Electric vehicle with reinforced sill

Abstract

The invention relates to a vehicle with a reinforced sill (10), wherein the sill (10) comprises a profile (1) with a closed cross-section and the profile (1) has a profile wall facing the inside (1.1) and a profile wall facing the outside (1.2) of the vehicle, and the profile (1) is reinforced with at least one corrugated reinforcement (2) in the y-axis of the vehicle, wherein the corrugations of the corrugated reinforcement (2) extend in the x-axis of the vehicle and the vertical extent of the corrugations of the corrugated reinforcement (2) extends in the z-axis of the vehicle, wherein the corrugated reinforcement (2) does not extend completely between the profile walls (1.1, 1.2) in the y-axis of the vehicle, so that in the plane (E) of the corrugated reinforcement (2) within the cross-section of the profile (1) towards the profile wall of the inside (1.1) there is a clearance (F) which has an extent (D) in the y-axis of the vehicle which is at least 15% of the distance (1.3) between the profile walls (1.1, 1.2).

Description

[0001] The invention relates to an electric vehicle reinforced sill, wherein the sill comprises a profile with a closed cross-section and the profile has a profile wall to the inside and a profile wall to the outside of the vehicle and the profile is reinforced with at least one wave-shaped reinforcement in the y-axis of the vehicle, wherein the waves of the wave-shaped reinforcement extend in the x-axis of the vehicle and the height extension of the waves of the wave-shaped reinforcement extends in the z-axis of the vehicle.

[0002] Under high local lateral loads, such as in a side pole impact, and with a small permissible deformation range to protect occupants or vehicle components, reinforcement must be flexurally rigid and distribute the local forces to the underlying support structure. The loads on the support structure, such as the seat crossbeams arranged along the y-axis of the vehicle, must not be too high to prevent its collapse. Known solutions with corrugated transverse structures meet the requirement of high flexural rigidity (see, for example, German patent applications JP 2008-100548 A and DE 10 2005 044 820 A1), but they place local loads on the support structure. Further prior art is cited in the publications DE 10 2018 219 489 B3, DE 10 2013 004 852 A1, DE 10 2021 006 094 A1 and DE 10 2009 015 655 A1.

[0003] With the increasing achievable range of electric vehicles and the associated use of correspondingly large batteries, which are required to power the electric motors, these are also in most cases mounted in the floor area between the sills of the vehicle.

[0004] The object of the invention is therefore to provide an electric vehicle with a reinforced sill which can absorb the crash loads in the event of a side pole impact without substantially overloading the support structure arranged behind the sill.

[0005] The problem is solved using the features of claim 1.

[0006] In order to achieve a uniform distribution of crash loads in the event of a side pole impact and without substantially overloading the support structure locally, the wave-shaped reinforcement does not extend completely between the profile walls on the inside and outside in the y-axis of the vehicle, so that in the plane of the wave-shaped reinforcement within the cross-section of the profile towards the profile wall on the inside there is a free space which has an extension in the y-axis of the vehicle which is at least 35% of the distance between the profile walls on the inside and outside.

[0007] In other words, since the wave-shaped reinforcement does not extend across the entire width of the sill profile cross-section of the W, a free space is created on the side facing away from the load, which acts as a deformation space and thus, in the event of a side pole impact crash, the very difficult-to-deform and stiff wave-shaped reinforcement can move into the free space without locally intruding into the supporting structure behind it.

[0008] The sill, located on the left and right sides of the vehicle, runs along the x-axis between the two axles below the door(s), essentially in the plane of the vehicle floor, and is generally designed as a profile with a closed cross-section. The sill can consist of one, but is usually composed of several, smaller profile sections.

[0009] The extent of the available clearance in the y-axis of the vehicle can preferably be at least 40% or at least 45%, more preferably at least 50% or at least 55% of the distance between the profile walls to the inside and to the outside. Conversely, this means that with an increase in clearance, the dimensions and thus the extent of the wave-shaped reinforcement in the y-axis of the vehicle can be reduced.

