A honeycomb aluminum door sill beam assembly for an automobile

Abstract

The utility model relates to a kind of honeycomb aluminum door sill beam assembly for automobile, including the door sill beam body of aluminium alloy section structure, and the inner cavity of door sill beam body is provided with honeycomb aluminum structure. The honeycomb aluminum structure includes the honeycomb aluminum core extending along the length direction of door sill beam body, and the outer circumferential side of honeycomb aluminum core is provided with honeycomb baffle, and the honeycomb baffle wraps honeycomb aluminum core. The utility model structure design is simple, reasonable, by setting honeycomb aluminum structure in the inside of aluminium alloy section structure's door sill beam body, honeycomb aluminum structure has very strong compression strength and energy-absorbing effect, improves the vehicle crashworthiness, strengthens the protection of passenger cabin when automobile side collision;While honeycomb aluminum structure is lighter, greatly reduces the weight of part, reaches the purpose of automobile light weight, and simplifies manufacturing procedure, improves production efficiency, reduces tooling cost.

Description

Technical Field

[0001] This utility model belongs to the field of automotive door sill beams, and particularly relates to an automotive honeycomb aluminum door sill beam assembly. Background Technology

[0002] More and more new energy vehicles are gradually replacing traditional gasoline-powered vehicles, becoming the mainstream of the future automotive market. For new energy vehicles, lightweighting and safety have become crucial directions. In terms of safety, effectively protecting the battery pack from external force during a collision has become a challenging problem in the design of new energy vehicles.

[0003] As one of the most important protective structures on the side of the battery pack, the sill beam's energy absorption performance directly affects the vehicle's side impact performance. Furthermore, as a crucial structural component running the length of the vehicle body from front to back, the sill beam is also vital to the vehicle's structural rigidity.

[0004] Traditional automotive door sill beams are typically made of high-strength, cold-stamped steel plates with relatively thick walls, and are usually composed of multiple components such as an inner door sill beam, an outer door sill beam, a door sill beam reinforcement plate, a front section of the door sill beam, and a rear section of the door sill beam. The number of sub-components is large and the weight is heavy, which does not meet the design goal of lightweighting. Multiple sets of welding fixtures are also required for welding and positioning, making the process complex and inefficient. At the same time, the energy absorption effect of steel parts is generally average, and the energy absorption protection for side collisions of automobiles is relatively average.

[0005] Compared to steel door sill beams, existing aluminum alloy door sill beams offer a higher degree of component integration and greater weight reduction efficiency. However, due to the stringent requirements for side impact testing in automobiles, door sill beams typically incorporate complex multi-cavity rib structures, with each rib layer generally 2-3mm thick, designed to absorb collision energy. This results in higher component molding difficulty, higher manufacturing costs, and lower production efficiency. Furthermore, the presence of internal ribs limits the overall weight reduction efficiency to only around 25%. This solution is currently the optimal option for mid-to-high-end vehicles and cannot be further improved. Utility Model Content

[0006] This utility model addresses the problems existing in the prior art, namely, the technical problem to be solved by this utility model is to provide a honeycomb aluminum door sill beam assembly for automobiles.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is: a honeycomb aluminum door sill beam assembly for automobiles, comprising a door sill beam body with an aluminum alloy profile structure, wherein the inner cavity of the door sill beam body is provided with a honeycomb aluminum structure.

[0008] Furthermore, the honeycomb aluminum structure includes a honeycomb aluminum core extending along the length direction of the sill beam body, and a honeycomb enclosure is provided on the outer periphery of the honeycomb aluminum core, the honeycomb enclosure wrapping around the honeycomb aluminum core.

[0009] Furthermore, the honeycomb aluminum core is in the shape of a honeycomb panel; the honeycomb surrounding panel includes an upper surrounding panel, a lower surrounding panel, a left surrounding panel, and a right surrounding panel, all made of aluminum plates. The upper surrounding panel is connected to the upper end of the honeycomb aluminum core, the lower surrounding panel is connected to the lower end of the honeycomb aluminum core, the left surrounding panel is connected to the left end of the honeycomb aluminum core, and the right surrounding panel is connected to the right end of the honeycomb aluminum core.

[0010] Furthermore, the upper panel, lower panel, left panel, and right panel are all made of 5-series aluminum sheet.

