Vehicle Door Sill Reinforcement with Longitudinal Stop
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Solution Overview
Problem
In electrically operated two-track vehicles, the reinforcement element designed to protect the traction battery from damage in collisions can longitudinally shift during head-on collisions with little lateral overlap, compromising the collision performance due to rupture of connecting points with the door sill.
Innovation Solution
Incorporating a jacking point sheet metal part integrated into the door sill to create a longitudinal clearance space, which acts as a stop to prevent shifting of the reinforcement element, and using sheet metal brackets to secure the reinforcement element rigidly to the door sill, enhancing the collision performance with a simple design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reinforcement element is rigidly secured to the door sill with large material outlay connecting points, then the collision performance is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The connection system is segmented into two functional parts: the longitudinal clearance space that allows controlled movement, and the jacking point sheet metal part that provides stop functionality. This segmentation enables the reinforcement element to move freely during normal operation while being restrained during collisions, avoiding the need for complex rigid connecting points throughout.
Solution Approach 2:
The jacking point sheet metal part acts as an intermediary between the reinforcement element and the door sill structure. It provides the stopping function during collisions without requiring direct rigid connection between the reinforcement element and door sill, simplifying the overall connection design while maintaining collision performance.
2Device complexity
If the reinforcement element is allowed to shift longitudinally, then the device complexity is reduced, but the collision performance deteriorates
Solution Approach 1:
The longitudinal clearance space is pre-configured during manufacturing to provide the exact amount of movement needed before collision. The jacking point sheet metal part is pre-positioned to act as a stop at the appropriate location, ensuring that during actual collision the reinforcement element is already in the correct position to absorb impact effectively.
Solution Approach 2:
The jacking point sheet metal part is designed to counteract the harmful longitudinal shifting of the reinforcement element during collision. By providing a predetermined stop, it prevents the reinforcement element from moving beyond the optimal collision position, thereby maintaining collision performance without requiring complex active control systems.
3Reliability
If large material outlay is used for connecting points, then the reliability of connection is improved, but the manufacturing cost and weight increase
Solution Approach 1:
The stopping function is extracted from the main door sill structure and embodied as a separate, lightweight jacking point sheet metal part. This allows the connection system to provide reliable collision restraint without requiring heavy material throughout the entire connecting structure, reducing overall weight while maintaining connection reliability where needed.
Solution Approach 2:
The connection system applies material and structural reinforcement only where locally needed - specifically at the jacking point sheet metal part that contacts the reinforcement element during collision. The rest of the door sill structure can be optimized for weight reduction, achieving reliable connection without excessive material outlay and weight.
Data Source
AI summary
A body structure for a vehicle has at least one side door sill that is made up of a door sill outer part on the outer side of the vehicle and a door sill inner part on the inner side of the vehicle, in the vehicle transverse direction, which delimit a door sill cavity that extends in the vehicle longitudinal direction between a front closing profile that closes off the door sill cavity in the direction of the front wheel housing, and a rear closing profile that closes off the door sill cavity in the direction of the rear wheel housing, wherein a reinforcement element, designed as an insert part, which extends in the vehicle longitudinal direction and acts as a side collision reinforcement is situated in the door sill cavity, and wherein in the event of a head-on collision the reinforcement element is acted on by a collision force directed toward the rear of the vehicle, in particular with load on at least one connecting point at which the reinforcement element is connected to the door sill. According to the invention, to relieve load on the connecting point, the reinforcement element is spaced apart from the rear closing profile by a longitudinal clearance space. A jacking point sheet metal part extends in the vertical vehicle direction, transversely through the longitudinal clearance space, and, in a head-on collision, the jacking point sheet metal part acts as a longitudinal stop by means of which longitudinal shifting of the reinforcement element is prevented.