[0010] Depending on the design of the wave-like reinforcement, the periodicity of the (multiple) waves running along the x-axis of the vehicle can be increased or decreased. The height of the waves along the z-axis of the vehicle can also be increased or decreased as required.

[0011] The wave-shaped reinforcement in the x-axis, y-axis and / or z-axis of the vehicle can also be designed variably, so that, for example, in the area of ​​the arranged B-pillar, or also called (B-) pillar base, a different, for example higher, resistance compared to the other areas along the x-axis of the vehicle can be adjusted via the shape / dimensioning of the waves.

[0012] The wave-shaped reinforcement can, but does not necessarily have to, completely fill the cross-section of the sill profile along the vehicle's z-axis. Thus, the wave-shaped reinforcement can only occupy a portion of the sill profile's cross-section along the vehicle's z-axis, whereby the arrangement along the z-axis can be designed to suit the load or be optimized, for example, by means of simulation.

[0013] The corrugated reinforcement is arranged on the profile wall facing the outside of the vehicle and is preferably connected to it. The extent of the corrugated reinforcement along the y-axis of the vehicle is a maximum of 85%, in particular a maximum of 80% or a maximum of 75%, preferably a maximum of 70% or a maximum of 65%, more preferably a maximum of 60% or a maximum of 55%, and more preferably a maximum of 50% or a maximum of 45% of the distance between the profile walls.

[0014] In its simplest form, corrugated reinforcement is a sheet of metal. Viewed in cross-section, the (multiple) corrugations can, in the simplest form, exhibit a sinusoidal shape. Alternatively, rectangular or trapezoidal shapes are also possible. Other shapes or combinations thereof are also possible.

[0015] According to one embodiment, at least two wave-shaped reinforcements can be arranged one above the other along the z-axis of the vehicle to increase resistance to intrusion. The two wave-shaped reinforcements can be spaced a defined distance apart along the z-axis of the vehicle or be bonded together. The two wave-shaped reinforcements can be identical, essentially as a single component, or they can have different wave periods and / or heights.

[0016] The invention is explained in more detail with reference to the following exemplary embodiments in conjunction with the drawing.

[0017] In the Fig. 1 and Fig. Figure 2 shows exemplary embodiments of the invention in schematic representations, wherein the left-hand representations show schematic sections through reinforced sills (10) in the y-axis of a vehicle (not shown) and the right-hand representations show the sections which are symbolically indicated in the left-hand representations.

[0018] The vehicle not shown is an electric vehicle.

[0019] The reinforced sill (10) of the vehicle (not shown) comprises a profile (1) with a closed cross-section. The cross-sectional shape can be customized, particularly manufacturer-specific, and may have a simple or complex geometry. In these exemplary embodiments, the cross-section is simple and shown as a profile (1) with a rectangular closed cross-section. The profile (1) has a profile wall facing the inside (1.1) of the vehicle (not shown), which is preferably oriented adjacent to the passenger compartment, and a profile wall facing the outside (1.2) of the vehicle (not shown).On the passenger compartment side, support structures (20) are present, in particular seat crossbeams (not shown) for receiving vehicle seats (not shown) or structures comprising, for example, battery boxes (not shown) for receiving accumulators (not shown) for operating electric motors (not shown) in electric vehicles. Within the closed cross-section, the profile (1) is reinforced with at least one corrugated reinforcement (2) along the y-axis of the vehicle. The corrugations of the corrugated reinforcement (2) extend along the x-axis of the vehicle, and the vertical extent of the corrugations of the corrugated reinforcement (2) extends along the z-axis of the vehicle.To substantially avoid local overloads resulting from a crash load caused by a side pole impact on the support structure (20) located behind the sill (10), the corrugated reinforcement (2) does not extend completely along the y-axis of the vehicle between the profile walls on the inside (1.1) and the outside (1.2), so that a clearance (F) exists in the plane (E) of the corrugated reinforcement (2) within the cross-section of the profile (1) towards the profile wall of the inside (1.1), which has an extent (D) along the y-axis of the vehicle that is at least 35% of the distance (1.3) between the profile walls on the inside (1.1) and the outside (1.2). The existing clearance (F) with a defined extent (D) in the plane (E) orThe y-axis of the vehicle acts as a deformation zone and allows a defined intrusion of the wave-shaped reinforcement (2) in the case of the crash load during a side pole impact, without locally loading the support structure (20).

