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
Engineering Contradiction Analysis
1Weight of moving object
If aluminum extruded material is used for reinforcement, then weight is reduced, but manufacturing cost increases
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
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
2Ease of manufacture
If steel press structure is used for reinforcement, then manufacturing cost is reduced, but weight increases
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
3Strength
If reinforcement structure is applied to side sill, then stiffness is improved, but weight increases
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
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
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
Implementation Method 2
bonded together using spot welding and CO2 welding
Data Source
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.


