DE102024000478B3 - energy absorption element of a vehicle side sill arrangement - Google Patents

Abstract

The invention relates to a side sill arrangement for a vehicle, having an inner side sill (1), an outer side sill (3), and a reinforcement unit arranged between the inner side sill (1) and the outer side sill (3), wherein the reinforcement unit has an upper cover plate (5) and a lower cover plate (7), wherein the upper cover plate (5) and the lower cover plate (7) are connected to one another at at least one joint (9), and wherein an intermediate element (13) is arranged between the upper cover plate (5) and the lower cover plate (7), wherein the intermediate element (13) is joined to the upper cover plate (5) and the lower cover plate (7) in the longitudinal or transverse direction, and wherein beads (15) are introduced into the cover plates (5, 7), which do not touch the intermediate element (13).

Description

The invention relates to a side sill arrangement for a vehicle, as well as a vehicle with such a side sill arrangement.

A side sill is a section of a body, particularly of a passenger car, that extends along a vehicle's longitudinal direction below a door entrance between a front and a rear wheel arch. Typically, vehicle sills are reinforced with solid aluminum extruded profiles to absorb the forces in a collision and, in the case of a battery-electric vehicle, to protect the battery.

In the prior art, various designs of side sills are known in order to meet certain requirements regarding collisions and/or regarding the connection of a vehicle battery of a battery-electric vehicle.

The DE 10 2022 124 460 A1 In this context, relates to a method for producing a side sill with a reinforcing profile for a motor vehicle, comprising the steps of: processing a steel sheet by a forming process, folding the steel sheet about its longitudinal axis so that a reinforcing profile with a closed cross-section is created, welding the side edges of the reinforcing profile which are adjacent to one another as a result of the folding, and inserting the reinforcing profile into and fastening it to a hollow side sill.

The US 2023/0339543 A1 relates to a side sill for a vehicle, the side sill capable of absorbing an impact during a side impact of the vehicle to maximally suppress the degree to which the side sill enters the interior and protect vehicle occupants and batteries. The side sill for a vehicle is composed of: a side sill inner panel; a side sill outer panel coupled to the side sill inner panel; and a first damping member disposed between the side sill inner panel and the side sill outer panel and forming a plurality of closed cross sections arranged in the width direction of the side sill. The first damping member includes a main body formed by bending a single plate and at least one partition member connecting both surfaces of the main body. A plurality of beads may be formed on the main body and the partition member.

The DE 10 2022 100 901 A1 also relates to a side sill assembly of a vehicle with reinforced rigidity, the side sill assembly comprising: an inner side sill, an outer side sill, and a reinforcing unit provided between the inner side sill and the outer side sill, the reinforcing unit comprising: an upper member having a first upper surface and a first lower surface arranged lower than the first upper surface, the first upper surface and the first lower surface being alternately arranged in a longitudinal direction of the vehicle, a lower member having a second upper surface and a second lower surface arranged lower than the second upper surface, the second upper surface and the second lower surface being alternately arranged in the longitudinal direction of the vehicle, and an intermediate member between the upper member and the lower member connected to the upper member and the lower member.

The DE 10 2021 004 342 A1 further relates to a side sill for a vehicle, comprising an outer and inner shell forming a cavity, wherein an energy absorber element is enclosed by a foam in the cavity, wherein the energy absorber element extends in a deformation direction, wherein the three-dimensional energy absorber element is embedded in a foam that is temperature-insensitive up to approximately 200°C, wherein the foam and energy absorber element form a stable prefabricated hybrid component and the energy absorber element has a variable cross-section in the deformation direction and/or a transverse direction thereto, and the hybrid component is attached on the foam side to at least one section of the outer and/or inner shell.

The use of extruded aluminum profiles to reinforce side skirts is very costly and their manufacture is complex. In addition, the profile of the current extruded aluminum profiles runs along a floor in the longitudinal direction of the vehicle, typically described with an x-axis; as a result, the extruded aluminum profile forms a homogeneous structure along the entire floor, without taking softer/harder areas in the floor into account. Current extruded aluminum profiles result in an even weight distribution (through a homogeneous cross-section in the transverse and vertical directions, typically described with a Y-axis or Z-axis), even in places where this weight/material does not lead to an increase in performance.

