EV Side Sill Reinforcement With Variable Wall Thickness for Battery Protection
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Solution Overview
Problem
Existing side sill reinforcement structures for electric vehicles do not efficiently balance battery protection performance with weight reduction and cost optimization, as they lack variation in cross-sectional wall thickness to effectively absorb collision energy.
Innovation Solution
A side sill reinforcement structure using an extruded aluminum alloy member with varying thicknesses in closed cross-sectional portions, where the innermost portions have increased thicknesses to enhance battery protection, and the outermost portions have larger thicknesses to manage deformation load, while maintaining stable extrusion processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cross-sectional wall thickness of the extruded shape material is made uniform throughout, then the manufacturing process is simple and cost-effective, but the battery protection performance cannot be optimized while maintaining weight reduction
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the extruded reinforcing member at different locations. Specifically, the wall thickness is increased at the innermost side in the vehicle width direction (closer to the battery) and decreased at the outermost side. This allows the structure to provide enhanced protection where needed (near the battery) while maintaining weight efficiency and manufacturability through the extrusion process.
2Reliability
If the wall thickness is increased throughout the reinforcing member to improve battery protection, then collision safety performance improves, but the weight of the component increases
Solution Approach 1:
The patent implements local quality by strategically increasing wall thickness only at specific critical locations (the innermost side near the battery) rather than uniformly throughout the entire reinforcing member. This localized thickening provides enhanced collision safety and battery protection where it is most needed, while keeping the overall component weight lower compared to a uniform thick-walled design.
3Reliability
If the wall thickness is varied to optimize battery protection, then protection performance improves, but the extrusion processing becomes less stable
Solution Approach 1:
The patent applies parameter changes by systematically varying the wall thickness parameter along the length of the extruded reinforcing member. The thickness transitions from greater at the innermost side to smaller at the outermost side. This controlled parameter variation optimizes battery protection performance while maintaining extrusion processing stability through gradual transitions that avoid abrupt geometric changes.
Data Source
AI summary
A side sill reinforcement structure includes a battery unit for drive, a side sill extending in a vehicle front-rear direction on an outer side in a vehicle width direction of the battery unit, and a reinforcing member that connects the battery unit and the side sill. The reinforcing member includes a closed cross-sectional portion group having a first closed cross-sectional portion disposed on the innermost side in the vehicle width direction and a second closed cross-sectional portion disposed adjacent to the first closed cross-sectional portion. The first closed cross-sectional portion includes a first upper wall and a first lower wall. The second closed cross-sectional portion includes a second upper wall and a second lower wall. The thickness of the first upper wall is larger than the thickness of the second upper wall, and the thickness of the first lower wall is larger than the thickness of the second lower wall.