[0020] The difference between the exemplary embodiments in the Fig. 1 and Fig. 2 consists in the fact that in Fig. 1 only a wave-shaped reinforcement (2) the profile (1) or the sill (10) reinforced and in Fig. 2 Two wave-shaped reinforcements (2) arranged one above the other in the z-axis of the vehicle are provided, which are preferably connected to each other. The preferably connection can be material-locking, force-locking and / or form-locking.

[0021] In the exemplary embodiment, the waves of the corrugated reinforcement (2) are trapezoidal in cross-section. Other wave shapes are also conceivable. The periodicity and / or the height extent of the waves along the x-axis of the vehicle can also vary (not shown here).

[0022] In the Fig. 3 and Fig. Figure 4 shows the condition after a lateral pole impact, determined using a simulation. The conditions and the technical design were identical in both simulations, except that in Fig. 3 a simulated crash result with a wave-shaped reinforcement (2) which completely filled the cross-section of the sill profile in the y-axis of the vehicle, and in Fig. 4 a simulated crash result with a wave-shaped reinforcement (2) which does not completely fill the cross-section of the profile (1) of the sill (10) in the y-axis of the vehicle and extends between the profile walls to the inside (1.1) and to the outside (1.2), such that in the plane (E) of the wave-shaped reinforcement (2) within the cross-section of the profile (1) towards the profile wall of the inside (1.1) there is a free space (F) which has an extent (D) in the y-axis of the vehicle which is at least 35% of the distance (1.3) between the profile walls to the inside (1.1) and to the outside (1.2).

[0023] It is easy to see that the one in the Fig. 4. The created or existing free space (F) allows the wave-shaped reinforcement (2) to "deviate" without locally overloading the support structure (20) located behind the sill (10) or even touching it in this design. Fig.3, however, an intrusion and thus a local load on the supporting structure (20) cannot be avoided.

Claims

[1] Electric vehicle with reinforced sill (10), wherein the sill (10) comprises a profile (1) with a closed cross-section and the profile (1) has a profile wall facing inwards (1.1) and an outer profile wall facing outwards (1.2) of the vehicle and the profile (1) is reinforced with at least one corrugated reinforcement (2) in the y-axis of the vehicle, wherein the corrugations of the corrugated reinforcement (2) extend in the x-axis of the vehicle and the height extension of the corrugations of the corrugated reinforcement (2) extends in the z-axis of the vehicle, characterized by, that the wave-shaped reinforcement (2) does not extend completely in the y-axis of the vehicle between the profile walls to the inside (1.1) and to the outside (1.2), so that in the plane (E) of the wave-shaped reinforcement (2) within the cross-section of the profile (1) towards the profile wall of the inside (1.1) there is a free space (F) which has an extent (D) in the y-axis of the vehicle which is at least 35% of the distance (1.3) between the profile walls to the inside (1.1) and to the outside (1.2). [2] Electric vehicle according to claim 1, wherein the available free space (F) in the y-axis is at least 45% of the distance (1.3) between the profile walls to the inside (1.1) and to the outside (1.2). [3] Electric vehicle according to one of the aforementioned claims, wherein the available free space (F) in the y-axis is at least 55% of the distance (1.3) between the profile walls to the inside (1.1) and to the outside (1.2). [4] Electric vehicle according to one of the preceding claims, wherein the wave-shaped reinforcement (2) is arranged on the profile wall towards the outside (1.2) of the vehicle. [5] Electric vehicle according to claim 4, wherein the wave-shaped reinforcement (2) is connected to the profile wall to the outside (1.2) of the vehicle. [6] Electric vehicle according to one of the preceding claims, wherein at least two wave-shaped reinforcements are arranged one above the other in the z-axis of the vehicle. [7] Electric vehicle according to claim 6, wherein the two wave-shaped reinforcements are connected to each other.

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