, after the sill beam is welded to the body, the supporting structure will distribute the remaining load to the body frame to prevent the battery pack from being directly squeezed and causing the risk of fire.

[0061] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They 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. Therefore, they should not be construed as limitations on this application.

[0062] The specific embodiments of this utility model have been described above. It should be understood that this utility model is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the substantive content of this utility model. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A six-cavity roll-formed threshold beam profile structure, characterized by, The profile is integrally formed by steel strip roll forming process, and the steel strip strength is not less than (500) MPa. The profile is divided into six cavities. The upper half of the profile is the second cavity (2), the sixth cavity (6) and the fourth cavity (4) from left to right. The lower half of the profile is the third cavity (3), the first cavity (1) and the fifth cavity (5) from left to right. The steel strip is divided into a left section, a middle section, and a right section. The left section of the steel strip is rolled into a first connecting plate section (7), a first arc structure (23), a second connecting plate section (8), a second arc structure (24), a third connecting plate section (9), a third arc structure (25), a fourth connecting plate section (10), a fourth arc structure (26), a fifth connecting plate section (11), and a fifth arc structure (27). The left section of the steel strip is rolled into a P-shaped structure. The middle section of the steel strip is rolled into a sixth connecting plate section (12), a sixth arc structure (28), a seventh connecting plate section (13), a seventh arc structure (29), an eighth connecting plate section (14), an eighth arc structure (30), a ninth connecting plate section (15), a ninth arc structure (31), and a tenth connecting plate section (10). 6) The middle section of the steel strip is rolled to form a square structure. The right section of the steel strip is rolled to form a tenth arc structure (32), an eleventh connecting plate section (17), an eleventh arc structure (33), a twelfth connecting plate section (18), a twelfth arc structure (34), a thirteenth connecting plate section (19), a thirteenth arc structure (35), a fourteenth connecting plate section (20), a fourteenth arc structure (36), a fifteenth connecting plate section (21), a fifteenth arc structure (37), and a sixteenth connecting plate section (22). The right section of the steel strip is rolled to form a zigzag structure. The joints between the connecting walls of each cavity are connected by laser welding. The left and right sections of the steel strip are rolled and welded to form a profile with a supporting structure distributed in the middle. The supporting structure is used to separate each cavity.

2. The six-cavity roll-formed threshold beam profile structure of claim 1, wherein, The first cavity (1) is formed by the left half of the second connecting plate segment (8), the third connecting plate segment (9), the fourth connecting plate segment (10), and the fifth connecting plate segment (11), forming a rectangular closed structure. The second connecting plate segment (8) serves as the left wall of the first cavity (1), and is connected to the third connecting plate segment (9) via the second arc-shaped structure (24). The third connecting plate segment (9) serves as the bottom wall of the first cavity (1), and is connected to the fourth connecting plate segment (11) via the third arc-shaped structure (25). The plate segments (10) are connected. The fourth connecting plate segment (10) serves as the right wall of the first cavity (1). The fourth connecting plate segment (10) is connected to the fifth connecting plate segment (11) through the fourth arc structure (26). The left half of the fifth connecting plate segment (11) serves as the top wall of the first cavity (1). The second connecting plate segment (8) is connected to the first connecting plate segment (7) through the first arc structure (23). The first connecting plate segment (7) extends into the third cavity (3) and is laser welded to the right half of the fifth connecting plate segment (11).

3. The six-cavity roll-formed threshold beam profile structure of claim 2, wherein, The second cavity (2) is a rectangular closed structure composed of the right section of the ninth connecting plate segment (15), the tenth connecting plate segment (16), the eleventh connecting plate segment (17), and the twelfth connecting plate segment (18). The right section of the ninth connecting plate segment (15) serves as the top wall of the second cavity (2). The ninth connecting plate segment (15) is connected to the tenth connecting plate segment (16) through the ninth arc-shaped structure (31). The tenth connecting plate segment (16) serves as the left wall of the second cavity (2). The tenth connecting plate segment (16) is connected to the eleventh connecting plate segment (17) through the tenth arc-shaped structure (32). The eleventh connecting plate segment (17) serves as the bottom wall of the second cavity (2). The eleventh connecting plate segment (17) is laser-welded to the fifth connecting plate segment (11). The eleventh connecting plate segment (17) is connected to the twelfth connecting plate segment (18) through the eleventh arc structure (33). The twelfth connecting plate segment (18) serves as the right wall of the second cavity (2). The twelfth connecting plate segment (18) is connected to the thirteenth connecting plate segment (19) through the twelfth arc structure (34). The thirteenth connecting plate segment (19) is laser-welded to the ninth connecting plate segment (15).

