Vehicle Underbody Side Sill Integration for Weight Reduction

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Solution Overview

Problem

The existing vehicle underbody structure is heavy and costly due to an excessive number of parts and reinforcing members, which complicates achieving sufficient strength while attempting to reduce weight.

Innovation Solution

A simplified vehicle underbody structure design featuring a side sill that protrudes upward to connect with the center pillar, a single cross member on the floor panel, and a seat mounting member that surrounds the cross member to support the seat, with a curved region for enhanced strength and load distribution, and additional reinforcing members for improved collision resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple cross members and reinforcing members are installed to achieve sufficient strength, then the strength is improved, but the weight and cost increase due to excessive number of parts

Engineering Contradiction:

Improveunderbody strengthVSAvoidunderbody weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent merges multiple structural functions into a single integrated side sill component. The side sill combines the functions of a cross member, reinforcing member, and seat mounting structure into one piece, eliminating the need for separate components while maintaining structural strength through optimized geometry and material distribution.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The side sill is divided into functionally distinct regions: a base region for general structural support, a connection region for joining to the center pillar, and a curved region for stress distribution. This segmentation allows each region to be optimized for its specific function while reducing overall material usage compared to a uniform multi-component design.

Inventive Principle:

Principle #1Segmentation

2Strength

If multiple cross members and reinforcing members are installed to achieve sufficient strength, then the strength is improved, but the cost increases due to excessive number of parts

Engineering Contradiction:

Improveunderbody strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The side sill serves multiple functions simultaneously: it acts as a cross member for structural support, a reinforcing member for collision resistance, and a mounting structure for seats. This multi-functionality reduces the total number of parts needed while maintaining all required structural capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Weight of moving object

If a simplified structure with fewer parts is used to reduce weight, then the weight is reduced, but the strength may be compromised

Engineering Contradiction:

Improveunderbody weightVSAvoidunderbody strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The side sill features local quality variations with different cross-sectional geometries in different regions. The connection region has enhanced thickness and geometry for optimal joining to the center pillar, while the base region has a geometry optimized for overall structural support. This localized optimization maintains strength where needed while reducing weight in less critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curved region of the side sill uses curved geometry to smoothly transition between the base region and connection region, distributing stresses more effectively than sharp corners would. This curvature enhances structural integrity while maintaining a streamlined shape that reduces material usage.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Object-affected harmful factors

If the side sill and center pillar connection is improved to reduce deformation, then the collision resistance is improved, but the structural complexity increases

Engineering Contradiction:

Improvecollision deformationVSAvoidconnection structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10822036B2Vehicle underbody structure

Publication Date: 2020.11.03 HYUNDAI MOTOR CO LTD

AI summary

A vehicle underbody structure includes a side sill protruding upward at its center to be coupled to a lower end of each center pillar, a cross member, an associated end of which is coupled to the side sill on a floor panel, and a seat mounting member installed to surround the end of the cross member to support a seat.