In addition, the length of the extruded aluminum profile leads to problems in the joining technology. Current extruded aluminum profiles are joined to a surrounding (steel) sill with (WES, rivets) or without (clinching) additional elements. Due to different thermal expansion coefficients of the materials (aluminum and steel), the joining technology can be damaged by temperature changes, as occurs with KTL, especially cataphoresis with subsequent furnace passage.

The object of the invention is therefore to develop an improved side sill arrangement for a vehicle.

The invention results from the features of the independent claims. Advantageous further developments and embodiments are the subject of the dependent claims.

A first aspect of the invention relates to a side sill arrangement for a vehicle, comprising an inner side sill, an outer side sill, and a reinforcement unit arranged between the inner side sill and the outer side sill, wherein the reinforcement unit has an upper cover plate and a lower cover plate, wherein the upper cover plate and the lower cover plate are connected to one another at at least one joint by welding or gluing, and wherein an intermediate element is arranged between the upper cover plate and the lower cover plate, and wherein beads are introduced into the cover plates which do not touch the intermediate element, and wherein beads of at least two pairs of beads have different distances and/or have different sizes.

The intermediate element is joined to the upper cover plate and the lower cover plate preferably in the longitudinal and/or transverse direction.

This advantageously provides a side sill arrangement which has increased rigidity compared to conventional side sills. This is achieved by using a reinforcement unit which, even in the case of battery-electric vehicles, is not used to connect the battery but rather serves as an energy absorption element to improve the mechanical behavior of a side sill in the event of a collision.

However, the improved mechanical properties, particularly through increased mechanical rigidity, also benefit battery-electric vehicles, which require correspondingly rigid structures due to their generally higher mass, but still have elements that dissipatively absorb impact energy.

For this purpose, a reinforcement unit is provided between the inner side sill and the outer side sill. The inner side sill and the outer side sill delimit a cavity running along the longitudinal extension of the side sill arrangement with the inner and outer side sills, within which the reinforcement unit is arranged. This therefore extends over a certain length between two sides of the side sill arrangement according to the invention.

An upper cover plate and a lower cover plate are provided for the reinforcement unit, between which an intermediate element is arranged. The cover plates are produced in particular by a forming process, such as hot forming or cold forming. In addition, the cover plates are connected to one another in the area of the inner side sill and/or in the area of the outer side sill by a flange, particularly preferably by a welded connection.

In addition, the cover plates are connected to the inner side sill and/or the outer side sill, either directly by means of a flange of one or both cover plates or indirectly by means of an additional plate. Particularly preferably, both the upper cover plate is connected to the inner side sill and the outer side sill, and the lower cover plate is connected to the inner side sill and the outer side sill. While at least the upper cover plate and the lower cover plate each run essentially laterally from the inner side sill to the outer side sill, just a joint between the upper cover plate and the lower cover plate can be connected to the inner side sill or the outer side sill, either directly or by means of a connecting element.

The cover plates can therefore be used variably and can be joined to the inner side sill or outer side sill using a flange, in particular by gluing, spot welding or laser welding. The cover plates can be cold-formed or hot-formed from inexpensive materials such as steel or aluminum. Ductile steel (preferably cold-formed) as well as high-strength steel (preferably hot-formed) or ultra-high-strength steel (cold-formed or hot-formed) can be used.

The intermediate element is joined to the cover sheets at the contact points, preferably by laser welding and/or gluing. Preferably, the reinforcement unit is also not enclosed by foam - however, foam can be used as an intermediate element.

The special feature of the cover plates are the beads incorporated into them, which increase the buckling resistance and thus the energy absorption of the cover plates in the event of a collision between the vehicle and the side sill arrangement. The beads can vary in shape, shape, length, width, number, geometry, orientation and arrangement and can be adapted to the area of application. Beads can be used locally; spacing and design do not need to be regular. Beads in the upper cover plate and lower cover plate do not have to be arranged in the same phases. Beads can be flat or round. The beads only serve to increase energy absorption (by stiffening, folding, etc.). No bead on one cover plate touches the other cover plate. Such beads are not present in conventional extruded profiles.

According to an advantageous embodiment, the upper cover plate and the lower cover plate are each connected to the inner side sill and to the outer side sill by a respective flange.

According to a further advantageous embodiment, the connection to the flange is carried out by gluing and/or welding, in particular spot welding or laser welding.