4. The six-cavity roll-formed threshold beam profile structure of claim 3, wherein, The third cavity (3) is a rectangular closed structure consisting of the second connecting plate segment (8), the right half of the fifth connecting plate segment (11), the sixth connecting plate segment (12), and the left segment of the seventh connecting plate segment (13). The second connecting plate segment (8) serves as the right wall of the third cavity (3), the left half of the fifth connecting plate segment (11) serves as the top wall of the third cavity (3), the fifth connecting plate segment (11) is connected to the sixth connecting plate segment (12) through the fifth arc structure (27), the sixth connecting plate segment (12) serves as the left wall of the third cavity (3), the sixth connecting plate segment (12) is connected to the seventh connecting plate segment (13) through the sixth arc structure (28), the left segment of the seventh connecting plate segment (13) serves as the bottom wall of the third cavity (3), and the middle segment of the seventh connecting plate segment (13) is laser welded to the third connecting plate segment (9).

5. The six-cavity roll-formed threshold beam profile structure of claim 4, wherein, The fourth cavity (4) is a rectangular closed structure composed of the eighth connecting plate segment (14), the ninth connecting plate segment (15), the fourteenth connecting plate segment (20), and the fifteenth connecting plate segment (21). The right half of the eighth connecting plate segment (14) serves as the right wall of the fourth cavity (4). The eighth connecting plate segment (14) is connected to the ninth connecting plate segment (15) through the eighth arc-shaped structure (30). The left half of the ninth connecting plate segment (15) serves as the top wall of the fourth cavity (4). The thirteenth connecting plate segment (19) is connected to the fourteenth connecting plate segment (20) through the thirteenth arc-shaped structure (35). The connecting plate segment (20) serves as the left wall of the fourth cavity (4). The fourteenth connecting plate segment (20) is connected to the fifteenth connecting plate segment (21) through the fourteenth arc structure (36). The fifteenth connecting plate segment (21) serves as the bottom wall of the fourth cavity (4). The bottom left side of the fifteenth connecting plate segment (21) is laser-welded to the top right side of the fifth connecting plate segment (11). The fifteenth connecting plate segment (21) is connected to the sixteenth connecting plate segment (22) through the fifteenth arc structure (37). The sixteenth connecting plate segment (22) extends into the fifth cavity (5) and is laser-welded to the eighth connecting plate segment (14).

6. The six-cavity roll-formed threshold beam profile structure of claim 5, wherein, The fifth cavity (5) is a rectangular closed structure consisting of the fourth connecting plate segment (10), the right segment of the seventh connecting plate segment (13), the left half of the eighth connecting plate segment (14), and the fifteenth connecting plate segment (21). The fourth connecting plate segment (10) serves as the left wall of the fifth cavity (5), the right segment of the seventh connecting plate segment (13) serves as the bottom wall of the fifth cavity (5), the fourth connecting plate segment (10) serves as the left wall of the fifth cavity (5), the seventh connecting plate segment (13) is fixedly connected to the eighth connecting plate segment (14) through the seventh arc structure (29), the left half of the eighth connecting plate segment (14) serves as the right wall of the fifth cavity (5), and the fifteenth connecting plate segment (21) serves as the top wall of the fifth cavity (5).

