A low-cost, high-rigidity wedge-type door sill reinforcement beam

Abstract

This invention provides a low-cost, high-rigidity wedge-type door sill reinforcement beam, comprising an outer closed component and a wedge reinforcement fixedly disposed inside the outer closed component. The outer closed component is a closed cavity formed by bending a single sheet of material through multiple bends, and the wedge reinforcement is formed by online punching from a single sheet of material. Multiple wedge openings are provided on the sidewalls of the outer closed component, and multiple wedges corresponding one-to-one with the wedge openings on the sidewalls of the wedge reinforcement are provided on both sides of the wedge reinforcement. The outer closed component and the wedge reinforcement are first installed using wedges and then welded together for fixation. This door sill reinforcement beam is easy to process, low-cost, high-strength, and has good energy absorption performance, meeting lightweight requirements. The profile structure has sufficient rigidity and strength to meet the overall anti-collision performance requirements of automobiles, and the connection method with the inner and outer door sill plates is flexible and highly practical.

Description

Technical Field

[0001] This utility model relates to the field of automotive profile technology, and in particular to a low-cost, high-rigidity wedge-type door sill reinforcement beam. Background Technology

[0002] The sill reinforcement beam is an indispensable part of a vehicle's safety structure. Its structural design and material selection directly affect the vehicle's safety performance in side impacts and rollover accidents. In side impacts, it absorbs and disperses collision energy, protecting occupants. In rollover accidents, the sill reinforcement beam provides necessary support, reduces vehicle deformation, and protects occupants. Due to increasingly stringent collision safety regulations, OEMs are continuously improving the rigidity and torsional resistance of sill reinforcement beams by enhancing structural design strength and using lightweight materials such as aluminum alloys. This results in overall vehicle weight reduction, improved fuel efficiency, and enhanced dynamic performance.

[0003] Currently, the door sill reinforcement beam structure mainly uses multi-cavity aluminum alloy profiles. Due to its low density, it can significantly reduce the weight of the car, thereby improving fuel efficiency and reducing emissions. However, compared with ordinary steel, aluminum alloy profiles have thicker walls, larger volume, and higher manufacturing costs. The connection methods between steel and aluminum are limited to screwing and riveting, which are complicated and increase the overall manufacturing cost of the vehicle. In addition, aluminum profiles are difficult to repair after collision deformation, and may require the replacement of the entire component, increasing maintenance costs.

[0004] Ultra-high strength steel roll forming technology has been successfully applied in many vehicle models both domestically and internationally. Door sill reinforcements, as key components for vehicle safety, have high strength requirements. Currently, the mainstream strength of roll-formed high-strength steel exceeds 1000MPa, with some reaching up to 1700MPa. Therefore, by using ultra-high strength steel to replace traditional aluminum alloy materials, the material utilization rate of high-strength steel plate roll forming can reach over 90%. While ensuring product quality, this significantly reduces the weight of the door sill reinforcement beam, improves overall vehicle safety, and ensures the integrity and safety performance of the passenger compartment. Utility Model Content

[0005] To address the aforementioned problems in the existing technology, the purpose of this utility model is to provide a low-cost, high-rigidity wedge-type door sill reinforcement beam.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0007] A low-cost, high-rigidity wedge-type door sill reinforcement beam includes an outer closed component and a wedge reinforcement fixed inside the outer closed component. The outer closed component is a closed cavity formed by bending a sheet of material through multiple bends, and the wedge reinforcement is formed by online punching from a sheet of material. The side wall of the outer closed component has multiple wedge openings, and the two sides of the wedge reinforcement have multiple wedges that correspond one-to-one with the wedge openings on the side wall of the outer closed component. The outer closed component and the wedge reinforcement are first installed by wedges and then welded together to form a whole.

[0008] A further improvement of this utility model is that the peripheral closing component includes an upper left wall, an upper right wall, a left side wall, a right side wall, and a lower wall. The upper left wall and the upper right wall are attached together and welded to form the upper wall.

