Energy absorption element of a vehicle side sill assembly

Abstract

The invention relates to a side sill arrangement for a vehicle, comprising an inner side sill (1), an outer side sill (3), and a reinforcement unit arranged between the inner side sill (1) and the outer side sill (3), wherein the reinforcement unit has an upper cover plate (5) and a lower cover plate (7), wherein the upper cover plate (5) and the lower cover plate (7) are connected to each other at at least one joint (9), and wherein an intermediate element (13) is arranged between the upper cover plate (5) and the lower cover plate (7), wherein the intermediate element (13) is joined to the upper cover plate (5) and the lower cover plate (7) in a longitudinal or transverse direction, and wherein grooves (15) are provided in the cover plates (5, 7) which do not touch the intermediate element (13).

Description

The invention relates to a side sill arrangement for a vehicle, and to a vehicle having such a side sill arrangement.A side sill is a portion of a body, in particular of a passenger car, which extends along a vehicle longitudinal direction below a door entry between a front and a rear wheel arch. Typically, vehicle sills are reinforced by solid extruded aluminum profiles to absorb the forces in a collision and, in the case of a battery electric vehicle, to protect the battery.Various designs of side sills are known in the prior art in order to meet specific requirements with respect to collisions and / or with respect to a connection of a vehicle battery of a battery-electric vehicle.DE 10 2022 124 460 A1 relates in this connection to a method for producing a side sill with a reinforcing profile for a motor vehicle, comprising the steps of: machining a steel sheet by a forming method, folding the steel sheet about its longitudinal axis so that a reinforcing profile with a closed cross section is produced, welding the side edges of the reinforcing profile which are adjacent to one another by the folding, and inserting the reinforcing profile into and fastening it to a hollow side sill.US 2023 / 0339543 A1 relates to a side sill for a vehicle, the side sill being capable of absorbing an impact during a side impact of the vehicle to maximally suppress the degree to which the side sill enters the interior and protect vehicle occupants and batteries. The side sill for a vehicle is configured of: a side sill inner liner; a side sill outer liner coupled to the side sill inner liner; and a first damping member that is disposed between the side sill inner liner and the side sill outer liner and forms a plurality of closed cross sections disposed in the width direction of the side sill. The first damping member includes a main body formed by bending a single plate and at least one partition member connecting both surfaces of the main body. A plurality of beads may be formed on the main body and the partition member.DE 10 2022 100 901 A1 also relates to a side sill assembly of a vehicle with enhanced rigidity, the side sill assembly comprising: an inner side sill, an outer side sill, and a reinforcing unit provided between the inner side sill and the outer side sill, the reinforcing unit comprising: an upper member having a first upper surface and a first lower surface arranged lower than the first upper surface, the first upper surface and the first lower surface being arranged alternately in a longitudinal direction of the vehicle, a lower member having a second upper surface and a second lower surface arranged lower than the second upper surface, the second upper surface and the second lower surface being arranged alternately in the longitudinal direction of the vehicle, an intermediate member between the upper member and the lower member connected to the upper member and the lower member.DE 10 2021 004 342 A1 furthermore relates to a side sill for a vehicle, comprising an outer and inner shell forming a cavity, wherein an energy absorber element is surrounded by a foam in the cavity, wherein the energy absorber element extends in a deformation direction, wherein the three-dimensional energy absorber element is embedded in a foam which is temperature-insensitive up to approximately 200° C., wherein the foam and the energy absorber element form a stable prefabricated hybrid component and the energy absorber element has a variable cross section in the deformation direction and / or a transverse direction extending thereto and the hybrid component is fastened on the foam side to at least one section of the outer and / or inner shell.The use of extruded aluminium profiles for reinforcing side sills is very cost-intensive, and their production is complicated. In addition, the profile of the current aluminum extrusion profiles runs along a floor along a vehicle longitudinal direction, typically described with an x-axis; as a result, the aluminum extrusion profile forms a homogeneous structure along the entire floor, without taking into account softer / harder locations in the floor. Current extruded aluminum profiles are followed by a uniform weight distribution (by homogeneous cross section in the transverse direction and in the vertical direction, typically described with a Y axis or Z axis, respectively), even at locations where this weight / material does not lead to an increase in performance.In addition, the length of the extruded aluminum profile leads to problems in joining technology. Current extruded aluminum profiles are joined to a surrounding (steel) sill with (WES, rivets) or without (clinching). Due to different thermal expansion coefficients of the materials (aluminum and steel), damage to the joining technique can occur in the event of temperature changes, as occur in the case of CTL, in particular a cataphoresis with subsequent passage of the furnace.It is therefore an object of the invention to develop an improved side sill arrangement for a vehicle.The invention results from the features of the independent claims. Advantageous refinements and refinements are the subject matter of the dependent claims.A first aspect of the invention relates to a side sill arrangement for a vehicle, having an inner side sill, an outer side sill, and a reinforcing unit arranged between the inner side sill and the outer side sill, wherein the reinforcing unit has an upper cover plate and a lower cover plate, wherein the upper cover plate and the lower cover plate are connected to one another at at least one joint by welding or bonding, and wherein an intermediate element is arranged between the upper cover plate and the lower cover plate, and wherein beads which do not touch the intermediate element are introduced into the cover plates, and wherein beads of at least two pairs of beads have different spacings and / or have different sizes.The intermediate element is joined