7. The six-cavity roll-formed threshold beam profile structure of claim 6, wherein, The sixth cavity (6) is a rectangular closed structure composed of the fifth connecting plate segment (11), the twelfth connecting plate segment (18), the thirteenth connecting plate segment (19) and the fourteenth connecting plate segment (20). The fifth connecting plate segment (11) serves as the bottom wall of the sixth cavity (6), the twelfth connecting plate segment (18) serves as the left wall of the sixth cavity (6), the thirteenth connecting plate segment (19) serves as the top wall of the sixth cavity (6), and the fourteenth connecting plate segment (20) serves as the right wall of the sixth cavity (6).

8. The six-cavity roll-formed threshold beam profile structure of claim 7, wherein, The fifth connecting plate segment (11) is divided into the first segment (111), the second segment (112), and the sixteenth arc structure (113) after being rolled. The first segment (111) is laser-welded to the eleventh connecting plate segment (17). The first segment (111) is connected to the second segment (112) through the sixteenth arc structure (113), making the fifth connecting plate segment (11) form a Z-shaped right angle. The first cavity (1) is composed of the second connecting plate segment (8), the third connecting plate segment (9), the fourth connecting plate segment (10), and the second segment (112). 112) Forms a rectangular closed structure. The second connecting plate segment (8) serves as the top wall of the first cavity (1). The right side of the second connecting plate segment (8) is laser-welded to the left side of the fifteenth connecting plate segment (21). The third connecting plate segment (9) serves as the right wall of the first cavity (1). The fourth connecting plate segment (10) serves as the bottom wall of the first cavity (1). The fourth connecting plate segment (10) is laser-welded to the seventh connecting plate segment (13). The second segment of the fifth connecting plate (112) serves as the left wall of the first cavity (1). The first connecting plate segment (7) extends into the first cavity (1) and is laser-welded to the second segment of the fifth connecting plate (112).

9. The six-cavity roll-formed threshold beam profile structure of claim 8, wherein, The first section (111) of the fifth connecting plate is divided into a long section (1111), a short section (1113), and a seventeenth arc structure (1112) after being rolled and bent. The long section (1111) of the fifth connecting plate is connected to the short section (1113) of the fifth connecting plate through the seventeenth arc structure (1112). The long section (1111) of the fifth connecting plate is laser welded to the eleventh connecting plate section (17). The short section (1113) of the fifth connecting plate and the eleventh connecting plate section (17) are spaced apart, so that the first section (111) of the fifth connecting plate sinks and bends to form a step shape. The first connecting plate section (7) is straight connected to the second connecting plate section (8). The first connecting plate section (7) extends into the gap between the short section (1113) of the fifth connecting plate and the eleventh connecting plate section (17) and is laser welded.

10. The six-cavity roll-formed threshold beam profile structure of claim 7, wherein, The ninth connecting plate segment (15) is divided into the right segment (151), the eighteenth arc-shaped structure (152), the middle segment (153), the nineteenth arc-shaped structure (154), and the left segment (155) of the ninth connecting plate after being rolled twice. The right segment (151) of the ninth connecting plate is connected to the middle segment (153) of the ninth connecting plate through the eighteenth arc-shaped structure (152). The middle segment (153) of the ninth connecting plate is laser-welded to the thirteenth connecting plate segment (19). The middle segment (153) of the ninth connecting plate is connected to the left segment (155) of the ninth connecting plate through the nineteenth arc-shaped structure (154). The left segment (155) of the ninth connecting plate is connected to the thirteenth connecting plate segment (19) through the ninth arc-shaped structure (31). The tenth connecting plate segment (16) is connected, and the right segment (151) of the ninth connecting plate is laser welded to the sixteenth connecting plate segment (22). The second cavity (2) is formed by the tenth connecting plate segment (16), the eleventh connecting plate segment (17), the twelfth connecting plate segment (18) and the left segment (155) of the ninth connecting plate to form a trapezoidal closed structure. The fourth cavity (4) is formed by the fourteenth connecting plate segment (20), the fifteenth connecting plate segment (21) and the right segment (151) of the ninth connecting plate to form a triangular closed structure. The fifth cavity (5) is formed by the upper right corner missing from the original rectangular closed structure to form a pentagonal closed structure, so that the second cavity (2), the fourth cavity (4) and the fifth cavity (5) can be adapted to the automotive assembly contour.

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