Sill assembly with half-shell profiles, hollow profile and reinforcing element for a motor vehicle, method for producing such a sill assembly and motor vehicle with such a sill assembly

Abstract

The invention relates to a sill assembly (10) for a motor vehicle (200) comprising an elongated hollow profile (12) made of a first metal; at least one reinforcing element (14) made of a plastic arranged in the hollow profile (12); and two interconnected half-shell profiles (16a, 16i) made of a second metal; wherein the hollow profile (12) with the reinforcing element (14) is received within a profile chamber (18) formed by the half-shell profiles (16a, 16i) and is supported on the half-shell profiles (16a, 16i) and / or connected to them by means of a support assembly, in particular a plurality of support elements (20a, 20b, 20c, 20d). Furthermore, a method for producing such a sill assembly (10) and a motor vehicle (200) comprising such a sill assembly (10) are described.

Description

[0001] The invention relates to a sill assembly for a motor vehicle, comprising an elongated hollow profile made of a first metal and at least one reinforcing element made of a plastic arranged in the hollow profile. Furthermore, the invention relates to a method for producing a sill assembly and a motor vehicle having such a sill assembly.

[0002] Such a threshold arrangement is known, for example, from DE 10 2022 113 527 A1. Reference is also made to DE 10 2020000 052 A1, DE 2015 207 376 A1, and DE 10 2021 118 423 A1.

[0003] A sill assembly, also known as a side sill, or rocker panel, is the lower lateral body section of a motor vehicle that extends between a front wheel arch and a rear wheel arch. Such a sill is usually designed as an assembly comprising several components (sill assembly). The sill has an essential protective function in the event of an accident, particularly a side impact. In particular, the crash behavior and crash characteristics of the sill assembly are crucial for the crash management of a motor vehicle. This applies in particular to at least partially electrically powered motor vehicles with a battery system located in the body floor, which is protected by the sills.

[0004] The object underlying the invention is to provide a sill arrangement with improved properties which can be produced simply and inexpensively.

[0005] This object is achieved by a sill assembly, a method, and a motor vehicle having the features of the respective independent patent claims. Advantageous embodiments with useful further developments are specified in the dependent patent claims.

[0006] The invention relates to a sill arrangement for a motor vehicle comprising an elongated hollow profile made of a first metal; at least one reinforcing element made of a plastic arranged in the hollow profile; two interconnected half-shell profiles made of a second metal; wherein the hollow profile with the reinforcing element is received within a profile chamber formed by the half-shell profiles and is supported on the half-shell profiles and / or connected to them by means of a support arrangement, in particular a plurality of support elements.

[0007] This provides a multi-part sill assembly made of different materials, in which optimal crash behavior is achieved through the design of the half-shell profiles, the hollow profile accommodated therein, and the at least one reinforcement element. Such a sill assembly forms a type of metal-plastic hybrid sill, optimized both in terms of stability and weight savings.

[0008] In the sill arrangement, the reinforcing element can have a honeycomb-shaped structure, wherein the longitudinal axis of the honeycombs is oriented in the width direction of the motor vehicle and wherein, in the reinforcing element, the honeycomb ends located on the inside on the vehicle side with respect to the mounted position are at least partially closed, in particular the honeycomb openings are closed like a wall.

[0009] The reinforcing element can be connected to the hollow profile in the area of ​​the closed honeycomb ends, in particular by fastening elements that protrude from the outside through the hollow profile into the closed honeycomb ends. The fastening elements can be flow-hole forming screws.

[0010] This allows the reinforcement element to be positioned at any desired location along the entire length of the hollow profile and to be fastened from the outside without having to arrange elements inside the hollow profile to hold the reinforcement element in position.

[0011] In the sill arrangement, the hollow profile can have a cross-section with multiple chambers, wherein at least one of the chambers accommodates the at least one reinforcement element. In particular, reinforcement elements can be arranged in one or more chambers facing a vehicle interior and secured therein from the outside.

[0012] In the sill assembly, the first metal can be aluminum or steel, with the hollow profile being an extruded aluminum profile or a roll-bonded steel profile, and the second metal can be steel, with the half-shell profiles being made of sheet steel. This allows for an optimal material selection with regard to stability and weight, with the half-shell profiles being made of harder sheet steel, while the hollow profile can be made of less hard but lighter aluminum.

[0013] A method for producing a sill arrangement as described above is also proposed, the method comprising the following steps: Providing a hollow profile; Providing at least one reinforcing element made of a plastic material produced by an extrusion process; Providing two half-shell profiles; Inserting the at least one reinforcing element into the hollow profile, in particular from a first end relative to the longitudinal direction of the hollow profile; Fastening the reinforcing element arranged in the hollow profile by means of fastening elements attached to the hollow profile from the outside, in particular flow-hole forming screws; Arranging the hollow profile using support elements between the two half-shell profiles; Closing the half-shell profiles and connecting the half-shell profiles together.

