Vehicle Sill Structure With U-Shaped Reinforcement for Side-Impact Loads

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Solution Overview

Problem

Existing sill structures for vehicles are not cost-effective to manufacture and assemble, and they do not effectively absorb the forces required for future safety standards, particularly in lateral collisions.

Innovation Solution

A sill structure comprising a hollow body made of two steel sheet shells with a U-shaped reinforcing element connected to the inner surface of one shell and spaced from the other, allowing for efficient force transmission and assembly simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If existing sill structures are used, then structural stability is provided, but manufacturing cost increases and assembly becomes complex

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing cost and assembly simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The sill structure is divided into a hollow body and a separate U-shaped reinforcing element that can be produced independently and then assembled together, simplifying manufacturing while maintaining structural stability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The structure combines steel sheet shells with a reinforcing element made of high-strength steel or aluminum alloy, creating a composite structure that achieves high strength with simplified manufacturing processes

Inventive Principle:

Principle #40Composite materials

2Strength

If existing sill structures are used, then basic protection is provided, but force absorption capability is insufficient for future safety standards

Engineering Contradiction:

Improveforce absorption capabilityVSAvoidsafety performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The U-shaped reinforcing element features curved geometries that optimize force distribution and absorption during lateral collisions, enhancing safety performance through shape-driven mechanical behavior

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The reinforcing element utilizes materials with changed parameters (high-strength steel or aluminum alloy) that provide superior force absorption capabilities compared to conventional materials, meeting future safety standards

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If the reinforcing element is connected to both shells, then structural stability improves, but assembly complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The connection to the second shell is extracted/removed, leaving only the connection to the first shell. This simplifies assembly while the U-shape and strategic positioning maintain sufficient structural stability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The hollow body's own structural design and the U-shaped reinforcing element's geometry work together to provide stability without requiring complex dual-sided connections, allowing the structure to serve itself

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20260042485A1Integrally reinforced sill structure for a vehicle, and vehicle

Publication Date: 2026.02.12 AUDI AG

AI summary

A sill structure for a vehicle, including a hollow body, which extends in an x-direction of the vehicle as intended and is made of a first steel sheet shell and a second steel sheet shell, and a U-shaped reinforcing element arranged in the hollow body and extending continuously in the x-direction over a length of the hollow body, which reinforcing element is connected to an inner surface of the first steel sheet shell, as well as to a vehicle comprising a sill structure.