Steel-aluminum hybrid rocker beam for electric vehicle with improved safety

Abstract

The utility model provides a kind of steel-aluminum mixed door sill beam for electric vehicle, belong to the technical field of automobile parts.The utility model includes shell and reinforcing beam, the reinforcing beam is located in the shell, and the gap is left between the reinforcing beam and shell, the shell is formed by the split groove fastening of left and right two trapezoidal, the split groove has the connecting outer plate extending outward in two sides, the connecting inner plate is equipped in the reinforcing beam two sides, the connecting outer plate clamps the connecting inner plate, the connecting inner plate is fixed with the connecting outer plate by connecting piece.It adopts ultrahigh strength steel shell and aluminum alloy reinforcing beam, and is connected by self-piercing resistance welding process, and the whole has good rigidity;The strength of the sill beam is improved.In the process of side collision, the product can play a good collapse energy absorption effect;At the same time, without using FDS connection mode, the sharp FDS rivet is reduced, and the risk of sharp structure piercing battery pack in component is further reduced.

Description

Technical Field

[0001] This utility model belongs to the technical field of automotive parts, and in particular to a steel-aluminum hybrid door sill beam for electric vehicles that can improve safety. Background Technology

[0002] With the increasing popularity of new energy vehicles, battery safety has become a major concern for consumers and automotive engineers. The widespread application of C2B and C2C technologies has led to higher integration of battery packs with the vehicle body, creating new demands for battery pack protection in side-impact collisions. In side-impact collisions, the sill beam plays a crucial role in energy absorption. Therefore, in the production of new energy vehicles, higher strength and energy absorption requirements are placed on the sill beam to improve its strength and reduce damage to the battery pack after an impact.

[0003] The existing technology has the following problems: First, traditional door sill beams are typically made of high-strength steel, forming a hollow structure composed of inner and outer sill beams. In a side impact, this hollow structure cannot adequately absorb energy during crushing. Second, most existing new energy vehicles use aluminum alloy door sill beams. However, aluminum alloy door sill beams are expensive, and the connection between them and surrounding steel components is complex, resulting in inefficient manufacturing processes. They often use FDS rivets, which, after impact deformation, could potentially puncture the battery pack, posing a danger.

[0004] Patent CN 212579992 U proposes a design using high-strength steel on the outer perimeter and aluminum alloy reinforcing beams on the inner perimeter. The aluminum alloy reinforcing beams are connected to the outer high-strength steel via a small intermediate bracket welded together. This is primarily because the outer sill beams are typically made of ultra-high-strength steel, and connection methods such as FDS and SPR have difficulty penetrating ultra-high-strength steel components. Therefore, a connecting plate with slightly lower material strength is needed, connecting to the aluminum alloy reinforcing beam via FDS, and then spot-welded to the outer perimeter. The disadvantages of this design are the need for an intermediate connecting plate, which complicates the process, and the relatively weak structure of the intermediate connecting plate results in poor overall rigidity.

[0005] Patent CN 220130213 U also proposes a steel outer perimeter and aluminum alloy reinforcing beam scheme. The aluminum alloy reinforcing beam is also connected to the outer perimeter via a connecting plate through spot welding, and its connection structure is similar to that of CN 212579992 U. The disadvantage of this scheme is that it requires an intermediate connecting plate, making the process more complex, and the overall rigidity is poor due to the relatively weak structure of the intermediate connecting plate. Summary of the Invention

[0006] This invention provides a steel-aluminum hybrid door sill beam for electric vehicles that improves safety. It significantly enhances the strength of the door sill beam and reduces the number of sharp FDS rivets, thereby lowering the risk of puncturing the battery pack.

[0007] This utility model solves the above-mentioned technical problems through the following technical solutions. A steel-aluminum hybrid door sill beam for electric vehicles to improve safety includes an outer shell and a reinforcing beam. The reinforcing beam is disposed inside the outer shell, with a gap between the reinforcing beam and the outer shell. The outer shell is formed by two trapezoidal split grooves on the left and right sides, and there are outwardly extending connecting outer plates on both sides of the split grooves. There are connecting inner plates on both sides of the reinforcing beam, and the connecting outer plates clamp the connecting inner plates. The connecting inner plates and the connecting outer plates are fixedly connected by connectors.