[0009] A further improvement of this utility model is that the cross-section of the outer closing member is trapezoidal or rectangular, preferably trapezoidal, and more preferably isosceles trapezoidal with left and right symmetry, that is, the angle between the left / right side wall and the lower wall is not greater than 90°, and the angle between the left / right side wall and the upper wall is not less than 90°.

[0010] A further improvement of this utility model is that the wedge reinforcement is formed by one-time punching of a plate, and the wedges correspond one-to-one with the wedge openings on the side walls of the outer closed member. The two are installed by wedges and the outer closed member and the wedge reinforcement are connected by welding.

[0011] A further improvement of this utility model is that the plate wall thickness n of the outer closed member and the plate wall thickness m of the wedge reinforcement member satisfy m≥n.

[0012] A further improvement of this utility model is that the length L of the insertion wedge is 25-30mm, the length a of the insertion wedge is 25-30mm, and L > a.

[0013] A further improvement of this utility model is that: when there is no sealing requirement for the reinforcing beam, the wedge length L-wedge length a > 1mm, and the wedge width K-wedge width c > 1mm; when there is a sealing requirement for the reinforcing beam, the wedge length L-wedge length a ≤ 1mm, and the wedge width K-wedge width c ≤ 1mm; the larger the wedge size, the more beneficial it is for the wedge installation of the outer parts and the reinforcing parts.

[0014] A further improvement of this utility model is that the wedge reinforcement is also provided with a downwardly recessed rib feature, which is preferably a U-shaped reinforcement rib.

[0015] The technological advancements achieved by this utility model due to the adoption of the above technical solution are as follows:

[0016] The utility model discloses a low-cost and high-rigidity plug-in wedge type sill reinforcing beam, which has the characteristics of easy processing, low cost, high strength and good energy absorption performance, meets the lightweight requirements, and the profile structure has sufficient rigidity and bending strength to meet the anti-collision performance requirements of the whole vehicle.

[0017] In the sill reinforcing beam of the utility model, the plugs of the plug-in wedge reinforcing members correspond to the plug-in wedge openings on the side walls of the peripheral closed members one by one. The two are installed through the plugs, and then the peripheral closed members and the plug-in wedge reinforcing members are fixedly connected by welding. The double connection method effectively improves the strength of the sill reinforcing beam.

[0018] The cross-section of the sill reinforcing beam of the utility model has higher strength, lighter weight and stronger practicability. According to the customer's collision performance requirements, multiple plug-in wedge reinforcing members can be arranged inside the peripheral closed members. Generally, one plug-in wedge reinforcing member forms a nearly "day" character structure, or two plug-in wedge reinforcing members form a nearly "eye" character structure. At the same time, the plate thickness and plate strength of the peripheral closed members and the plug-in wedge reinforcing members can be the same or different, which is beneficial to the different stiffness design and lightweight design of the sill reinforcing beam structure to meet the collision performance requirements of different customers. For example, two different thickness plates are used to process the peripheral closed members and the plug-in wedge reinforcing members. The plate thickness of the peripheral closed members is appropriately reduced, which has little impact on the strength and rigidity of the sill reinforcing beam structure, and further reduces the weight of the profile, meeting the requirements of high strength and lightweight.

[0019] For traditional integral steel roll-formed profiles, there are many roll-forming passes, the process is complex, and the costs of die manufacturing and equipment modification are high. Moreover, there are a large number of forming blind corners in the integral steel roll-formed profiles, and the cross-section forming accuracy is low. Multiple stacking areas and process edges need to be set for the integral steel roll-formed profiles to be closed for cross-section closing and welding, resulting in more plate materials used, which is not conducive to the lightweight design requirements. However, the cross-section of the sill reinforcing beam of the utility model is simple, there is no need to design a stacking process edge, the plate material consumption is significantly reduced, the raw materials are greatly saved, the processing process is simple, and the manufacturing cost is low.

