Reinforcement member assembly for side sill of vehicle
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Solution Overview
Problem
Existing reinforcement members for vehicle side sills made of aluminum extrusion materials are expensive, increase manufacturing costs, hinder electrodeposition painting, and reduce bearing capacity against side collisions, particularly in vehicles with batteries, due to their thickness and the need for additional assembly processes.
Innovation Solution
A reinforcement member assembly comprising upper, lower, and internal reinforcement members made of metal plates, connected by welding, which form a structured cross-section to enhance rigidity, support collision loads, and facilitate electrodeposition painting by incorporating through-holes, reducing weight and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement member is made of aluminum extrusion material, then manufacturing cost increases, but collision resistance is improved
Solution Approach 1:
The reinforcement member is divided into multiple segments (first reinforcement member and second reinforcement member) connected by connection portions. This segmentation allows the use of simpler, cheaper materials for each segment while maintaining overall collision resistance through the combined structure, eliminating the need for expensive aluminum extrusion.
Solution Approach 2:
The reinforcement member uses composite construction with different materials for the connection portion and the main body portions. The connection portion uses material compatible with welding to the side sill, while other portions can use cost-effective materials, achieving both collision resistance and reduced manufacturing cost through material optimization.
2Strength
If a reinforcement member is made of aluminum extrusion material, then collision resistance is improved, but assembly process complexity increases
Solution Approach 1:
The reinforcement member is integrated directly with the side sill through welding at the connection portion, merging two components into a unified structure. This eliminates the need for separate brackets and multiple assembly steps (FDS method + welding), reducing assembly process complexity while maintaining collision resistance.
3Strength
If a reinforcement member has thick cross section, then structural strength is improved, but painting quality deteriorates
Solution Approach 1:
The reinforcement member has different thickness characteristics at different locations: the connection portion has sufficient thickness for welding strength, while the main body portions have optimized thickness that provides structural strength but allows adequate gap for electrodeposition painting. This local differentiation resolves the conflict between structural strength and painting quality.
4Strength
If a reinforcement member has thick cross section, then structural strength is improved, but weight increases
Solution Approach 1:
The reinforcement member is segmented into multiple portions with optimized thickness for each function. The connection portion has sufficient thickness for welding, while other portions use thinner walls to reduce weight. This segmentation allows achieving required structural strength with minimum necessary material, reducing overall weight compared to a uniformly thick extrusion.
Solution Approach 2:
The thickness parameter of the reinforcement member is varied along its length and at different locations based on functional requirements. The connection portion maintains greater thickness for strength, while other portions use reduced thickness for weight savings, optimizing the strength-to-weight ratio through parameter optimization.
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 assembly improves rigidity and collision resistance, reduces production costs, ensures uniform painting, and prevents battery damage in side collisions, while maintaining a lightweight design.
Implementation Method 1
connected by welding
Implementation Method 2
electrodeposition painting
Data Source
AI summary
A reinforcement member assembly for a side sill of a vehicle includes an upper reinforcement member formed in a longitudinal direction of the vehicle and provided inside a side sill of the vehicle; a lower reinforcement member positioned below the upper reinforcement member, including one side in a width direction of the vehicle, which is connected to the upper reinforcement member in the longitudinal direction of the vehicle, provided inside the side sill; and internal reinforcement members connected to a bottom surface of the upper reinforcement member and an upper surface of the lower reinforcement member, respectively, which reduces weight of the vehicle and improves strength of the vehicle against a side collision.