[0008] The aforementioned steel-aluminum hybrid door sill beam for electric vehicles, which improves safety, features a self-piercing rivet as the connector. The inner connecting plate has a through hole at its edge, through which the self-piercing rivet passes. Both ends of the self-piercing rivet are welded to the outer connecting plate by resistance welding.

[0009] The aforementioned steel-aluminum hybrid door sill beam for electric vehicles improves safety. The shape of the reinforcing beam matches the internal cavity of the outer shell, and the reinforcing beam is an integral structure formed by extrusion molding.

[0010] The aforementioned steel-aluminum hybrid door sill beam for electric vehicles, designed to improve safety, comprises a shell, a vertical beam, a horizontal beam, and a support beam. The shell has a vertical beam running longitudinally in the middle, and horizontal beams running horizontally on both sides of the vertical beam. The horizontal beams are arranged in parallel, and their two ends are respectively connected to the vertical beam and the inner wall of the shell. The support beam is located on the left side of the vertical beam, and its two ends are respectively connected to the corner of the shell and the vertical beam.

[0011] The aforementioned steel-aluminum hybrid door sill beam for electric vehicles improves safety, wherein the outer shell is made of high-strength steel and the reinforcing beam is made of aluminum alloy.

[0012] Compared with the prior art, this utility model has a double-layer structure of outer shell and reinforcing beam, which greatly enhances the strength of the sill beam; at the same time, since it does not use FDS connection method, it reduces the sharp FDS rivets, which can reduce the risk of sharp structures in the component puncturing the battery pack. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the internal structure of this utility model; Figure 3 This is a structural schematic diagram of the end face of this utility model; Figure 4 yes Figure 3 A magnified view of part A in the image; The markings in the attached diagram represent: 1. Outer shell, 2. Reinforcing beam, 3. Split groove, 4. Connecting outer plate, 5. Connecting inner plate, 6. Self-piercing rivet, 7. Through hole, 8. Shell, 9. Vertical beam, 10. Horizontal beam, 11. Support beam. Detailed Implementation

[0014] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model.

[0015] like Figures 1 to 4 This utility model includes a shell 1 and a reinforcing beam 2. The reinforcing beam 2 is disposed inside the shell 1, with a gap between the reinforcing beam 2 and the shell 1. The shell 1 is formed by two trapezoidal split grooves 3 on the left and right sides, with outwardly extending connecting outer plates 4 on both sides of the split grooves 3. The reinforcing beam 2 has outwardly extending connecting inner plates 5 on both sides. The connecting outer plates 4 clamp the connecting inner plates 5, and the connecting inner plates 5 and the connecting outer plates 4 are fixedly connected by connectors. There are no connectors on the main body of the shell 1 and the reinforcing beam 2; the connection is only made on the connecting inner plates 5 and the connecting outer plates 4, which slows down the manufacturing process. At the same time, the number of sharp FDS rivets on the main body is reduced, avoiding the rivets puncturing the battery pack after impact.

[0016] Furthermore, to reduce the use of sharp parts, the connector employs a self-piercing rivet 6 with flat ends. The inner connecting plate 5 has through holes 7 along its edge, through which the self-piercing rivet 6 passes. Both ends of the self-piercing rivet 6 are welded to the outer connecting plate 4 by resistance welding. Resistance welding fuses the ends of the self-piercing rivet 6 to the outer connecting plate 4, reducing the presence of sharp points and lowering the likelihood of the battery pack being punctured.

[0017] The reinforcing beam 2 has a shape that matches the internal cavity of the outer shell 1. Furthermore, to further enhance the strength of the sill beam, the reinforcing beam 2 is an extruded, one-piece structure. This also simplifies production and improves efficiency. Preferably, the outer shell 1 is made of high-strength steel, and the reinforcing beam 2 is made of aluminum alloy. This ensures overall stability and strength.

