Integrated Side Sill Liner Tabs for Chassis Rigidity
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Solution Overview
Problem
Existing chassis reinforcements for motor vehicles, particularly at the running gear mounting interfaces, increase complexity, mass, and cost due to additional structural elements, compromising passive safety and economic viability.
Innovation Solution
A side member liner with integrated support tabs, formed from a thin metal sheet, that reinforces the side member by covering its upper face and attaching via support lugs, facilitating assembly and load distribution without significantly increasing mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional reinforcements are added at the running gear interfaces on the side members, then the rigidity and passive safety are improved, but the device complexity, mass, and manufacturing cost increase
Solution Approach 1:
The reinforcement is divided into two separate support lugs (first support lug near the rear edge, second support lug near the front edge) rather than using a single complex reinforcement structure. This segmentation allows for simpler manufacturing and assembly while achieving the required rigidity distribution at critical mounting points.
Solution Approach 2:
The liner provides localized reinforcement only at the specific areas where running gear interfaces are mounted, rather than reinforcing the entire side member uniformly. The support lugs are positioned precisely at the rear and front edges to provide strength exactly where needed for suspension mounting, reducing overall material usage and complexity.
2Strength
If additional reinforcements are added at the running gear interfaces on the side members, then the rigidity and passive safety are improved, but the mass increases
Solution Approach 1:
The reinforcement structure is segmented into two discrete support lugs rather than a continuous heavy reinforcement, allowing material to be placed only where structurally necessary for running gear mounting, thus reducing overall mass while maintaining required rigidity.
Solution Approach 2:
The liner implements local reinforcement at the support lug positions corresponding to running gear interface locations, providing high rigidity only where needed for safety-critical mounting points, rather than adding mass throughout the entire side member structure.
3Strength
If additional reinforcements are added at the running gear interfaces on the side members, then the rigidity and passive safety are improved, but the manufacturing cost increases
Solution Approach 1:
The reinforcement is segmented into two simple support lugs that can be manufactured as separate components and attached to the liner, simplifying the manufacturing process compared to creating a single complex integrated reinforcement structure, thereby reducing manufacturing cost while maintaining rigidity.
Solution Approach 2:
The liner provides localized reinforcement at specific support lug positions rather than requiring a complex overall structure, allowing for simpler manufacturing processes and lower material costs while achieving the necessary rigidity for running gear interface reinforcement.
4Ease of operation
If a side member liner with integrated support tabs is used, then the assembly process is simplified, but the manufacturing complexity of the liner itself increases
Solution Approach 1:
The support lugs are integrated directly into the liner as a single unified component rather than being separate parts that require additional fastening hardware or complex assembly steps. This merging of the support lugs with the liner body simplifies the overall assembly process while the liner itself is manufactured as an integrated piece with built-in support structures.
Data Source
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Figure 3
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AI summary
The invention relates to a side member liner (1) for a motor vehicle, the liner (1) being configured to be integrated into a side member in order to reinforce an upper face of the side member and thus increase its rigidity. The liner (1) comprises a main face (11) configured to extend vertically along the upper face of the side member, and a first support tab (12) configured to be affixed to the upper face of the side member. The first support tab (12) extends from the main face (11) through an opening (13) provided on said main face (11), near a rear edge (111) of the main face (11). According to the invention, the first support tab (12) is formed by a section of the main face (11) of the liner (1) cut and shaped to form said first support tab (12).