Z-Shaped Sill Reinforcement for Impact Resistance and Mass Reduction
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Solution Overview
Problem
Current motor vehicle sill structures are heavy, particularly in electric vehicles, and face challenges in balancing impact resistance and manufacturing complexity, especially with Omega-shaped reinforcements which are difficult to produce and add unnecessary mass.
Innovation Solution
A sill structure featuring a Z-shaped internal reinforcement within a hollow body formed by two casings, allowing for reduced mass while maintaining impact absorption capabilities, using simpler manufacturing processes and materials like ultra-high yield strength steel, and optional reinforcing angles and shock absorption means for enhanced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an Omega-shaped reinforcement is used inside the sill, then impact resistance is improved, but manufacturing complexity increases and mass increases
Solution Approach 1:
The internal reinforcement is divided into three separate planar walls (first, second, and third walls) arranged at right angles to form a Z-shaped section. These segmented walls are easier to manufacture individually using roll forming technology compared to a complex Omega-shaped reinforcement, while still providing effective impact resistance through their coordinated geometric arrangement.
Solution Approach 2:
The reinforcement geometry is changed from a complex Omega-shaped section to a simpler Z-shaped section formed by three planar walls. This parameter change in the geometric configuration maintains the structural function of absorbing impact forces while significantly simplifying the manufacturing process and reducing material requirements.
2Strength
If conventional Omega-shaped reinforcement is used, then impact resistance is maintained, but the mass of the sill structure increases
Solution Approach 1:
The reinforcement is segmented into three thin planar walls arranged in a Z-shape, which reduces the total material volume compared to a solid Omega-shaped reinforcement. The segmented structure provides sufficient strength through its geometric configuration while using less material, thereby reducing the overall mass of the sill structure.
Solution Approach 2:
The geometric parameters of the reinforcement are changed from a bulky Omega-shaped cross-section to a slender Z-shaped configuration formed by three planar walls. This parameter change reduces the material volume and mass while maintaining the structural capability to absorb impact forces through the Z-shaped geometry's inherent mechanical properties.
3Strength
If complex Omega-shaped reinforcement is used, then structural strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The reinforcement is segmented into three separate planar walls that can be manufactured independently using standard roll forming processes. This segmentation transforms a complex, difficult-to-manufacture Omega-shaped component into simpler, more manufacturable planar elements that can be produced with conventional equipment and materials like ultra-high yield strength steel.
Solution Approach 2:
The geometric parameters are simplified from a complex curved Omega-shaped section to straight planar walls arranged in a Z-configuration. This parameter simplification makes the component compatible with roll forming technology and other standard manufacturing processes, significantly improving ease of manufacture while maintaining structural integrity.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a valance panel structure (1) including a first (10) and second shell (20) extending in a longitudinal direction and assembled such as to form a hollow body and including an inner reinforcement (30) inside said hollow body. The inner reinforcement (30) includes three planar walls (32, 34, 36) arranged two-by-two at right angles or substantially at right angles such as to form an approximately Z-shaped cross-section, a longitudinal free edge (33) of a first planar wall (32) being inserted between two assembled securing rims (16a, 22a) of the first and second shells, at least on one portion of the length of said securing rims, a third planar wall (36) which is parallel or substantially parallel to the first wall (32) being applied against the bottom wall (12) of the first shell and attached to same.