[0018] Furthermore, the reinforcing beam 2 includes a shell 8, a vertical beam 9, a horizontal beam 10, and a support beam 11. The vertical beam 9 is longitudinally arranged in the middle of the shell 8, and horizontal beams 10 are arranged on both sides of the vertical beam 9. The horizontal beams 10 are arranged in parallel, and their two ends are respectively connected to the vertical beam 9 and the inner wall of the shell 8. The support beam 11 is located to the left of the vertical beam 9, and its two ends are respectively connected to the corner of the shell 8 and the vertical beam 9. This allows for improved internal support within the shell 8 during extrusion molding, ensuring the supporting strength of the reinforcing beam 2.

[0019] The following is an example: The outer shell 1 is made of ultra-high strength steel with a strength of 1500MPa or higher, which has good resistance to deformation and can be easily welded to the steel environmental parts around the vehicle body; the central reinforcing beam 2 is made of aluminum alloy extruded profile, and a stable collapse energy absorption curve can be obtained by reasonably arranging the cross-sectional reinforcing ribs; the outer shell 1 and the central reinforcing beam 2 are connected by resistance welding with self-piercing rivets, eliminating the central connecting bracket between the outer shell 1 and the reinforcing beam 2, reducing the number of parts and the complexity of the process.

[0020] This invention employs an ultra-high-strength steel outer shell 1 and an aluminum alloy reinforcing beam 2, connected via a self-piercing resistance welding process, resulting in excellent overall rigidity and enhanced strength of the sill beam. During side impacts, this product effectively absorbs energy through crumple zones. For different vehicle models on the same platform, varying thicknesses of the outer shell 1 and reinforcing beam 2 can be used to achieve different combinations of compressive strength and energy absorption levels. External components or the internal reinforcing beam 2 can be modified independently without redeveloping all parts, improving compatibility and reducing product development cycle and cost. This patented steel-aluminum hybrid sill beam improves vehicle performance in side impacts and reduces the risk of battery pack deformation and fire during a collision. Furthermore, the absence of an FDS connection method reduces the use of sharp FDS rivets, further lowering the risk of sharp structures puncturing the battery pack. Depending on the specific needs, this invention can also be used in non-electric vehicles.

[0021] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A steel-aluminum hybrid rocker beam for an electric vehicle that improves safety, characterized by, The device includes an outer shell (1) and a reinforcing beam (2). The reinforcing beam (2) is located inside the outer shell (1). There is a gap between the reinforcing beam (2) and the outer shell (1). The outer shell (1) is formed by two trapezoidal split grooves (3) on the left and right. There are connecting outer plates (4) extending outward on both sides of the split grooves (3). There are connecting inner plates (5) on both sides of the reinforcing beam (2). The connecting outer plates (4) clamp the connecting inner plates (5). The connecting inner plates (5) and the connecting outer plates (4) are fixedly connected by connectors.

2. The steel-aluminum hybrid rocker beam for an electric vehicle with improved safety according to claim 1, wherein The connector is a self-piercing rivet (6), and the inner connecting plate (5) has a through hole (7) on its edge. The self-piercing rivet (6) passes through the through hole (7), and the two ends of the self-piercing rivet (6) are welded together with the outer connecting plate (4) by resistance welding.

3. The steel-aluminum hybrid rocker beam for an electric vehicle with improved safety according to claim 2, wherein The shape of the reinforcing beam (2) matches the internal cavity of the outer shell (1), and the reinforcing beam (2) is an integral structure formed by extrusion molding.

4. The steel-aluminum hybrid rocker beam for an electric vehicle with improved safety according to claim 2, wherein The reinforcing beam (2) includes a shell (8), a vertical beam (9), a horizontal beam (10), and a support beam (11). The shell (8) has a vertical beam (9) longitudinally arranged in the middle, and horizontal beams (10) are arranged on the left and right sides of the vertical beam (9). The horizontal beams (10) are arranged in parallel, and the two ends of the horizontal beams (10) are respectively connected to the vertical beams (9) and the inner wall of the shell (8). The support beam (11) is located on the left side of the vertical beams (9), and the two ends of the support beam (11) are respectively connected to the corner of the shell (8) and the vertical beams (9).

5. The steel-aluminum hybrid rocker beam for an electric vehicle with improved safety according to claim 2, wherein The outer shell (1) is made of high-strength steel, and the reinforcing beam (2) is made of aluminum alloy.

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