[0011] Furthermore, the honeycomb enclosure and the honeycomb aluminum core are connected by structural adhesive.

[0012] Furthermore, the honeycomb aluminum core is made of aluminum foil with a thickness of 0.05 to 0.3 mm.

[0013] Furthermore, the honeycomb aluminum structure has regular hexagonal honeycomb holes with a side length of 3–10 mm.

[0014] Furthermore, the axis of the honeycomb holes in the honeycomb aluminum core extends in the left and right directions.

[0015] Furthermore, the left end of the honeycomb aluminum structure is fixed to the sill beam body by a core-pulling riveting connection.

[0016] Furthermore, the cross-section of the honeycomb aluminum structure is rectangular. The left end of the inner cavity of the threshold beam body has a vertical left fitting plane, the upper right end has a vertical right fitting plane, the upper end has a horizontal top fitting plane, and the lower end has a horizontal bottom fitting plane. The left end face of the honeycomb aluminum structure is in contact with the left fitting plane, the upper right end face is in contact with the right fitting plane, the upper end face is in contact with the top fitting plane, and the lower end face is in contact with the bottom fitting plane.

[0017] Compared with the prior art, the present invention has the following advantages: The present invention has a simple and reasonable structural design. By setting a honeycomb aluminum structure inside the door sill beam body of the aluminum alloy profile structure, the honeycomb aluminum structure has extremely strong compressive strength and energy absorption effect, which improves the vehicle's anti-collision performance and strengthens the protection of the passenger compartment during side collisions of the car. At the same time, the honeycomb aluminum structure is lighter, which greatly reduces the weight of the parts, achieves the purpose of lightweighting the car, simplifies the manufacturing process, improves production efficiency, and reduces tooling costs. Attached Figure Description

[0018] Figure 1 This is a cross-sectional structural schematic diagram of an embodiment of the present invention;

[0019] Figure 2 This is a schematic diagram of the exploded state of the honeycomb aluminum structure in an embodiment of this utility model;

[0020] Figure 3 This is a schematic diagram of the honeycomb aluminum structure in an embodiment of this utility model (upper and lower panels omitted).

[0021] Figure 4 This is a schematic diagram of the cross-sectional structure of the threshold beam body in an embodiment of this utility model;

[0022] Figure 5 This is a schematic diagram of the cross-sectional structure of the honeycomb aluminum core in an embodiment of this utility model. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0024] In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "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 utility model 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 utility model.

[0025] like Figures 1-5 As shown, this utility model discloses a honeycomb aluminum door sill beam assembly for automobiles, comprising a door sill beam body 1 with an aluminum alloy profile structure, wherein a honeycomb aluminum structure 2 is disposed in the inner cavity 8 of the door sill beam body 1. The composite structure of the door sill beam body with a honeycomb aluminum structure and an aluminum alloy profile structure leverages the strong energy absorption and compressive strength of the honeycomb aluminum structure, effectively balancing the external matching surface and performance requirements of the door sill beam.

[0026] In this embodiment, the honeycomb aluminum structure 2 is a plate-shaped structure, including a honeycomb aluminum core 3 extending along the length direction of the threshold beam body 1. A honeycomb enclosure is provided on the outer periphery of the honeycomb aluminum core 3, and the honeycomb enclosure wraps around the honeycomb aluminum core 3.

[0027] In this embodiment, the honeycomb aluminum core 3 is in the form of a honeycomb panel; the honeycomb surrounding panel includes an upper surrounding panel 4, a lower surrounding panel 5, a left surrounding panel 6, and a right surrounding panel 7, all made of aluminum plates. The upper surrounding panel 4 is connected to the upper end of the honeycomb aluminum core 3, the lower surrounding panel 5 is connected to the lower end of the honeycomb aluminum core 3, the left surrounding panel 6 is connected to the left end of the honeycomb aluminum core 3, and the right surrounding panel 7 is connected to the right end of the honeycomb aluminum core 3.

[0028] In this embodiment, the upper panel 4, lower panel 5, left panel 6, and right panel 7 are all made of 5-series aluminum plates.

[0029] In this embodiment, the upper panel 4, lower panel 5, left panel 6, and right panel 7 are all connected to the honeycomb aluminum core 3 using a room-temperature curing two-component structural adhesive 14, which can be cured at room temperature for 1 hour.

