Side Sill Reinforcement Pipe for EV Battery Mounting
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Solution Overview
Problem
Conventional electric vehicle underbodies require additional mounting units and increased weight, limiting battery pack installation space and safety during side collisions due to inadequate support of the battery pack by the side sill and battery cross member.
Innovation Solution
A reinforcement unit for the side sill featuring a reinforcement pipe member between the side sill inner and outer panels, with a connection apparatus including fixing brackets, pipe nuts, and engaging bolts, which absorbs and scatters impact loads, ensuring impact safety and improved battery pack installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional mounting units and battery cross members are used to support the battery pack, then the battery pack can be mounted to the lower portion of the center floor panel, but the number of parts and assembling processes increases, causing an increase in vehicle body weight
Solution Approach 1:
The side sill is designed to integrate multiple functions: it serves as both the mounting structure for the battery pack and the lateral impact protection structure. The battery pack is directly mounted to the side sill, eliminating the need for separate mounting units and battery cross members, thereby reducing part count and vehicle weight while maintaining support reliability
Solution Approach 2:
The side sill is designed as a multi-functional component that simultaneously provides battery pack mounting support and lateral impact protection. This universal structure eliminates the need for dedicated mounting brackets and cross members, reducing overall vehicle weight while maintaining both mounting and safety functions
2Reliability
If additional mounting units and battery cross members are used, then the battery pack can be mounted, but the number of parts increases, leading to increased assembling processes and manufacturing complexity
Solution Approach 1:
The side sill integrates the mounting function directly into its structure, eliminating the need for separate mounting units and battery cross members. This consolidation reduces the number of parts and simplifies the assembling process while maintaining reliable battery pack support
Solution Approach 2:
The side sill serves as a multi-functional component that provides both battery pack mounting and lateral impact protection. This universal design eliminates the need for dedicated mounting brackets and cross members, significantly reducing part count and assembly complexity
3Device complexity
If the battery pack is simply supported by the lower portion of the center floor panel through the side sill and battery cross member, then the structure is simple, but when a side collision occurs, safety and durability with respect to impact load cannot be sufficiently assured
Solution Approach 1:
The side sill combines the simple support function with enhanced impact protection capabilities. By integrating the mounting structure directly into the side sill with reinforced geometry, it maintains structural simplicity while providing sufficient safety and durability against lateral impact loads
4Reliability
If space is allocated for mounting units and gaps for noise suppression, then the battery pack can be installed, but alignment of the battery panel cannot be freely designed and increase of battery pack capacity is limited
Solution Approach 1:
The side sill serves as a universal mounting structure that provides flexible alignment capabilities and supports battery pack installation without requiring dedicated mounting units or noise suppression gaps. This multi-functional design enables free alignment of the battery panel and allows for future capacity expansion
Data Source
AI summary
A reinforcement unit of a side sill for an electric vehicle is disclosed. The side sill includes side sill inner panels and side sill outer panels that are respectively provided under opposite ends of a center floor panel. The reinforcement unit includes a reinforcement pipe member provided between the side sill inner panel and the side sill outer panel along a length direction of a vehicle body, and a connection apparatus comprising a plurality of fixing brackets and a plurality of pipe nuts. The connection apparatus fixes the reinforcement pipe member to the side sill inner panel.