to the upper cover plate and the lower cover plate preferably in the longitudinal and / or transverse direction.Advantageously, a side sill arrangement is thus provided which has an increased stiffness compared to conventional side sills. This is achieved by using a reinforcing unit which, however, is not used for connecting the battery even in the case of battery-electric vehicles, but rather serves in its function as an energy absorption element merely for improving the mechanical behavior of a side sill in the event of a collision.The improved mechanical properties, in particular by increasing the mechanical rigidity, are also useful for battery-electric vehicles, which, because of their increasingly high mass, require correspondingly rigid structures, but nevertheless have elements which absorb parasitic impact energy.For this purpose, a reinforcing unit arranged between the inner side sill and the outer side sill is provided. The inner side sill and the outer side sill delimit a cavity running along the longitudinal extension of the side sill arrangement with the inner and outer side sill, within which the reinforcing unit is arranged. This therefore extends over a certain length between two sides of the side sill arrangement according to the invention.For the reinforcing unit, an upper cover plate and a lower cover plate are provided, between which an intermediate element is in turn arranged. The cover sheets are produced in particular by a forming process, such as hot forming or cold forming. In addition, the cover plates are connected to one another in the region of the inner side sill and / or in the region of the outer side sill by a flange, particularly preferably by a welded connection.In addition, the cover plates are connected to the inner side sill and / or the outer side sill, either directly by means of a flange of one or both cover plates or indirectly by means of an additional plate. Particularly preferably, both the upper cover plate is connected to the inner side sill and the outer side sill, and the lower cover plate is connected to the inner side sill and the outer side sill. While at least the upper cover plate and the lower cover plate each run from the inner side sill substantially laterally to the outer side sill, only one joint between the upper cover plate and the lower cover plate can also be connected to the inner side sill or the outer side sill, either directly or by means of a connecting element.The cover plates can thus be used variably and can be joined to the inner side sill or outer side sill by a flange, in particular by adhesive bonding, spot welding, or laser welding. The cover sheets can be produced by cold or hot forming from cost-effective material, such as steel or aluminum. Both ductile steel (preferably cold formed) and high-strength steel (preferably hot formed) or ultra-high-strength steel (cold or hot formed) can be used.The intermediate element is joined to the cover plates at the contact points, preferably by laser welding and / or adhesive bonding. Preferably, the reinforcing unit is additionally not surrounded by a foam-foam, but foam can be used as an intermediate element.The special feature of the cover plates are beads introduced therein, which increase the buckling resistance and thus the energy absorption of the cover plates in the event of a collision of the vehicle with the side sill arrangement. The beads can vary in shape, form, length, width, number, geometry, orientation and arrangement and can be adapted to the field of application. Beads can be inserted locally; spacings and design do not require any regularity. In addition, beads in the upper cover plate and lower cover plate do not have to be arranged in the same phases. Beads may be flat or round. The beads serve only for increased energy absorption (by stiffening, folding, etc.). No bead of one cover plate touches the other cover plate. Such beads are not present in conventional extruded profiles.According to an advantageous embodiment, the upper cover plate and the lower cover plate are each connected to the inner side sill and to the outer side sill by a respective flange.According to a further advantageous embodiment, the connection to the flange is implemented by adhesive bonding and / or welding, in particular spot welding or laser welding.According to a further advantageous embodiment, the reinforcing unit has an angled sheet which is applied to the upper cover sheet or the lower cover sheet by a first angled sheet element and projects from a flat upper side or flat lower side of the attached cover sheet and is connected to the inner side sill or to the outer side sill by a second angled sheet element. The fastening can likewise be effected by means of a console.According to a further advantageous embodiment, the intermediate element is joined to the upper cover plate and the lower cover plate by at least one of: laser welding, spot welding, projection welding, adhesive bonding.According to a further advantageous embodiment, the intermediate element comprises one of the following:roll profiled shaft plate of single or double design;cold-formed or hot-formed corrugated sheet of single design or double design;- honeycomb structure;- tube;- particle foam;The roll-profiled shaft plate of single or double design can also be referred to as a plate with a transverse shaft.The cold / hot formed corrugated sheet of single or double design can also be referred to as a sheet with a longitudinal shaft.According to a further advantageous embodiment, at least one of the beads is designed as a transverse bead. Transverse beads advantageously increase the resistance to buckling of the cover plates. In this case, the beads extend transversely to the direction of extent of the reinforcing unit and therefore also transversely to the extent of the inner and outer side sills. Preferably, all beads are formed from transverse beads.According to a further advantageous embodiment, at least one of the beads is designed as a longitudinal bead. Longitudinal beads force the cover sheets to fold. In contrast to the transverse beads, the longitudinal beads extend in the extension of the inner and outer side sills and thus also along an extension direction of the reinforcing unit. Preferably, all beads introduced into the cover sheets are formed from longitudinal beads.According to a further advantageous embodiment, the at least one joint is formed by means of a welded connection.A further aspect of the invention relates to a vehicle having a side sill arrangement as described above and below.Advantages and preferred refinements of the proposed vehicle result from an analogous and analogous transfer of the explanations given above in connection with the proposed side sill arrangement.Further advantages, features and details are evident