[0030] In this embodiment, the honeycomb aluminum core 3 is made of 3003-H14 aluminum foil, and the honeycomb aluminum core is honeycomb-shaped, composed of countless regular hexagons. Preferably, the thickness of the aluminum foil is 0.05-0.3mm, significantly reducing the weight of the part and achieving the purpose of lightweighting; the side length of the honeycomb holes is 3-10mm. It should be noted that in the actual production process, the thickness of the aluminum foil and the side length of the honeycomb holes are selected according to different collision performance requirements. Aluminum alloy itself has a low material density, combined with the ultra-thin thickness of the honeycomb aluminum. The overall weight can be reduced by about 50% compared to the steel solution, and by about 30% compared to the aluminum profile solution, achieving the lightweight design goal and significantly improving the driving range of the vehicle.

[0031] In this embodiment, the axis of the honeycomb holes of the honeycomb aluminum core 3 extends in the left and right directions.

[0032] In this embodiment, the left end of the honeycomb aluminum structure 2 (i.e., the left side panel 6) and the sill beam body 1 are fixed by a pull rivet 13, which is a simple process.

[0033] In this embodiment, the honeycomb aluminum structure 2 has a rectangular cross-section. The inner cavity 8 of the sill beam body 1 has a vertically arranged left contact plane 9 at its left end, a vertically arranged right contact plane 10 at its upper right end, a horizontally arranged top contact plane 11 at its upper end, and a horizontally arranged bottom contact plane 12 at its lower end. The left end face of the honeycomb aluminum structure 2 contacts the left contact plane 9, the upper right end face contacts the right contact plane 10, the upper end face contacts the top contact plane 11, and the lower end face contacts the bottom contact plane 12. It should be noted that the sill beam body in this embodiment directly adopts the automotive aluminum alloy sill beam assembly structure disclosed in Chinese Patent Publication No. CN219056395U, only removing the horizontal and vertical interlaced stiffeners inside that patent. The remaining structure is the same as that patent, and further detailed descriptions of the sill beam body in this embodiment will not be repeated here. By combining the existing aluminum alloy profile sill beam body with a honeycomb aluminum structure, the sill beam body can be matched with the body floor, side panels and other surfaces. At the same time, it can meet the installation matching functions such as fixing the wiring harness and trim panels on the sill beam. The honeycomb aluminum structure can provide the sill beam with higher performance energy absorption and collision resistance. At the same time, this structure can significantly reduce the overall weight of the components and achieve the goal of lightweighting.

[0034] In this embodiment, the honeycomb aluminum core has extremely high density, and its honeycomb structure can effectively disperse and transfer external forces to each hexagonal aluminum foil structure. Its compressive strength per unit area far exceeds that of profiles and sheet metal structures. In the event of a collision, this sill beam assembly has two layers of energy-absorbing structures. The aluminum alloy profile sill beam structure is the first to be impacted. Because it lacks internal ribs or other structural support on its outer side, it undergoes the first stage of energy-absorbing collapse until the collapse point contacts the honeycomb aluminum structure. When the external force per unit area exceeds the yield strength of the honeycomb aluminum structure, the honeycomb aluminum structure undergoes a second stage of uniform collapse, ensuring the stability of force transmission. Side impact forces are transmitted and decomposed through the honeycomb aluminum structure, dispersing concentrated stress to every part of the sill beam structure, effectively improving collision resistance and energy absorption, thereby effectively ensuring the safety of the battery pack and occupants. From a structural mechanics perspective, the honeycomb aluminum structure also has extremely high rigidity, simultaneously improving the torsional stiffness of the vehicle body during driving, ensuring the rigidity and reliability of the vehicle body, and thus improving the vehicle's stability and comfort.

[0035] Meanwhile, traditional door sill cold stamping dies are expensive, with a development cycle of 4 to 6 months. They also require the development of multiple sets of welding fixtures for welding positioning. In contrast, door sills with honeycomb aluminum structures only require the development of stamping dies for the aluminum plate, which is relatively cheaper. They do not require the development of welding fixtures, which significantly reduces tooling manufacturing costs. Moreover, the development cycle is generally 40 days, greatly reducing the development cycle and improving production efficiency.

