Double-C Sill Panel Welding Direction for Crash Safety
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Solution Overview
Problem
Current motor vehicle body designs face challenges in enhancing crash safety and dynamic travel properties while maintaining driver comfort and reducing background noise.
Innovation Solution
The motor vehicle body features a double-C-shaped sill panel construction with overlapping C-profile flanges connected to an inner longitudinal carrier, allowing for Z-direction welding of the floor panel, which increases load absorption and rigidity, and includes reinforced connection profiles and support carriers to improve load path and vibration reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the floor panel is welded to the longitudinal carrier in the Y direction, then the connection is established, but the welding locations are subjected to shearing loads and cannot absorb sufficient load
Solution Approach 1:
The patent changes the welding direction from the Y direction (longitudinal) to the Z direction (vertical). By orienting the welding locations perpendicular to the floor panel flange, the connection transforms the load-bearing mechanism from shear-dominated to normal-force-dominated, thereby doubling the load absorption capacity while maintaining manufacturing feasibility through standard welding processes.
2Strength
If the sill panel uses a single C-profile construction, then the structure is simple, but the rigidity and crash safety are insufficient
Solution Approach 1:
The patent employs a composite construction consisting of an inner C-profile and an outer C-profile with overlapping flanges. This composite structure combines two C-profiles to create a double-C-shaped sill panel that achieves superior rigidity and crash safety compared to a single C-profile, while the overlapping design allows for integrated welding to the longitudinal carrier, balancing complexity with performance.
3Strength
If the body rigidity is increased to improve crash safety, then the passenger compartment protection is enhanced, but the background noise and driver comfort are adversely affected
Solution Approach 1:
The patent applies local reinforcement specifically to the sill panels through the double-C-profile construction with overlapping flanges. This localized strengthening of critical load-bearing regions enhances overall body rigidity and crash safety without requiring a complete reinforcement of the entire body structure, thereby minimizing the transmission of vibrations and noise to the passenger compartment while maintaining driver comfort.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances crash safety, reduces vibrations, improves travel dynamics, and increases the overall rigidity of the body, leading to better passenger compartment protection and comfort.
Implementation Method 1
wherein a welding is a particularly preferred embodiment of this connection
Data Source
AI summary
A motor vehicle has a body with a front section, a floor structure which adjoins the front section, and a floor panel, on the two longitudinal sides of which a sill is in each case arranged. The sills run from an A pillar, adjoining the front section, of the body as far as a C pillar of the body. An inner longitudinal member is on each longitudinal side of the floor panel. A bulkhead is arranged between the front section and the floor structure. Each sill is constructed from an inner C profile and an outer C profile. The first and second profile flanges of the C profiles, arranged in an overlapping manner, are connected, in particular welded, to the inner longitudinal member.