[0020] For traditional aluminum alloy profiles, the wall thickness is large, the space volume is large, and the manufacturing cost is relatively high. Moreover, due to the limited connection methods of steel-aluminum dissimilar materials, only methods such as screwing and riveting can be used, and the strength of the connection positions is low, and the processing procedures are cumbersome, increasing the manufacturing cost of the whole vehicle. In addition, after the aluminum alloy profile collides and deform, it is difficult to repair, and the whole component may need to be replaced, increasing the maintenance cost. However, the sill reinforcing beam of the utility model and the inner and outer sill plates are both of the same steel material, and the connection methods are flexible. Multiple connection methods such as using bolt assemblies, riveting, welding, and bonding can be used. Laser penetration welding is preferably used for welding, and the connection strength is high to ensure the stability of the reinforcing beam and the effective transmission of collision force during the collision process.

[0021] The application range of this utility model sill reinforcement beam is very wide. When the cross section of the outer closed member is an isosceles trapezoid, it is mainly used as a sill reinforcement beam; when the cross section of the outer closed member is rectangular or right-angled trapezoid, in addition to being used as a sill reinforcement beam, it can also be used as a car anti-collision beam, seat crossbeam, battery side beam or other side beam type profile. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0023] Figure 2 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 1 of this utility model;

[0024] Figure 3 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 2 of this utility model;

[0025] Figure 4 This is a cross-sectional schematic diagram of the threshold reinforcement beam in Embodiment 3 of this utility model;

[0026] Figure 5 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 4 of this utility model;

[0027] Figure 6 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 5 of this utility model;

[0028] Figure 7 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 6 of this utility model;

[0029] Figure 8 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 7 of this utility model;

[0030] Figure 9 This is a schematic cross-sectional view of the threshold reinforcement beam in Embodiment 8 of this utility model;

[0031] Figure 10 A partial schematic diagram of the wedge insertion port of the outer closed component;

[0032] Figure 11 A partial schematic diagram of the wedge reinforcement component;

[0033] Figure 12 This is a schematic diagram of the assembly and connection method of the reinforcing beam profile of this utility model;

[0034] In the figure, 1. Outer closed part, 1-1. Upper right wall, 1-2. Right side wall, 1-3. Lower wall, 1-4. Left side wall, 1-5. Upper left wall, 1-6. Weld point; 2. Wedge reinforcement, 2-1. Short reinforcement, 2-2. Long reinforcement, 3. U-shaped reinforcement rib. Detailed Implementation

[0035] The present invention will be further described below.

[0036] A low-cost, high-rigidity wedge-type sill reinforcement beam, such as Figure 1 As shown, the device includes an outer closure member 1 and several wedge reinforcement members 2 disposed inside the outer closure member 1. The outer closure member 1 is a closed cavity formed by bending a single sheet of material through multiple bends. Multiple wedge openings are provided along the length of the side walls of the outer closure member 1, and the wedge openings on both side walls are symmetrically arranged. The wedge reinforcement members 2 are flat sheet materials with several wedges on both sides, and the wedges of the wedge reinforcement members 2 correspond one-to-one with the wedge openings of the outer closure member 1. The wedge reinforcement members 2 and the outer closure member 1 are first installed using wedges and then welded together to form a single unit.

[0037] The cross-section of the outer closure member 1 is trapezoidal or rectangular, preferably trapezoidal, and more preferably isosceles trapezoidal with symmetrical left and right sides. When the cross-section of the outer closure member 1 is isosceles trapezoidal, it is mainly used as a door sill reinforcement beam; when the cross-section of the outer closure member 1 is rectangular (the angle between the two side walls of the outer closure member 1 and the upper / lower wall 1-3 is 90°) or right trapezoidal (the angle between any one side wall of the outer closure member 1 and the upper / lower wall 1-3 is 90°, and the angle between the other side wall and the upper / lower wall 1-3 is not equal to 90°), in addition to being used as a door sill reinforcement beam, it can also be used as a car anti-collision beam, seat crossbeam, battery side beam or other side beam type profile.

