Vehicle Frame Pillar and Side Sill Integration
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Solution Overview
Problem
Current vehicle frame structures, particularly in aluminum bodies, face challenges in efficient load transfer between the front/center pillar and side sill due to different extrusions and complex welding processes, which can lead to increased machining costs and rotational moments during crashes.
Innovation Solution
The vehicle frame structure incorporates a side sill and pillar design with internal ribs that partition the components into outer and inner lateral portions, allowing the inner lateral pillar portion to be secured within a cutout of the side sill, enabling efficient load transfer and reducing rotational moments through strategic welding along different planes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the front/center pillar and side sill are formed as separate extrusions in aluminum vehicle bodies, then manufacturing flexibility and material utilization are improved, but the load transfer efficiency between components deteriorates and complex welding processes are required
Solution Approach 1:
The patent merges the pillar and side sill into a single integrated extrusion, eliminating the interface between separate components. This unified structure allows direct load transfer without welding, resolving the contradiction by maintaining manufacturing flexibility through extrusion while dramatically improving load transfer efficiency through structural integration.
Solution Approach 2:
The integrated extrusion incorporates internal ribs that segment the internal space into distinct regions, creating functional zones for different load paths. This segmentation allows the single component to handle multiple load transfer functions simultaneously, maintaining the benefits of integration while providing structured load management.
2Device complexity
If traditional spot welding is used to connect pillar and side sill, then assembly is simplified, but rotational moments during crashes increase and connection strength is reduced
Solution Approach 1:
By combining the pillar and side sill into one continuous extrusion, the patent eliminates the welded joint entirely. This removes the weak connection point that would experience rotational moments during crashes, while the integrated structure maintains assembly simplicity through a single-piece construction that requires no post-assembly welding operations.
3Ease of operation
If the pillar is positioned outside the side sill extrusion, then assembly is easier, but the connection interface complexity and machining costs increase
Solution Approach 1:
The patent nests the pillar section within the side sill extrusion, with the pillar's internal space containing the side sill's internal space. This nested configuration eliminates the need for external positioning and complex interface machining, as the nested geometry naturally guides assembly while reducing the number of external connection surfaces required.
4Strength
If complex welding processes are used to connect separate extrusions, then connection strength can be achieved, but manufacturing costs and production time increase
Solution Approach 1:
The patent eliminates the welding process entirely by combining the pillar and side sill into a single extrusion. This resolves the contradiction by achieving maximum connection strength through structural continuity while dramatically improving production efficiency by removing the time-consuming welding operations and associated quality control requirements.
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
This design enhances the strength of the connection between the front pillar and side sill, minimizing moment and rotation during tire impact and side crash loads, while reducing machining costs and trim tolerance requirements.
Implementation Method 1
The side sill and the pillar are welded to each other along an interface between the side sill and the pillar
Implementation Method 2
an axial end face of the outer lateral pillar portion is in abutment with the outer lateral side sill portion
Implementation Method 3
an axial end face of the inner lateral pillar portion is in abutment with and supported by the horizontal rib of the side sill
Data Source
AI summary
A vehicle frame structure includes a side sill having an internal space partitioned by a vertical rib and a horizontal rib intersecting the vertical rib. The vertical rib separates the side sill into an outer lateral portion and an inner lateral portion. The inner lateral side sill portion includes a cutout extending vertically therethrough. A pillar has an internal space partitioned by a longitudinally extending first rib and a laterally extending second rib intersecting the first rib. The first rib separates the pillar into an outer lateral portion and an inner lateral portion. The inner lateral pillar portion is disposed through and secured in the cutout of the portion, and an axial end face of the outer lateral pillar portion is in abutment with the outer lateral side sill portion. The side sill and the pillar are welded to each other along an interface between the two components.