from the following description, in which--possibly with reference to the drawing--at least one exemplary embodiment is described in detail. Identical, similar and / or functionally identical parts are provided with the same reference numerals.The following are shown: FIG. 1 : a side sill arrangement in perspective in a cross section according to an embodiment of the invention. FIG. 2 : The side sill arrangement of FIG. 1 in cross section. FIG. 3 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 4 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 5 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 6 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 7 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 8 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 9 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 10 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 11 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 12 : shows a side sill arrangement according to a further exemplary embodiment of the invention. FIG. 13 : a cover plate with a variable bead arrangement according to an exemplary embodiment of the invention. FIG. 14 : a cover plate according to a further exemplary embodiment of the invention. FIG. 15 : a cover plate according to a further exemplary embodiment of the invention.The representations in the figures are schematic and not to scale.FIG. 1 shows a side sill arrangement for a vehicle in perspective with a cross section. In the left half of the figure, an inner side sill 1 is indicated, in the right half of the figure, an outer side sill 3. The side sill extends from a rear wheel arch to a front wheel arch, wherein a section transverse to this extension direction is shown in FIG. 1. Between the inner side sill 1 and the outer side sill 3 a reinforcement unit is introduced which comprises a substantially horizontally inserted upper cover plate 5 and a likewise substantially horizontally inserted lower cover plate 7. The upper cover plate 5 and the lower cover plate 7 are connected to one another at a joint 9 by welding or adhesive bonding. The joint 9 shown in FIG. 1 is also connected to the outer side sill 3 by an adhesive bond or welding. The inner side sill 1 is connected by a respective flange 11 to the respective cover plate 5, 7, again by adhesion or welding. Between the upper cover plate 5 and the lower cover plate 7 there is also arranged an intermediate element 13, in this example in double wave form. The intermediate element 13 is joined to the upper cover plate 5 and the lower cover plate 7 at respective contact points, again preferably by adhesive bonding or welding. In the example of FIG. 1, both the upper cover plate 5 and the lower cover plate 7 have transverse beads 15, which do not touch the intermediate element 13, however. The glued or welded points of contact of the intermediate element 13 with the upper cover plate 5 or the lower cover plate 7 are therefore not located in the region of the beads 15, but in the region of the unsickened material sections of the cover plates 5, 7. an angle plate 17 is part of the reinforcing unit and extends from a surface of the upper cover plate 5 toward the inner side sill 1.FIG. 2 shows the side sill arrangement of FIG. 1 in a pure cross section without perspective. Here, in particular the shape of the intermediate element 13 carried out by double corrugation is visible, which in particular contributes to energy absorption in the event of a collision and stabilizes the cover plate 5, 7, just like the angled plate 17.FIG. 3 shows the core of a further side sill arrangement, wherein the joint 9 between the upper cover plate 5 and the lower cover plate 7 is shown. The beads 15 are provided in a transverse direction, i.e. transversely to the longitudinal extent of the side sill. The intermediate element 13 comprises a double corrugated plate with extension direction in the longitudinal direction.FIG. 4 shows the core of a further side sill arrangement, in which a distance distribution of the beads 15 in the upper cover plate 5 and in the lower cover plate 7 that is variable along the side sill longitudinal direction is provided. Thus, a different reinforcement is achieved by incorporating round beads 15.FIG. 5 shows the core of a further side sill arrangement with an expanding angle between the lower cover plate 7 and the upper cover plate 5, so that the intermediate element 13, designed as a simple shaft, has greater amplitudes in the increasing transverse direction.FIG. 6 shows a further side sill arrangement with an intermediate element 13 which is designed as a double shaft which extends in the longitudinal direction of the side sill. Again, the beads 15 are arranged irregularly on the lower cover plate 7 and on the upper cover plate 5.FIG. 7 shows a further side sill arrangement including the inner side sill 1 and the outer side sill 3.Fig. 8 shows a reinforcing unit of another side sill assembly with variation in the beads 15 extending in the longitudinal direction of the side sill. Further transverse bead sections are introduced into the beads 15.Fig. 9 shows a reinforcing unit of another side sill assembly with variation in the beads 15 extending in the longitudinal direction of the side sill. In this case, further impressions or recesses of the first type are provided in the beads 15.Fig. 10 shows a reinforcing unit of another side sill assembly with variation in the beads 15 extending in the longitudinal direction of the side sill. In this case, further impressions or recesses of a second type are provided in the beads 15.Fig. 11 shows a reinforcing unit of another side sill assembly with variation in the beads 15 extending in the longitudinal direction of the side sill. In this case, further impressions or recesses of a third type are provided in the beads 15.Fig. 12 shows a reinforcing unit of another side sill assembly with variation in the beads 15 extending in the longitudinal direction of the side sill. In this case, further impressions or recesses of a fourth type are provided in the beads 15.FIGS. 13 to 15 show examples of an upper cover plate 5 and / or a lower cover plate 7, on each of which beads 15 are provided with an unevenly distributed arrangement. In FIG. 13, the distance between the beads 15 designed as transverse beads varies. In FIG. 14, the width of the beads 15 designed as transverse beads varies-for example, a widening and a depression of the beads 15 is provided at the height of a seat cross member, since these may absorb more energy in the event of a crash. In FIG. 15, both the widths and the distances of the beads 15 to one another vary.List of reference characters1 Inner side sill 3 Outer side sill 5 Upper cover plate 7 Lower cover plate 9 Joint 11 Flange 13 Intermediate element 15 Beads 17 Angle plate

