Vehicle Side Sill Cushioning Structure for Controlled Lateral Crush
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Solution Overview
Problem
Conventional side sills in vehicles are fragile and poorly equipped to absorb lateral collision energy, leading to significant deformation and increased risk of injury to occupants and damage to internal components like batteries during lateral collisions.
Innovation Solution
Incorporating a side sill design with a first cushioning member featuring a main body formed by bending a single plate and partition members, along with beads, to create closed cross-sections that absorb impact energy through self-deformation and improved stiffness, thereby minimizing the side sill's intrusion into the vehicle interior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the side sill structure is simplified, then manufacturing cost and complexity are reduced, but the ability to absorb lateral collision energy deteriorates
Solution Approach 1:
The side sill is divided into multiple closed cross-sections arranged along the longitudinal direction, with each cross-section containing partition members that segment the internal space. This segmentation allows the structure to absorb collision energy through progressive deformation of individual sections while maintaining overall structural integrity, resolving the contradiction between simplicity and energy absorption capability.
Solution Approach 2:
The side sill employs a composite structure combining the outer skin panels with internal cushioning members featuring closed cross-sections and partition members. This composite design integrates multiple functional elements (structural support, energy absorption, crashworthiness) into a unified system that achieves high collision energy absorption without proportionally increasing manufacturing complexity.
2Strength
If reinforcing members are added inside the side sill, then structural strength is improved, but the side sill becomes more fragile under lateral collision stress
Solution Approach 1:
The cushioning members are designed with specific geometric parameters including closed cross-sections and partition members that change the structural response to lateral forces. These parameter optimizations allow the side sill to maintain strength while achieving controlled deformation characteristics that prevent catastrophic failure during lateral collisions.
Solution Approach 2:
The side sill structure incorporates dynamic deformation characteristics through its cushioning members with closed cross-sections. During lateral collision, these members are designed to deform in a controlled manner, transitioning from rigid strength-providing elements to energy-absorbing deformable structures, thereby maintaining reliability under collision stress.
3Strength
If the side sill structure is strengthened to prevent deformation, then occupant protection is improved, but the side sill enters the interior more during collision
Solution Approach 1:
The cushioning members with closed cross-sections and partition members are designed to convert the harmful collision energy into beneficial controlled deformation. The structure is optimized to deform in a predetermined manner during lateral collision, absorbing energy while limiting intrusion into the vehicle interior, thereby transforming the potential harm of deformation into a protective mechanism.
Solution Approach 2:
The side sill incorporates pre-designed cushioning members with closed cross-sections and partition members that are positioned and configured to provide ahead-of-time energy absorption capability. These members are designed to engage and deform during lateral collision, providing predetermined cushioning action that prevents excessive intrusion into the interior before the collision force can cause harmful deformation.
4Reliability
If cushioning members with closed cross-sections are added, then impact energy absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The cushioning members are segmented into multiple closed cross-sections with partition members that divide the internal space. This segmentation enables the structure to absorb impact energy through progressive collapse of individual sections, achieving high energy absorption capability while maintaining a modular structure that can be manufactured using standardized processes.
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 enhanced side sill design effectively absorbs impact energy, reducing the degree of intrusion during lateral collisions and providing superior protection for occupants and batteries by inducing stable crush deformation and increasing support stiffness.
Implementation Method 1
absorb an impact during the lateral collision of the vehicle through the self-deformation and support stiffness of the cushioning member
Implementation Method 2
absorb an impact during the lateral collision of the vehicle
Data Source
AI summary
The present disclosure relates to a side sill for a vehicle, wherein the side sill is capable of absorbing an impact during lateral collision of the vehicle to maximally suppress the degree to which the side sill enters the interior, and protecting vehicle occupants and batteries. The side sill for a vehicle comprises: a side sill inner panel; a side sill outer panel coupled to the side sill inner panel; and a first cushioning member disposed between the side sill inner panel and the side sill outer panel and constituting a plurality of closed cross-sections arranged in the width direction of the side sill. The first cushioning member includes a main body formed by bending a single plate, and at least one partition member connecting both surfaces of the main body. A plurality of beads may be formed on the main body and the partition member.