Vehicle Body Sill with Interlocking Recess and Protrusion
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Solution Overview
Problem
The existing vehicle body manufacturing methods fail to provide a reliable connection between the vehicle frame and superstructure, which inadequately absorbs side impact forces, particularly in pole impacts.
Innovation Solution
The vehicle body sill is constructed in two parts, with a lower sill part forming part of the vehicle frame and an upper sill part as part of the vehicle superstructure, connected via a defined interface featuring a recess and protrusion design that interlocks, enhancing the connection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the vehicle body is divided into modules with separate chassis and superstructure, then manufacturing flexibility and assembly ease are improved, but the connection reliability and side impact protection are worsened
Solution Approach 1:
The sill is divided into two distinct parts: a first sill part integrated with the vehicle frame and a second sill part integrated with the vehicle superstructure. This segmentation allows independent manufacturing of frame and superstructure modules while maintaining a reliable connection interface between them, resolving the contradiction between manufacturing flexibility and connection reliability.
Solution Approach 2:
The connection interface merges the first sill part and second sill part into a unified load-bearing structure. The interface design combines mechanical interlocking features with adhesive bonding surfaces, creating a merged connection that ensures reliable force transfer between the separate chassis and superstructure modules.
2Productivity
If the vehicle body is divided into modules with separate chassis and superstructure, then assembly ease and manufacturing efficiency are improved, but the side impact force absorption capability is worsened
Solution Approach 1:
The sill is segmented into two parts that can be manufactured separately and assembled efficiently, while the connection interface ensures continuous load paths for side impact forces. This allows modular assembly without compromising impact resistance.
Solution Approach 2:
The connection interface uses a composite connection approach combining mechanical features (protrusions, recesses) with adhesive materials. This composite connection method provides both assembly efficiency and high strength for withstanding side impact forces.
3Device complexity
If a simple adhesive connection is used between sill parts, then manufacturing simplicity is improved, but the contact surface area and connection strength are worsened
Solution Approach 1:
The connection interface has different local qualities: mechanical interlocking features (protrusions and recesses) in critical load-bearing areas and adhesive bonding surfaces in areas requiring distributed stress. This localized differentiation increases connection strength without significantly increasing overall complexity.
Solution Approach 2:
The connection interface merges mechanical interlocking and adhesive bonding into a single integrated connection system. This combination provides both the simplicity of adhesive application and the strength of mechanical connection, resolving the contradiction between simplicity and strength.
4Device complexity
If the sill is constructed as a single integrated piece, then structural simplicity is improved, but manufacturing flexibility and adaptability are worsened
Solution Approach 1:
The sill is segmented into two parts that can be manufactured using different processes and materials according to specific requirements, then assembled into a complete sill structure. This provides manufacturing flexibility while maintaining structural integrity.
Solution Approach 2:
The connection interface design is universal and can be applied to different vehicle models and configurations. The same interface concept works for various sill part designs, providing manufacturing flexibility and adaptability across different applications.
Data Source
AI summary
The present invention relates to a sill of a vehicle body (1), comprising a lower sill part (5) and an upper sill part (6) placed on and attached to the lower sill part (5). The sill is characterized in that the upper sill part (6) is part of a vehicle superstructure (3), in that in one side of a first sill part (5, 6), which faces the further sill part (6, 5), a recess (7) and, on one side of the further sill part (6, 5), which faces the first sill part (5, 6), a protrusion (61) is provided, wherein the shape of the recess (7) corresponds to the shape of the protrusion (61) and the protrusion (61) interlocks form-fittingly in the recess (7). In addition, the invention relates to a vehicle body (1) with two sills (4) and a method of manufacturing such a vehicle body.