[0014] In the method, before or during the insertion of the at least one reinforcing element from the first end of the hollow profile, a stop element movable relative to the hollow profile can be inserted from a second end of the hollow profile, so that the reinforcing element and the stop element come into contact with each other. In other words, the stop element can be inserted into the hollow profile up to a target position, so that the reinforcing element can be inserted into the hollow profile only up to the stop element and can be connected to the hollow profile from the outside by means of the fastening element at this position.

[0015] In this method, the stop element can be removed from the hollow profile after the reinforcement element has been secured in the hollow profile. In other words, the stop element can be designed to be reversible, such as a hydraulically, pneumatically, or electromechanically driven tool that can be repeatedly inserted into the hollow profiles being produced.

[0016] Furthermore, a motor vehicle with at least one sill arrangement described above is also proposed.

[0017] Further advantages and details of the invention will become apparent from the following description of embodiments with reference to the figures. Fig. 1 a simplified and schematic sectional view of a sill arrangement; Fig. 2 a simplified and schematic sectional view of another example of a hollow profile; Fig. 3 a simplified and schematic representation of a method for producing a sill assembly.

[0018] In Fig. 1 shows a simplified and schematic sectional view of a sill assembly 10 for a motor vehicle 200, illustrated here only as a dashed rectangle. With respect to the sectional plane, which is formed by the width direction Y and the height direction Z with respect to the motor vehicle 200, an outer side AU of the motor vehicle 200 is located on the right, and an inner side IN of the motor vehicle 200 is located on the left.

[0019] The sill assembly 10 comprises an elongated hollow profile 12 made of a first metal. At least one reinforcing element 14 made of a plastic is arranged in the hollow profile 12. Furthermore, the sill assembly 10 has two interconnected half-shell profiles 16a, 16i made of a second metal. The two half-shell profiles 16a, 16i can also be referred to as the inner half-shell profile 16 and the outer half-shell profile 16.

[0020] In the sill arrangement 10, the hollow profile 12 with the reinforcing element 14 is received within a profile chamber 18 formed by the half-shell profiles 16a, 16i and is supported on the half-shell profiles 16a, 16i by means of a support arrangement, in particular by means of several support elements 20a, 20b, 20c, which are shown here only in simplified form, and / or is connected to these.

[0021] The reinforcement element 14 has a honeycomb structure, with the longitudinal axis LW of the honeycombs 14w oriented in the width direction Y of the motor vehicle 200. In the reinforcement element 14, the honeycomb ends 14e located on the inside of the vehicle, relative to the installed position, are at least partially closed. In particular, the honeycomb ends 14e are closed in a wall-like manner or by means of an end wall 22.

[0022] The reinforcement element 14 is connected to the hollow profile 12 in the region of the closed honeycomb ends 14e. The connection is or will be established in particular by fastening elements 24 that protrude from the outside through the hollow profile 12 into the closed honeycomb ends 14e or the end wall 22. The fastening elements 24 can be, for example, flow-hole-forming screws. In other words, the fastening elements 24 are connected from the outside to the reinforcement element 14, in particular its end wall 20, through a side wall 12s of the hollow profile 12, which is located on the inside when mounted on the motor vehicle 200.

[0023] In the example shown the Fig. 1, the hollow profile 12 is shown with only one chamber 12k. It is pointed out that the hollow profile 12 can also have a cross-section with several chambers 12k, 12i, 12j, as shown in simplified form in Fig. 2. In the example shown, the Fig. 2, respective reinforcing elements 14 are accommodated in the two chambers 12k, 12j.

[0024] In the described sill assembly 10, the first metal can be aluminum or steel, with the hollow profile 12 being an extruded aluminum profile or a roll-bonded steel profile. The second metal can be steel, with the half-shell profiles 16a, 16i being made of sheet steel.

[0025] In Fig. 3 shows a simplified and schematic representation of a method 500 for producing a sill assembly 10 described above.

[0026] The method 500 comprises, in particular, the following steps. In a step S501, a hollow profile 12 is provided. In a step S502, at least one reinforcing element 14 made of a plastic material and produced by an extrusion process is provided. In a step S503, two half-shell profiles 16i, 16a are provided.

[0027] According to a step S504, the at least one reinforcing element 14 is inserted into the hollow profile 12, in particular from a first end E1 relative to the longitudinal direction of the hollow profile 12. The insertion of the reinforcing element 14 is in Fig. 3 illustrated by a double arrow.

[0028] According to a step S505, the reinforcing element 14 arranged in the hollow profile 12 is fastened by fastening elements 24, in particular flow-hole forming screws, attached to the hollow profile 12 from the outside.