Claims

Side sill arrangement for a vehicle, having an inner side sill (1), an outer side sill (3), and a reinforcing unit arranged between the inner side sill (1) and the outer side sill (3), wherein the reinforcing unit has an upper cover plate (5) and a lower cover plate (7), wherein the upper cover plate (5) and the lower cover plate (7) are connected to one another at at at least one joint (9) by welding or bonding, and wherein an intermediate element (13) is arranged between the upper cover plate (5) and the lower cover plate (7), and wherein beads (15) which do not touch the intermediate element (13) are introduced into the cover plates (5, 7), and wherein beads (15) of at least two pairs of beads (15) have different spacings and / or have different sizes.Side sill arrangement according to claim 1, wherein the upper cover plate (5) and the lower cover plate (7) are respectively connected to the inner side sill (1) and / or to the outer side sill (3) by a respective flange (11).Side sill arrangement according to one of the preceding claims, wherein the reinforcing unit has an angled sheet (17) which is applied to the upper cover sheet (5) or the lower cover sheet (7) by a first angled sheet element and projects from a flat upper side or flat lower side of the attached cover sheet (5, 7) and is connected to the inner side sill (1) or to the outer side sill (3) by a second angled sheet element.The side sill assembly according to any one of the preceding claims, wherein the intermediate member (13) is joined to the upper cover plate (5) and the lower cover plate (7) by at least one of: laser welding, spot welding, projection welding, adhesion.Side sill arrangement according to any of the preceding claims, wherein the intermediate element (13) comprises one of the following: - roll-profiled corrugated sheet of single or double design; - cold-formed or hot-formed corrugated sheet of single or double design; - honeycomb structure; - pipe; - particulate foam;Side sill arrangement according to one of the preceding claims, wherein at least one of the beads (15) is designed as a transverse bead.Side sill arrangement according to one of the preceding claims, wherein at least one of the beads (15) is formed as a longitudinal bead.Side sill arrangement according to one of the preceding claims, wherein the at least one joint (9) is formed by means of a welded connection.A vehicle having a side sill assembly according to any preceding claim.

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