EV Side Sill Reinforcement Structure for Lightweight Crash Absorption
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Solution Overview
Problem
Conventional electric vehicle side part reinforcement structures are heavy due to large sectional areas and volumes, leading to increased vehicle weight and inadequate collision energy absorption.
Innovation Solution
The proposed device includes load-supporting structures such as side sill inner patches and battery mounting pipes that secure the side sill inner reinforcement, preventing sagging and improving collision energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a side sill inner reinforcement with large sectional area and volume is used, then collision energy absorption performance is improved, but vehicle weight increases
Solution Approach 1:
The patent changes the geometric parameters of the side sill inner reinforcement by introducing a hollow cylindrical structure with optimized outer diameter (D1) and inner diameter (D2). This parameter optimization allows the reinforcement to maintain adequate collision energy absorption while significantly reducing material volume and weight compared to solid cross-sections.
Solution Approach 2:
The patent employs a hollow cylindrical structure with optimized wall thickness as a porous-like configuration. The hollow section reduces material usage and weight while the carefully designed wall thickness maintains the structural strength needed for collision energy absorption, effectively creating a lightweight yet strong reinforcement element.
2Weight of moving object
If a side sill inner reinforcement with reduced sectional area and volume is used, then vehicle weight is reduced, but collision energy absorption performance deteriorates
Solution Approach 1:
The patent optimizes the geometric parameters including outer diameter D1, inner diameter D2, and length L1 of the hollow cylindrical reinforcement. By carefully selecting these parameters, the design achieves the minimum required collision energy absorption performance while minimizing weight, thereby resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent utilizes a composite structure combining the hollow cylindrical reinforcement with the side sill inner panel and side sill outer panel. This composite arrangement distributes collision loads effectively throughout the structure, allowing the use of lighter materials and thinner sections while maintaining overall collision energy absorption performance.
3Device complexity
If the side sill inner reinforcement is secured only by a fastening bolt, then device complexity is reduced, but reliability of positioning deteriorates due to sagging
Solution Approach 1:
The patent merges the fastening function with the structural reinforcement function by integrating the hollow cylindrical reinforcement into the side sill inner panel structure. The reinforcement is positioned within a designated space formed by the side sill inner panel and side sill outer panel, and secured through combined welding and fastening methods. This integration ensures reliable positioning and prevents sagging while maintaining relatively simple construction procedures.
Data Source
AI summary
A device for reinforcing a side part of an electric vehicle body, in which load-supporting structures supporting a bottom part of a side sill inner reinforcement may be installed on a side sill inner panel to ensure that the side sill inner reinforcement remains secured in place. As a result of the configuration, weight reduction compared to conventional technology is realized and a collision energy absorption performance following a small overlap collision and a side collision is improved.