Vehicle Side Sill Assembly Reinforcement Stiffness

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Solution Overview

Problem

Eco-friendly vehicles, such as electric and hybrid electric vehicles, face the risk of high-voltage battery damage and fire during side collisions due to insufficient stiffness in the side sill assembly, with existing reinforcement methods either being costly or increasing vehicle weight.

Innovation Solution

A side sill assembly with a reinforcement unit comprising an upper member, a lower member, and an intermediate member, formed from steel, which are bonded together using spot welding and CO2 welding, providing equivalent stiffness to aluminum extruded materials while using a more affordable steel material, thereby enhancing collision resistance and preventing battery damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If aluminum extruded material is used for reinforcement, then weight is reduced, but manufacturing cost increases

Engineering Contradiction:
Improveweight of reinforcement memberVSAvoidmanufacturing cost
Core Design Contradiction:
Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from aluminum to steel and modifies the structural parameters by creating a multi-member reinforcement unit with specific geometric configurations (first, second, and third reinforcement members with varying thicknesses and orientations). This allows achieving the required stiffness with steel while controlling weight through optimized geometry rather than relying solely on material density

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite reinforcement structure by combining multiple steel reinforcement members (first reinforcement member with first thickness, second reinforcement member with second thickness, third reinforcement member with third thickness) into a unified reinforcement unit. This composite approach allows different sections to have different thicknesses optimized for their specific structural roles, achieving overall stiffness equivalence to aluminum while using cost-effective steel material

Inventive Principle:
Principle #40Composite materials

2Ease of manufacture

If steel press structure is used for reinforcement, then manufacturing cost is reduced, but weight increases

Engineering Contradiction:
Improvemanufacturing costVSAvoidweight of reinforcement member
Core Design Contradiction:
Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent optimizes the geometric parameters of the steel reinforcement members, specifically varying the thicknesses (first thickness, second thickness, third thickness) and orientations of different reinforcement members. This parameter optimization allows the steel structure to achieve the required stiffness with minimized material usage, thereby controlling weight while maintaining cost-effectiveness through steel material selection

Inventive Principle:
Principle #35Parameter changes

3Strength

If reinforcement structure is applied to side sill, then stiffness is improved, but weight increases

Engineering Contradiction:
Improvestiffness of side sillVSAvoidweight of side sill assembly
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The patent divides the reinforcement structure into multiple segmented members (first reinforcement member, second reinforcement member, third reinforcement member) with distinct functions and orientations. This segmentation allows each member to efficiently resist specific directional forces, achieving comprehensive stiffness enhancement while minimizing total material usage and weight compared to a solid monolithic reinforcement

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent varies the thickness parameters across different reinforcement members (first thickness, second thickness, third thickness) to optimize the stiffness-to-weight ratio. Thinner sections are used where less structural support is needed, while thicker sections are strategically placed for maximum stiffness efficiency, thereby achieving required overall stiffness with minimized weight

Inventive Principle:
Principle #35Parameter changes

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 side sill assembly achieves the necessary stiffness to prevent high-voltage battery damage and fire in side collisions while maintaining a lightweight structure, improving cost-effectiveness and collision performance.

Implementation Method 1

bonded together using spot welding and CO2 welding

Methodology Applied
Scientific EffectSpot welding: Welding

Implementation Method 2

bonded together using spot welding and CO2 welding

Methodology Applied
Scientific EffectCO2 welding: Welding

Data Source

PatentUS11999412B2Side sill assembly of vehicle with reinforced stiffness
Publication Date: 2024.06.04 HYUNDAI MOTOR CO LTD
  • US11999412B2 patent drawing
  • US11999412B2 patent drawing
  • US11999412B2 patent drawing

AI summary

A side sill assembly of the vehicle includes a side sill inner, a side sill outer, and a reinforcement unit provided between the side sill inner and the side sill outer. The reinforcement unit includes an upper member provided in a longitudinal direction of the vehicle; a lower member provided in the longitudinal direction of the vehicle, and located to be spaced from the upper member under the upper member; and an intermediate member having an upper surface bonded to a bottom portion of the upper member and a lower surface bonded to an upper surface of the lower member alternately formed thereon.