Vehicle Side Sill Structure for Lightweight Crash Energy Absorption
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Solution Overview
Problem
Existing side sills for eco-friendly vehicles, such as electric vehicles, face challenges in efficiently absorbing collision energy and achieving weight reduction while ensuring passenger and battery safety by minimizing indoor inflow during collisions.
Innovation Solution
A side sill design featuring a first and second side sill frame, with first and second reinforcing frames forming concavo-convex portions continuously in the longitudinal direction, enhancing energy absorption and mechanical rigidity without increasing material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum extrusion material is used for side sill, then weight is reduced, but collision energy absorption performance is insufficient
Solution Approach 1:
The side sill structure combines aluminum extrusion material with steel reinforcing frames to create a composite structure. The aluminum profile provides lightweight base structure while the steel reinforcing frames embedded within the hollow portions provide enhanced strength and collision energy absorption performance, resolving the contradiction between weight reduction and strength improvement.
Solution Approach 2:
The side sill is divided into multiple segments including the aluminum profile and multiple steel reinforcing frames (first reinforcing frame, second reinforcing frame, etc.) positioned at different locations. This segmentation allows each component to be optimized independently - the aluminum for weight savings and the steel frames for strength - while working together as an integrated structure.
2Volume of moving object
If side space is reduced to accommodate batteries, then vehicle width is optimized, but collision energy absorption capacity is compromised
Solution Approach 1:
The reinforcing frames are strategically positioned at specific locations within the hollow portions of the aluminum profile where collision forces are most likely to occur. This local reinforcement approach provides enhanced strength exactly where needed without increasing the overall side space, allowing the battery compartment to maintain its compact dimensions while achieving superior collision energy absorption capacity.
3Strength
If reinforcing frames are added to aluminum profile, then collision energy absorption is improved, but structural complexity increases
Solution Approach 1:
The steel reinforcing frames are nested within the hollow portions of the aluminum extrusion profile. This nesting arrangement allows the reinforcing frames to be integrated into the existing aluminum structure without requiring additional external space or complex assembly procedures. The reinforcing frames are positioned inside the hollow sections, utilizing the existing structural voids to reduce overall complexity.
Data Source
AI summary
The present disclosure provides a side sill for a vehicle comprising: a first side sill frame; a second side sill frame coupled to the first side sill frame to form a hollow portion together with the first side sill frame; a first reinforcing frame disposed in the hollow portion and having one side bonded to the first side sill frame to form a first closed cross-section; and a second reinforcing frame disposed in the hollow portion and having one side bonded to the first reinforcing frame to form a second closed cross-section, wherein the first reinforcing frame and the second reinforcing frame include a concavo-convex portion that is continuously formed along the longitudinal direction of the vehicle.