[0038] The edges and corners of the outer closure component 1 are all rounded, so that the impact force is transmitted synchronously along the symmetrically arranged plates when subjected to force, the force is more uniform, and there are no dead corners.

[0039] According to the customer's collision performance requirements, the number of the wedge reinforcement 2 is generally 1 to 3, which are evenly distributed along the height direction of the outer closing member 1, and preferably 2.

[0040] To enhance the strength of the sill beam, the wedge reinforcement 2 may also be provided with downwardly recessed ribs. Depending on the actual strength requirements of the sill reinforcement beam, the ribs may be provided in one or two sets, evenly arranged along the width direction of the wedge reinforcement 2.

[0041] Furthermore, the concave rib feature is preferably a U-shaped reinforcing rib 3.

[0042] The outer sealing member 1 consists of two plates joined together and then welded to achieve a seal. Laser welding is preferred for this connection.

[0043] The processing plates of the outer closure member 1 and the wedge reinforcement member 2 can be set as materials of different strengths or different thicknesses, which is beneficial for the different stiffness designs and lightweight designs of the sill reinforcement beam structure, and meets the collision performance requirements of different customers.

[0044] This utility model discloses a low-cost, high-rigidity wedge-type door sill reinforcement beam. The wall thickness of the outer closed part 1 and the wedge reinforcement 2 can be the same or different. The wall thickness of the outer closed part 1 is set as n, and the wall thickness of the wedge reinforcement 2 is set as m. Usually, m ≥ n, to ensure the strength of the door sill reinforcement beam structure.

[0045] like Figure 10 As shown, the dimensions of the wedge opening on the side wall of the outer closure component 1 include: wedge opening length L, wedge opening width K, and the distance P between two adjacent wedge openings. The preferred wedge opening length L is L = 25-30 mm. Figure 11 As shown, the wedge reinforcement 2 includes the following wedge dimensions: wedge length a, wedge width c, and distance b between two adjacent wedges. The wedge length a is matched with the wedge opening length L, preferably a = 25-30 mm. To ensure welding strength and avoid excessive welding deformation, the above parameters must also meet the following requirements:

[0046] The wedge length a ≤ the distance between two adjacent wedges b,

[0047] The wedge width c ≥ the wall thickness n of the outer closed part;

[0048] The length of the wedge insertion hole L is less than or equal to the distance P between two adjacent wedge insertion holes.

[0049] The width of the wedge insertion opening K is greater than or equal to the wall thickness of the wedge reinforcement (m).

[0050] When there is no sealing requirement for the sill reinforcement beam, the wedge length L - wedge length a > 1mm and the wedge width K - wedge width c > 1mm are usually used to facilitate assembly. When there is a sealing requirement for the reinforcement beam, the wedge length L - wedge length a ≤ 1mm and the wedge width K - wedge width c ≤ 1mm. The larger the wedge size, the more beneficial it is for the wedge installation of the outer parts and the reinforcement.

[0051] This utility model features a wedge-type door sill reinforcement beam structure with higher cross-sectional strength and lighter weight. It is not only strong and lightweight, but also simple to process and easy to mass-produce.

[0052] Traditional aluminum alloy profiles are thick and bulky, resulting in high manufacturing costs. Furthermore, the limited connection methods between dissimilar materials like steel and aluminum restrict the use to adhesive bonding, screwing, and riveting, leading to low strength at the connection points, complex processing, and increased overall vehicle manufacturing costs. Additionally, aluminum profiles are difficult to repair after collisions, potentially requiring replacement of the entire component, further increasing maintenance costs. In contrast, this new low-cost, high-rigidity wedge-shaped sill reinforcement beam offers flexible connection methods to both inner and outer sill beams, including bolt assemblies, riveting, welding, and adhesive bonding (see [link to original text]). Figure 12), preferably by laser penetration welding, which has high connection strength to ensure the stability of the reinforcement beam and the effective transmission of collision forces during a collision.