[0036] The advantages of this utility model are:

[0037] (1) A honeycomb aluminum structure is made of aluminum foil with a thickness of 0.05 to 0.3 mm, which greatly reduces the weight of the parts and achieves the purpose of lightweighting the car;

[0038] (2) The honeycomb aluminum structure has extremely strong compressive strength and energy absorption effect, which improves the vehicle's anti-collision performance and strengthens the protection of the passenger compartment during side collisions.

[0039] (3) Integrate multiple components into a single design, optimize the number of parts, simplify manufacturing processes, improve production efficiency, and reduce tooling costs;

[0040] (4) The honeycomb aluminum structure has excellent sealing performance, eliminating the need for additional sealing accessories on the sill beam, ensuring the waterproof sealing of the passenger compartment and reducing costs;

[0041] (5) The composite structure of honeycomb aluminum plate and irregular profile can effectively take into account both the external matching surface of the threshold beam and the performance requirements of the threshold beam;

[0042] (6) The cost of honeycomb aluminum parts is low, making them more economical than aluminum alloy profile door sill beams.

[0043] If this utility model discloses or relates to mutually fixedly connected parts or structural components, then, unless otherwise stated, a fixed connection can be understood as: a detachable fixed connection (e.g., using bolts or screws), or a non-detachable fixed connection (e.g., riveting, welding). Of course, mutually fixed connections can also be replaced by an integral structure (e.g., manufactured using a casting process) (except where it is obviously impossible to use an integral forming process).

[0044] In addition, unless otherwise stated, the terms used to indicate positional relationships or shapes in any of the technical solutions disclosed in this utility model above include states or shapes that are similar to, close to, or approximate with them.

[0045] Any component provided by this utility model can be assembled from multiple individual components, or it can be a single component manufactured by a one-piece molding process.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it; although the utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of this utility model or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solution of this utility model, and all such modifications and substitutions should be covered within the scope of the technical solution claimed by this utility model.

Claims

1. A honeycomb aluminum door sill beam assembly for automobiles, comprising a door sill beam body with an aluminum alloy profile structure, characterized in that: The inner cavity of the threshold beam body is provided with a honeycomb aluminum structure. The honeycomb aluminum structure includes a honeycomb aluminum core extending along the length of the sill beam body, and a honeycomb enclosure is provided on the outer periphery of the honeycomb aluminum core, the honeycomb enclosure wrapping around the honeycomb aluminum core. The honeycomb aluminum core is in the shape of a honeycomb panel; the honeycomb surrounding panel includes an upper surrounding panel, a lower surrounding panel, a left surrounding panel, and a right surrounding panel, all of which are made of aluminum plates. The upper surrounding panel is connected to the upper end of the honeycomb aluminum core, the lower surrounding panel is connected to the lower end of the honeycomb aluminum core, the left surrounding panel is connected to the left end of the honeycomb aluminum core, and the right surrounding panel is connected to the right end of the honeycomb aluminum core. The honeycomb enclosure and the honeycomb aluminum core are connected by structural adhesive. The honeycomb aluminum structure has regular hexagonal honeycomb holes with a side length of 3 to 10 mm. The left end of the honeycomb aluminum structure is fixed to the sill beam body by a core-pulling riveting connection. The cross-section of the honeycomb aluminum structure is rectangular. The left end of the inner cavity of the threshold beam body has a vertical left fitting plane, the upper right end has a vertical right fitting plane, the upper end has a horizontal top fitting plane, and the lower end has a horizontal bottom fitting plane. The left end face of the honeycomb aluminum structure is in contact with the left fitting plane, the upper right end face is in contact with the right fitting plane, the upper end face is in contact with the top fitting plane, and the lower end face is in contact with the bottom fitting plane.

2. The automotive honeycomb aluminum door sill beam assembly according to claim 1, characterized in that: The upper panel, lower panel, left panel, and right panel are all made of 5-series aluminum sheet.

3. The automotive honeycomb aluminum door sill beam assembly according to claim 1, characterized in that: The honeycomb aluminum core is made of aluminum foil with a thickness of 0.05 to 0.3 mm.

4. The automotive honeycomb aluminum door sill beam assembly according to claim 1, characterized in that: The axis of the honeycomb holes in the honeycomb aluminum core extends in the left and right directions.

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