Vehicle Side Sill Corner Reinforcement for Battery Crash Protection
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Solution Overview
Problem
Existing vehicle bodywork support structures fail to achieve optimal crash behavior, particularly in side impacts, which can lead to inadequate protection of energy stores such as batteries or fuel tanks.
Innovation Solution
A bodywork support structure featuring two side sills with hollow spaces containing separately formed reinforcing elements, specifically corner reinforcements, which are strategically positioned to displace inwards and downwards during a side impact, creating an additional load path that protects the energy store.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side sill is reinforced broadly and excessively, then the structural strength is improved, but the displacement of the reinforcing element during impact is hindered
Solution Approach 1:
The side sill is reinforced only in specific local areas (corner regions) rather than uniformly throughout. The reinforcing elements are strategically positioned at corners where strength is most needed, while leaving other areas with reduced reinforcement to allow for controlled deformation and energy absorption during impact.
Solution Approach 2:
The reinforcing elements are designed to be movable rather than fixed, allowing them to displace inward and downward during a side impact. This dynamic behavior enables the reinforcement to transition from a static strength-providing component to an active energy-absorbing element that moves with the deformation of the side sill.
2Stability of the object's composition
If the reinforcing element is attached to the upper flange, then the structural stability is improved, but the crash behavior and energy absorption are worsened
Solution Approach 1:
The reinforcing element is deliberately separated from attachment to the upper flange, extracting it from the load path that would otherwise transmit impact forces directly to the energy store. This separation allows the reinforcing element to move independently during impact, absorbing energy through displacement rather than rigidly transferring loads.
3Manufacturing precision
If the corner reinforcement is positioned close to the internal wall, then the manufacturing precision is improved, but the energy absorption capability is worsened
Solution Approach 1:
The corner reinforcement is positioned to create a controlled deformation zone that prevents excessive intrusion into the passenger compartment. By strategically placing the reinforcement at a specific distance from the internal wall, the design anticipates the deformation path during impact and guides it in a way that absorbs energy while maintaining safety margins.
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
The described bodywork support structure enhances crash behavior by effectively absorbing and redirecting impact energy, thereby protecting the energy store from excessive loads and ensuring its safety during side impacts.
Implementation Method 1
in the case of a crash, as described in more detail below, the corner reinforcement can be shifted or lowered downwards in the vertical direction of the vehicle (z direction) to the level of a fastening flange of the energy store, in particular of the housing or of the support frame
Implementation Method 2
The described bodywork support structure enhances crash behavior by effectively absorbing and redirecting impact energy, thereby protecting the energy store from excessive loads
Data Source
AI summary
A bodywork support structure for a vehicle includes two side sills that are spaced apart in a transverse direction where the two side sills have a reinforcing element that is disposed in a hollow space. A floor is disposed between the two side sills and connected to the two side sills and an energy store for storing electrical energy and/or a fuel for powering the vehicle is disposed under the floor. The reinforcing element is formed as a corner reinforcement disposed in a corner area where the corner reinforcement has a first connection area that is attached to an external wall, a second connection area that is attached to a lower flange, and a wall area that connects the first and second connection areas with each other across the corner. An open space is formed between the corner reinforcement and an internal wall in the transverse direction of the vehicle.