Vehicle Sill Reinforcement Impact Absorption
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Solution Overview
Problem
Existing vehicle exterior panels and frames face challenges in uniformly absorbing side impact forces due to directional and magnitude variations, while also needing to comply with logistical, manufacturing, and cost constraints.
Innovation Solution
A sill reinforcement design featuring alternating steps and walls in elongate members that deform to absorb impact forces, stabilizing the structure and resisting bending, twisting, and crushing, while being compact to fit within packaging constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exterior panels and frames are designed to absorb side impact forces, then impact absorption capability is improved, but structural uniformity deteriorates due to directional and magnitude variations in impact forces
Solution Approach 1:
The sill reinforcement features alternating steps and walls along its length, creating localized variations in structural properties. The steps provide targeted reinforcement at specific locations while the walls maintain overall structural integrity, allowing the structure to adapt to directional impact forces from different directions and magnitudes
Solution Approach 2:
The sill reinforcement is divided into multiple segments including alternating steps and walls rather than being a uniform continuous structure. This segmentation allows different portions to respond differently to impact forces from various directions, improving overall impact absorption while maintaining manufacturability
2Reliability
If sill reinforcement uses alternating steps and walls structure, then impact force distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The sill reinforcement is manufactured as separate components (steps and walls) that are subsequently assembled together. This segmentation allows each component to be manufactured using standard processes, reducing the complexity of manufacturing the intricate alternating pattern while achieving improved impact force distribution through the assembled structure
Solution Approach 2:
The alternating steps and walls create a three-dimensional structure from two-dimensional base components. By adding vertical dimensionality through the step heights and wall thicknesses, the design achieves complex impact distribution characteristics while maintaining relative simplicity in the base manufacturing processes
3Volume of moving object
If sill reinforcement is designed to be compact, then packaging constraints are satisfied, but impact absorption volume is reduced
Solution Approach 1:
The sill reinforcement achieves compactness by utilizing vertical space through alternating steps of varying heights. This three-dimensional configuration allows the structure to maintain effective impact absorption volume while fitting within constrained horizontal packaging spaces, satisfying both compactness requirements and energy absorption demands
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 sill reinforcement effectively absorbs and distributes side impact forces, reducing deformation and potential battery compartment intrusion in electric vehicles, while meeting energy absorption demands and logistical requirements.
Implementation Method 1
During a side impact, the steps and the walls of both the first elongate member and the second elongate member of the sill reinforcement may deform to absorb an impact force F
Implementation Method 2
The sill reinforcement may absorb impact forces F directed from multiple directions
Data Source
AI summary
A vehicle sill reinforcement includes a first elongate member and a second elongate member. Each of the first elongate member and the second elongate member includes steps and walls disposed in alternating arrangement along an axis. The walls of the first elongate member are fixed to the walls of the second elongate member. The steps of the first elongate member and the steps of the second elongate member are aligned along the axis and define cavities therebetween. The steps and walls of the sill reinforcement resist buckling in response to both vertical and horizontal components of impact force applied to the sill reinforcement.