Vehicle Side Sill Structure Using Battery Mounting Pipe

Solution Overview

Problem

The existing side sill structures for vehicles face challenges in efficiently and cost-effectively mounting side sill reinforcements due to the use of dissimilar materials like steel and aluminum, which require expensive equipment and labor-intensive mechanical joining methods, leading to increased weight and manufacturing costs.

Innovation Solution

A side sill structure that eliminates the need for brackets and welding by using a battery mounting pipe to join the side sill reinforcement, where the pipe includes a deformable portion that bulges under axial load to securely fasten the reinforcement within the side sill, allowing for riveting and bolt fastening without the need for additional support structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If brackets and welding are used to join side sill reinforcement to side sill, then the side sill reinforcement can be firmly mounted, but the weight and manufacturing cost increase

Engineering Contradiction:

Improvemounting firmnessVSAvoidside sill assembly weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The battery mounting pipe is integrated directly into the side sill reinforcement as a unified structure, eliminating the need for separate brackets. The pipe serves dual functions: mounting the battery and reinforcing the side sill, thereby reducing component count and overall weight while maintaining structural integrity and mounting firmness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery mounting pipe performs multiple functions simultaneously: it acts as a structural reinforcement for the side sill, a mounting fixture for the battery assembly, and a load-bearing element. This multi-functionality eliminates the need for dedicated brackets, reducing weight and manufacturing complexity while ensuring firm mounting.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If brackets and welding are used to join side sill reinforcement to side sill, then the side sill reinforcement can be firmly mounted, but the manufacturing cost increases

Engineering Contradiction:

Improvemounting firmnessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The battery mounting pipe is integrated directly into the side sill reinforcement as a unified structure, eliminating the need for separate brackets. The pipe serves dual functions: mounting the battery and reinforcing the side sill, thereby reducing component count and overall weight while maintaining structural integrity and mounting firmness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery mounting pipe performs multiple functions simultaneously: it acts as a structural reinforcement for the side sill, a mounting fixture for the battery assembly, and a load-bearing element. This multi-functionality eliminates the need for dedicated brackets, reducing weight and manufacturing complexity while ensuring firm mounting.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If mechanical joining using bolts and nuts is used, then steel and aluminum can be joined, but a relatively large amount of man hours is required

Engineering Contradiction:

Improvematerial joining capabilityVSAvoidassembly speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The battery mounting pipe performs multiple functions simultaneously: it acts as a structural reinforcement for the side sill, a mounting fixture for the battery assembly, and a load-bearing element. This multi-functionality eliminates the need for dedicated brackets, reducing weight and manufacturing complexity while ensuring firm mounting.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The battery mounting pipe and side sill reinforcement are both made of aluminum alloy, creating a homogeneous material system. This eliminates the need for dissimilar material joining techniques like FDS or SPR, allowing the use of simpler, more cost-effective aluminum-to-aluminum joining methods such as riveting or self-tapping screws, thereby significantly reducing equipment costs.

Inventive Principle:

Principle #33Homogeneity

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 solution reduces manufacturing costs and weight while ensuring secure mounting of the side sill reinforcement, enhancing the structural integrity and impact performance of the vehicle by uniformly distributing loads through the side sill structure.

Implementation Method 1

the cylindrical portion may include a deformable portion and an upper portion located above the deformable portion... As the deformable portion is expanded or bulged outwards by an axial load which is applied in an axial direction of the battery mounting pipe

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentUS11420681B2Side sill structure for vehicle

Publication Date: 2022.08.23 HYUNDAI MOTOR CO LTD

AI summary

A side sill structure for a vehicle includes: a side sill having a cavity; a side sill reinforcement which is received in the cavity of the side sill; and a battery mounting pipe which is joined to the side sill reinforcement, wherein the side sill reinforcement is joined to the side sill as a mounting bolt is fastened to the battery mounting pipe.