Side Sill Structure with Rearward Outer Reinforcement for Small Overlap Crash Absorption
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Solution Overview
Problem
Current vehicle side sill structures are ineffective in absorbing the load applied during a small overlap crash, as the weak portions overlap with brake calipers, leading to inadequate deformation and potential damage.
Innovation Solution
A side sill structure with a closed cross-sectional design, featuring a side sill outer panel and inner panel, reinforced with an outer shoulder reinforcement positioned rearward from the front ends of both panels, creating a crush area to absorb the load and reduce deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the front end of the side sill is positioned at the rear of and spaced apart from the front tire-wheel unit, then the side sill can avoid interference with brake calipers during normal operation, but the side sill cannot effectively absorb load during small overlap crashes
Solution Approach 1:
The side sill is divided into distinct functional zones: a reinforced section with outer reinforcement for load-bearing, and a non-reinforced front end section serving as a crush area for energy absorption. This segmentation allows different portions of the same component to perform conflicting functions simultaneously.
Solution Approach 2:
The side sill structure implements varying levels of reinforcement at different locations. The outer reinforcement is strategically positioned to provide strength where needed while leaving the front end section weaker and more deformable, creating localized differences in mechanical properties to achieve both reliability and crash absorption.
2Strength
If the side sill is reinforced to prevent deformation, then structural integrity is improved, but the ability to absorb crash load through controlled deformation is reduced
Solution Approach 1:
The side sill is segmented into reinforced and non-reinforced sections, allowing the structure to exhibit different mechanical behaviors in different regions during crash events. The reinforced section maintains integrity while the non-reinforced section deforms to absorb energy.
Solution Approach 2:
The design intentionally creates a weak point (non-reinforced front end) that is meant to deform during crash events to absorb energy, converting what would normally be a structural deficiency into a beneficial energy absorption mechanism. The harmful effect of deformation is redirected to a controlled location.
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 structure effectively absorbs the load from a small overlap crash by differentiating non-crush and crush areas, reducing the load on the side sill and minimizing deformation, while maintaining the integrity of the front pillar and side sill.
Implementation Method 1
the portion that does not include the outer reinforcement acts as the crush area to absorb the load applied from the outer side of the wheel
Data Source
AI summary
A side sill outer panel and a side sill inner panel form a closed cross-sectional structure. A front end of a side sill is located at a rear of and spaced apart from a front tire-wheel unit on a front side of a vehicle. The side sill extends rearward. A front end portion of an outer reinforcement is located rearward from front end portions of both the side sill outer panel and the side sill inner panel.