Vehicle Side Sill Assembly for EV Battery Side-Impact Load Paths
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Solution Overview
Problem
In electric vehicles, the existing side sill assemblies are prone to damaging batteries during side collisions due to uneven load distribution, which increases the risk of battery damage and vehicle weight, affecting power efficiency and manufacturing costs.
Innovation Solution
A side sill assembly that unifies the load path of a side collision load to the upper portion of the side sill, using a reinforcement member positioned between the side sill inner and outer, with a cross-member and connection member aligned to absorb collision energy and prevent battery damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the side sill cross section is reduced to secure battery mounting space, then battery installation is enabled, but stiffness of the side sill is weakened leading to increased battery damage risk in side collision
Solution Approach 1:
The patent employs a composite structure combining side sill inner, side sill outer, and extruded material to achieve both battery mounting space and collision resistance. The composite design allows the side sill to maintain adequate stiffness while providing space for battery installation, resolving the contradiction between volume reduction for mounting and strength maintenance for safety.
Solution Approach 2:
The side sill is divided into multiple segments (side sill inner, side sill outer, extruded material) with distinct functions. The side sill inner provides mounting space, while the extruded material and side sill outer provide structural strength. This segmentation allows simultaneous optimization of both battery mounting space and collision resistance.
2Strength
If extruded material is applied inside the side sill to resist collision load, then collision load resistance is improved, but vehicle body stiffness increases and battery side frame stiffness decreases, increasing vehicle weight
Solution Approach 1:
The extruded material is strategically positioned at specific locations within the side sill structure where collision loads are most severe. This local reinforcement provides maximum collision load resistance with minimum material usage, thereby limiting the increase in vehicle body weight while maintaining adequate battery side frame stiffness.
3Ease of operation
If connection member and cross member are not disposed on the same line, then battery mounting is enabled, but load supported by upper portion of side sill is limited, concentrating load on lower portion and increasing battery damage
Solution Approach 1:
The side sill inner acts as an intermediary element that connects the cross member and battery mounting structure. By positioning the connection member and cross member on the same line through the side sill inner, the structure enables both proper load distribution through the upper portion and adequate battery mounting space, resolving the contradiction between ease of mounting and structural strength.
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
This design effectively absorbs collision loads, reducing battery damage and minimizing the need for excessive vehicle body stiffness, thereby reducing the risk of injury and maintaining power efficiency while controlling manufacturing costs.
Implementation Method 1
an extruded material provided therein is deformed to absorb a collision load
Data Source
AI summary
A side sill assembly for a vehicle includes a side sill inner, a side sill outer connected to an outer side of the vehicle from the side sill inner, and a reinforcement member in an internal space between the side sill inner and the side sill outer. The side sill assembly also includes a floor panel having a side end portion connected to the side sill inner. A cross-member is installed on an upper surface of the floor panel in a longitudinal direction of the vehicle, and a connection member connects the cross-member with the side sill inner. A lower end portion of the reinforcement member is positioned within a predetermined length from an upper end portion of the internal space. The connection member is disposed at the same height as an upper surface of the reinforcement member from the ground of a reference height.