[0029] According to a step S506, the hollow profile 12 is arranged by means of support elements 20a, 20b, 20c, 20d between the two half-shell profiles 16a, 16i

[0030] Finally, in a step S507, the half-shell profiles 16a, 16i are closed and the half-shell profiles 16a, 16i are connected to one another.

[0031] Optionally, in the method 500, before or during the insertion (S504) of the at least one reinforcing element 14 from the first end E1 of the hollow profile 12, a stop element 30 movable relative to the hollow profile 12 can be introduced from a second end E2 of the hollow profile 12, which is illustrated by a step S504a, so that the reinforcing element 14 and the stop element 30 come into contact with each other.

[0032] The fastening of the reinforcing element 14 to the hollow profile 12 according to step S505 can take place as long as the stop element 30 is in contact with the reinforcing element 14.

[0033] According to a step S505a, the stop element 30 can be removed from the hollow profile 12 after the reinforcing element 14 has been fastened in the hollow profile 12 (S505). QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 113 527 A1

[0002] DE 10 2020000 052 A1

[0002] DE 2015 207 376 A1

[0002] DE 10 2021 118 423 A1

[0002]

Claims

[1] Sill assembly (10) for a motor vehicle (200) having an elongated hollow profile (12) made of a first metal; at least one reinforcing element (14) made of a plastic arranged in the hollow profile (12); two interconnected half-shell profiles (16a, 16i) made of a second metal; wherein the hollow profile (12) with the reinforcing element (14) is received within a profile chamber (18) formed by the half-shell profiles (16a, 16i) and is supported on the half-shell profiles (16a, 16i) by means of a support arrangement, in particular a plurality of support elements (20a, 20b, 20c, 20d) and / or is connected to the half-shell profiles. [2] Sill arrangement (10) according to claim 1, characterized byin that the reinforcing element (14) has a honeycomb-shaped structure, wherein the longitudinal axis (LW) of the honeycombs (14w) is oriented in the width direction (Y) of the motor vehicle (200) and wherein in the reinforcing element (14) the honeycomb ends (14e) lying on the inside on the vehicle side with respect to the mounted position are at least partially closed, in particular the honeycomb openings are closed like a wall. [3] Sill arrangement (10) according to claim 2, characterized by that the reinforcing element (14) is connected to the hollow profile (12) in the region of the closed honeycomb ends (14e), in particular by fastening elements (24) which project from the outside through the hollow profile (12) into the closed honeycomb ends (14e). [4] Sill arrangement (10) according to claim 3, characterized by that the fastening elements (24) are flow hole forming screws. [5] Sill arrangement (10) according to one of the preceding claims, characterized bythat the hollow profile (12) has a cross-section with a plurality of chambers (12k, 12i, 12j), wherein the at least one reinforcing element (14) is accommodated in at least one of the chambers (12k, 12j). [6] Sill arrangement (10) according to one of the preceding claims, characterized by that the first metal is aluminum or steel, wherein the hollow profile (12) is an extruded profile made of aluminum or a roll-bonded profile made of steel, and that the second metal is steel, wherein the half-shell profiles (16a, 16i) are made of a steel sheet. [7] Method (500) for producing a sill assembly (10) according to one of the preceding claims, wherein the method (500) comprises the following steps: Providing (S501) a hollow profile (12); Providing (S502) at least one reinforcing element (14) made of a plastic material and produced by an extrusion process; Providing (S503) two half-shell profiles (16a, 16i); Inserting (S504) the at least one reinforcing element (14) into the hollow profile (12), in particular from a first end (E1) relative to the longitudinal direction of the hollow profile (12); Fastening (S505) the reinforcing element (14) arranged in the hollow profile (12) by means of fastening elements (24), in particular flow-hole forming screws, attached to the hollow profile (12) from the outside; Arranging (S506) the hollow profile (12) by means of support elements (20a, 20b, 20c, 20d) between the two half-shell profiles (16a, 16i); Closing (S507) the half-shell profiles (16a, 16i) and connecting the half-shell profiles (16a, 16i) to each other. [8] Method (500) according to claim 7, wherein before or during the insertion (S504) of the at least one reinforcing element (14) from the first end (E1) of the hollow profile (12), a stop element (30) movable relative to the hollow profile (12) is introduced (S504a) from a second end (E2) of the hollow profile (12) so that the reinforcing element (14) and the stop element (30) come into contact with each other. [9] Method (500) according to claim 8, wherein the stop element (30) is removed from the hollow profile (12) (S505a) after the reinforcing element (14) has been fastened in the hollow profile (12) (S505). [10] Motor vehicle (200) with at least one sill arrangement (10) according to one of claims 1 to 6.

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