Side Sill Structure Plastic Resin Reinforcement Load Transfer
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Solution Overview
Problem
Conventional side sill structures face challenges in achieving sufficient rigidity due to inadequate load transfer between reinforcement members and plate members, particularly in side impacts, and require additional heating processes that complicate manufacturing.
Innovation Solution
A side sill structure featuring a plate member and a reinforcement made of plastic resin, where the reinforcement is disposed outside the plate member and bonded to the side sill, with projecting portions on the reinforcement fitting into receiving portions on the plate member, eliminating the need for extra heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bonding is performed in the hollow closed section of the side sill, then the structure can be compact and integrated, but heat transfer to the bonded portion becomes insufficient, compromising adhesive hardening
Solution Approach 1:
A heat conductive member is introduced as an intermediary between the reinforcement member and the side sill inner wall. This mediator facilitates efficient heat transfer from the external heating source to the bonded portion located in the hollow closed section, enabling adhesive hardening without compromising the compact integrated structure
Solution Approach 2:
The thermal conductivity parameter is enhanced at the bonded portion by introducing the heat conductive member. This local parameter change allows sufficient heat accumulation at the bonding interface despite the hollow closed section geometry, enabling proper adhesive curing
2Strength
If additional heating process is applied to ensure adhesive hardening, then bonding strength is improved, but manufacturing process complexity increases
Solution Approach 1:
The heat conductive member serves as a mediator that concentrates and directs heat efficiently to the bonded portion during the adhesive curing process. This enables reliable bonding strength achievement while using a simpler, more controlled heating approach rather than complex multi-zone heating systems
Solution Approach 2:
The heat conductive member is placed specifically at the bonded portion where heat is most needed. This local quality enhancement ensures adequate adhesive hardening without requiring uniform heating of the entire side sill structure, simplifying the overall manufacturing process
3Volume of moving object
If reinforcement members are positioned in the hollow closed section, then space utilization is optimized, but load transfer effectiveness during side impact is reduced
Solution Approach 1:
The heat conductive member acts as a structural intermediary that not only facilitates heat transfer but also serves as a load transfer path during side impact. It connects the reinforcement member to the side sill inner wall, ensuring effective force transmission while maintaining the compact hollow closed section configuration
Solution Approach 2:
The side sill structure employs composite construction with the heat conductive member having high thermal conductivity and the reinforcement member made of plastic resin. This composite approach enables both thermal management for adhesive curing and mechanical load transfer during impact, while optimizing space utilization
Data Source
AI summary
A side sill structure includes a side sill extending in a front-rear direction of a vehicle on an outer side in a vehicle width direction of the vehicle, a plate member configured to divide at least a part of a cross-section of the side sill in the vehicle width direction, and a reinforcement made of plastic resin, the reinforcement being disposed outside the plate member in the vehicle width direction and bonded to the side sill. At least one of the reinforcement and the plate member has a plurality of projecting portions, and the other one of the reinforcement and the plate member has a plurality of receiving portions into which the projecting portions are inserted.