[0053] The present utility model will be further described in detail below through embodiments. Embodiment 1

[0054] A low-cost and high-rigidity plug-in wedge type sill reinforcement beam, as Figure 2 shown, the peripheral closed member 1 includes a right upper wall 1-1, a right side wall 1-2, a lower wall 1-3, a left side wall 1-4, and a left upper wall 1-5. The right upper wall 1-1 and the left upper wall 1-5 are welded together after being fitted to form a complete upper wall. The solder joint 1-6 is located at the junction of the right upper wall 1-1 and the left upper wall 1-5.

[0055] As Figure 4 shown, the cross-section of the peripheral closed member 11 is an isosceles trapezoid, and the included angles between the two side walls and the lower wall 1-3 are both less than 90°, and the included angles between the two side walls and the upper wall are both greater than 90°; two rows of left-right symmetric plug-in wedge openings are provided at the upper and lower parts of the left side wall 1-4 and the right side wall 1-2, and the plug-in wedge openings are formed by punching with a mechanical press.

[0056] As Figure 2 shown, the plug-in wedge reinforcement member 2 is provided in two groups, namely a short reinforcement member 2-1 and a long reinforcement member 2-2. The short reinforcement member 2-1 and the long reinforcement member 2-2 are both formed by online punching of flat plates, and a number of plug-in wedges are provided on both sides thereof. The short reinforcement member 2-1 and the long reinforcement member 2-2 are arranged parallel to the lower wall 1-3 / upper wall, and the short reinforcement member 2-1 and the long reinforcement member 2-2 are evenly arranged along the height direction of the peripheral closed member 1, effectively improving the connection strength of the peripheral closed member 1. Embodiment 2

[0057] As Figure 3 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference is that: a set of U-shaped reinforcing ribs 3 are provided in the middle of the short reinforcement member 2-1 and the long reinforcement member 2-2. Embodiment ३

[0058] As Figure 4 [[ID=3५]]shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference is that: two sets of U-shaped reinforcing ribs 3 are evenly arranged along the width direction of the short reinforcement member 2-1 and the long reinforcement member 2-2. Embodiment 4

[0059] As Figure 5 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference is that: only one set of plug-in wedge reinforcement members 2 is provided inside the peripheral closed member 1, and its cross-section is approximately "day" shaped. Embodiment 5

[0060] As Figure 6 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference lies in that: three groups of wedge strengthening members 2 are arranged inside the peripheral closed member 1 and are evenly distributed along the height direction of the peripheral closed member 1. Embodiment 6

[0061] As Figure 7 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference lies in that: the cross-section of the peripheral closed member 11 is rectangular. At this time, the included angles between the two side walls and the lower wall 1-3 and the included angles between the two side walls and the upper wall are both 90°, and the wedge strengthening members 2 are arranged in two groups. The threshold strengthening beam structure is in the shape of "mu".

[0062] Compared with the traditional "mu"-shaped profile, the sectional dimensions of both are 125mm×50mm, and the overall sheet thickness is 1.8mm. After measurement, the weight of the traditional "mu"-shaped profile is 7.97 Kg, and the weight of the "mu"-shaped profile of this embodiment is 7.16 Kg, which is 10.2% lighter than the traditional "mu"-shaped profile, meeting the lightweight design requirements.

