Side Sill Reinforcement Structure for EV Side Collision Energy Absorption
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Solution Overview
Problem
Existing vehicle body structures for electric vehicles face challenges in maintaining side collision safety performance due to reinforcement members prone to bending and breaking, which reduces collision energy absorption and increases the risk of damage to the vehicle cabin and battery during side collisions.
Innovation Solution
A vehicle body structure featuring a hollow side sill with a reinforcement member having a continuous cylindrical structure and a deformation control member that restricts deformation in the longitudinal direction, maintaining the shape of the reinforcement member and enhancing reaction force, thereby improving collision energy absorption and side collision safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement member with a closed cross section is disposed inside the side sill and extends in the same direction as the side sill, then the side collision safety performance is improved, but the reinforcement member is prone to bending and breaking under tensile stress in the longitudinal direction
Solution Approach 1:
The reinforcement member is divided into multiple segments along its longitudinal direction, with each segment capable of independent deformation. This segmentation allows the reinforcement member to absorb collision energy through controlled deformation of individual segments rather than experiencing catastrophic bending or breaking of the entire structure.
Solution Approach 2:
The reinforcement member is designed with dynamic deformation characteristics, allowing it to change shape in a controlled manner during collision. The structure transitions from a rigid configuration to a dynamically deforming one, enabling energy absorption while maintaining overall structural integrity and preventing catastrophic failure.
2Loss of energy
If the reinforcement member is disposed inside the side sill, then the collision energy absorption performance is improved, but the reinforcement member is prone to fall on either side when the vehicle body side collides with an object
Solution Approach 1:
The reinforcement member is pre-configured with deformation control mechanisms and positioning structures that prepare it for collision events. These preliminary arrangements ensure that during actual collision, the reinforcement member deforms in a controlled manner and maintains proper positioning, preventing it from falling to either side while effectively absorbing collision energy.
Solution Approach 2:
Deformation control members are introduced as intermediary elements between the reinforcement member and the side sill. These intermediaries control the deformation behavior of the reinforcement member and prevent it from falling sideways, while still allowing effective collision energy absorption through controlled deformation.
3Strength
If the reinforcement member is designed to be strong against axial load, then the side collision safety is improved, but the structure becomes more complex and difficult to manufacture
Solution Approach 1:
The reinforcement member utilizes parameter changes in its cross-sectional geometry along the longitudinal direction, with variations in wall thickness, cross-sectional area, and shape characteristics. These parameter changes enable the structure to achieve high axial load resistance while maintaining manufacturability through standardized production techniques for varying geometric parameters.
Data Source
AI summary
A vehicle body structure includes: a battery disposed at a vehicle body central lower portion, i.e., at a central lower portion of the vehicle body; a side sill of a hollow shape, the side sill disposed at an outer side of the battery in a vehicle width direction and extending in a vehicle longitudinal direction; a reinforcement member disposed inside the side sill, having a closed cross section of a polygonal shape, and having a continuous cylindrical structure where a plurality of the closed cross sections are continuous when viewed in the vehicle width direction; and a deformation control member attached to the reinforcement member and configured to control a deformation of the continuous cylindrical structure of the reinforcement member in the vehicle longitudinal direction.