Resin Cone-and-Bridge Side Sill Reinforcement for Battery Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle side sills do not adequately protect vehicle batteries from side impacts, and there is a need for improved energy absorption features to manage such impacts effectively.
Innovation Solution
A reinforcement assembly for a vehicle side sill comprising resin-based first and second reinforcement structures with arrayed cones and bridges, designed to absorb and redirect impact energy away from the battery compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional side sill structures are used, then manufacturing simplicity is maintained, but protection of vehicle battery from side impacts is insufficient
Solution Approach 1:
The reinforcement structure is divided into multiple segments including first and second reinforcement structures with multiple cones each. These segments are arranged in arrays along the longitudinal direction and can independently deform during impact, allowing localized energy absorption while maintaining overall structural integrity. The segmentation enables the complex protective function to be achieved through modular, repetitive units.
Solution Approach 2:
The reinforcement structures utilize composite material construction with cones and bridges formed from resilient and rigid materials. The first and second reinforcement structures are made of different materials with varying mechanical properties, creating a composite system that optimizes both energy absorption and structural strength. This composite approach enables enhanced impact protection while managing the complexity through material selection rather than purely geometric complexity.
2Object-affected harmful factors
If energy absorption features are added to protect occupants, then occupant safety is improved, but battery protection from side impacts remains insufficient
Solution Approach 1:
The first and second reinforcement structures are nested within the cavity of the side sill, with cones positioned inside the cavity space. The bridges connect the cones while remaining within the confined cavity volume. This nesting arrangement provides enhanced battery protection by placing multiple reinforcement elements within the existing side sill structure, maximizing protection within available space without requiring external additions that would increase overall complexity.
Solution Approach 2:
The reinforcement structures are strategically positioned and configured to provide localized protection where impact forces are most likely to affect the battery. The cones are arranged in arrays at specific locations within the cavity, and the bridges are designed with specific geometries to redirect forces away from the battery compartment. This local quality approach concentrates protective features where needed rather than uniformly distributing complexity throughout the entire side sill.
3Strength
If multiple reinforcement structures with cones and bridges are implemented, then impact energy absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The reinforcement assembly is segmented into modular units (cones and bridges) that can be manufactured separately and then assembled. Each cone and bridge can be produced as an individual component using standardized processes, allowing for easier manufacturing and quality control. The segmented design enables parallel production of multiple identical units, reducing overall manufacturing complexity despite the presence of multiple reinforcement elements.
Solution Approach 2:
The first and second reinforcement structures are combined within the same cavity space, with their respective cones and bridges integrated to work together as a unified system. The bridges of both structures are positioned to interconnect and share load paths, effectively merging the protective functions of multiple elements into a coordinated system. This merging reduces the need for separate mounting structures and simplifies the overall assembly process.
Data Source
AI summary
A reinforcement assembly for a side sill includes a first reinforcement structure arranged inside a cavity of the side sill and including a plurality of first segments arrayed in a longitudinal direction of the vehicle. Each first segment includes a plurality of first cones arrayed in the longitudinal direction of the vehicle and a plurality of first bridges interconnecting the first cones. A second reinforcement structure is coupled to the first reinforcement structure and is arranged inside the cavity. The second reinforcement structure includes a plurality of second segments arrayed in the longitudinal direction with each second segment including a plurality of second cones arrayed in the longitudinal direction and a plurality of second bridges interconnecting the plurality of second cones. The first cones are arranged facing the second cones and engaged with the second cones. Also, the first reinforcement structure and the second reinforcement structure are made of resin.