[0063] The main reason is that the cross-section of the wedge-type threshold strengthening beam structure of the present utility model is simple, there is no need to design a stacking process edge, the sheet material usage is significantly reduced, the raw materials are greatly saved, and the profile weight is reduced. For the traditional integral steel roll-pressed profile, ① there are many roll-forming passes, the process is complex, and the costs of mold manufacturing and equipment modification are high; ② there are a large number of forming blind corners in the integral steel roll-pressed profile, and the sectional forming accuracy is low; ③ multiple stacking areas and process edges need to be set for the integral steel roll-pressed profile to be closed for sectional closing and welding, and the sheet material usage is large, which is not conducive to the lightweight design requirements. Embodiment 7

[0064] As Figure 8 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference lies in that: the sheet thicknesses of the peripheral closed member 1 and the wedge strengthening member 2 are different. The sheet thickness m for processing the peripheral closed member 1 is 1.5mm, and the sheet thickness n for processing the wedge strengthening member 2 is 3.5mm. Embodiment 8

[0065] As Figure 9 shown, the structure of this embodiment is basically the same as that of Embodiment 1, and the difference lies in that: the strengths of the sheets for processing the peripheral closed member 1 and the wedge strengthening member 2 are different. The strength of the sheet for processing the peripheral closed member 1 is 1300 MS, and the strength of the sheet for processing the wedge strengthening member 22 is 1500 MS.

[0066] The above description is only a preferred embodiment of the present utility model. All equivalent changes and modifications made within the scope of the patent application of the present utility model shall be covered by the present utility model.

Claims

1. A low cost, high stiffness, wedge-in-slot door sill reinforcement beam characterized by: It includes an outer closure component (1) and a wedge reinforcement component (2) fixed inside the outer closure component (1); the outer closure component (1) is a closed cavity formed by bending a piece of plate through multiple bends, and the wedge reinforcement component (2) is formed by online punching of a piece of plate; the outer closure component (1) has multiple wedge openings on its side wall, and the wedge reinforcement component (2) has multiple wedges on both sides that correspond one-to-one with the wedge openings on the side wall of the outer closure component (1). The outer closure component (1) and the wedge reinforcement component (2) are first installed by wedges and then welded together.

2. A low cost, high stiffness insert wedge door sill reinforcement beam according to claim 1, characterized in that: The outer closed component (1) includes an upper left wall (1-5), an upper right wall (1-1), a left side wall (1-4), a right side wall (1-2), and a lower wall (1-3). The upper left wall (1-5) and the upper right wall (1-1) are bent and welded together to form a complete upper wall.

3. A low cost, high stiffness insert wedge door sill reinforcement beam according to claim 2, characterized in that: The cross-section of the peripheral closure member (1) is trapezoidal or rectangular.

4. The low-cost, high-rigidity wedge-type sill reinforcement beam according to claim 3, characterized in that: The outer closure member (1) is an isosceles trapezoidal structure; the angle between the left side wall (1-4) / right side wall (1-2) and the lower wall (1-3) is not greater than 90°, and the angle between the left side wall (1-4) / right side wall (1-2) and the upper wall is not less than 90°.

5. A low cost, high stiffness insert wedge door sill reinforcement beam according to claim 1, characterized by: The plate wall thickness n of the outer closed member (1) and the plate wall thickness m of the wedge reinforcement member (2) satisfy m≥n.

6. A low cost, high stiffness insert wedge door sill reinforcement beam according to claim 1, characterized by: The length L of the insertion wedge is 25-30mm, the length a of the insertion wedge is 25-30mm, and L > a.

7. A low cost, high stiffness insert wedge threshold beam according to claim 6, characterized in that: When there is no sealing requirement for the reinforcing beam, the wedge length L - wedge length a > 1mm, and the wedge width K - wedge width c > 1mm; when there is a sealing requirement for the reinforcing beam, the wedge length L - wedge length a ≤ 1mm, and the wedge width K - wedge width c ≤ 1mm.

8. A low cost, high stiffness insert wedge door sill reinforcement beam according to claim 1, characterized by: The wedge reinforcement (2) is also provided with a downwardly recessed rib feature.

9. A low-cost, high-rigidity wedge-type sill reinforcement beam according to claim 8, characterized in that: The concave rib is characterized as a U-shaped reinforcing rib (3).

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