Side Sill Tubular Structure for EV Side Collision Protection
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Solution Overview
Problem
Existing vehicle body structures for electric vehicles face challenges in side collision safety due to the risk of bending fracture and lateral fall of reinforcing members, which compromises collision energy absorption and overall side collision performance.
Innovation Solution
A vehicle body structure featuring a hollow side sill with a continuous tubular reinforcing member formed from a series of polygonal closed cross sections, arranged in a single row within the side sill, providing enhanced axial strength and flexibility to absorb collision energy while minimizing the risk of bending fracture and lateral displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing member with a closed cross section is disposed in the side sill to improve strength and collision energy absorbing performance, then the side collision performance is improved, but the reinforcing member is prone to bending fracture and lateral fall when receiving force from the side part
Solution Approach 1:
The patent changes the orientation of the tubular structure from extending in the vehicle front-rear direction (parallel to side sill) to extending in the vehicle width direction (perpendicular to side sill). This dimensional change allows the tubular structure to resist lateral forces more effectively, preventing bending fracture and lateral fall while maintaining collision energy absorption capability.
Solution Approach 2:
The patent creates a composite structure by combining the side sill (first hollow structural body) with the tubular structure (second hollow structural body) at right angles. This composite configuration integrates the strength of both components, allowing the side sill to handle axial loads while the perpendicular tubular structure resists lateral bending and falling forces.
2Ease of manufacture
If the reinforcing member extends in the same direction as the side sill to maintain structural alignment, then the manufacturing is simplified, but the reinforcing member easily falls laterally when colliding with objects such as a pole
Solution Approach 1:
The patent positions the tubular structure to extend in the vehicle width direction, perpendicular to the side sill's front-rear orientation. This crosswise arrangement provides lateral stability against pole collisions while the right-angle connection to the side sill maintains structural integration and manufacturability.
3Use of energy by moving object
If a conventional reinforcing member is used to protect the battery and vehicle compartment, then the collision energy absorption is limited, but the structure may fail to generate sufficient reaction force during side collision
Solution Approach 1:
The patent forms a composite load-bearing system where the side sill and perpendicular tubular structure work together. The tubular structure's orientation perpendicular to the side sill enables it to generate substantial reaction force during side collisions, enhancing overall collision energy absorption and protection of the battery and vehicle compartment.
Data Source
AI summary
A vehicle body structure includes a battery disposed in a lower central part of a vehicle body, a hollow side sill extending in a vehicle front-rear direction and disposed outside the battery in a vehicle width direction, and a reinforcing member configuring at least a part of a continuous tubular structure formed inside the side sill. The continuous tubular structure has a shape in which a plurality of octagons are continuously arranged as viewed from the vehicle width direction.