According to a further advantageous embodiment, the reinforcement unit has an angle plate which is attached to the upper cover plate or the lower cover plate with a first angle plate element and protrudes from a flat upper side or flat lower side of the connected cover plate and is connected to the inner side sill or to the outer side sill with a second angle plate element. The fastening can also be carried out by means of a bracket.

According to a further advantageous embodiment, the intermediate element is joined to the upper cover plate and the lower cover plate by at least one of: laser welding, spot welding, projection welding, gluing.

• - rollprofiliertes Wellenblech in Einfach- oder Doppelausführung;
• - kaltumgeformtes oder warmumgeformtes Wellenblech in Einfachausführung oder Doppelausführung;
• - Wabenstruktur;
• - Rohr;
• - Partikelschaum;

According to a further advantageous embodiment, the intermediate element comprises one of the following:

• - roll-profiled corrugated sheet in single or double design;
• - cold-formed or hot-formed corrugated sheet in single or double design;
• - honeycomb structure;
• - Pipe;
• - particle foam;

The roll-profiled corrugated sheet in single or double design can also be referred to as sheet with transverse corrugation.

The cold/hot formed corrugated sheet in single or double design can also be referred to as sheet with longitudinal corrugation.

According to a further advantageous embodiment, at least one of the beads is designed as a transverse bead. Transverse beads advantageously increase the buckling resistance of the cover plates. The beads extend transversely to the direction of extension of the reinforcement unit and thus also transversely to the extension of the inner and outer side sills. Preferably, all beads are designed as transverse beads.

According to a further advantageous embodiment, at least one of the beads is designed as a longitudinal bead. Longitudinal beads force the cover plates to fold. In contrast to the transverse beads, the longitudinal beads extend in the extension of the inner and outer side sills and thus also along an extension direction of the reinforcement unit. Preferably, all beads introduced into the cover plates are formed from longitudinal beads.

According to a further advantageous embodiment, the at least one joint is made by means of a welded connection.

A further aspect of the invention relates to a vehicle with a side sill arrangement as described above and below.

Advantages and preferred further developments of the proposed vehicle result from an analogous and analogous transfer of the statements made above in connection with the proposed side sill arrangement.

Further advantages, features and details emerge from the following description, in which - if necessary with reference to the drawing - at least one embodiment is described in detail. Identical, similar and/or functionally identical parts are provided with the same reference symbols.

• 1: Eine Seitenschwelleranordnung perspektivisch in einem Querschnitt gemäß einem Ausführungsbeispiel der Erfindung.
• 2: Die Seitenschwelleranordnung der 1 im Querschnitt.
• 3: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 4: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 5: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 6: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 7: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 8: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 9: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 10: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 11: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 12: Eine Seitenschwelleranordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 13: Ein Deckblech mit einer variablen Sickenanordnung gemäß einem Ausführungsbeispiel der Erfindung.
• 14: Ein Deckblech gemäß einem weiteren Ausführungsbeispiel der Erfindung.
• 15: Ein Deckblech gemäß einem weiteren Ausführungsbeispiel der Erfindung.

They show:

• 1 : A side sill arrangement in perspective in a cross section according to an embodiment of the invention.
• 2 : The side sill arrangement of the 1 in cross-section.
• 3 : A side sill arrangement according to another embodiment of the invention.
• 4 : A side sill arrangement according to another embodiment of the invention.
• 5 : A side sill arrangement according to another embodiment of the invention.
• 6 : A side sill arrangement according to another embodiment of the invention.
• 7 : A side sill arrangement according to another embodiment of the invention.
• 8 : A side sill arrangement according to another embodiment of the invention.
• 9 : A side sill arrangement according to another embodiment of the invention.
• 10 : A side sill arrangement according to another embodiment of the invention.
• 11 : A side sill arrangement according to another embodiment of the invention.
• 12 : A side sill arrangement according to another embodiment of the invention.
• 13 : A cover plate with a variable bead arrangement according to an embodiment of the invention.
• 14 : A cover plate according to another embodiment of the invention.
• 15 : A cover plate according to another embodiment of the invention.

The representations in the figures are schematic and not to scale.

1 shows a side sill arrangement for a vehicle in perspective with a cross section. In the left half of the picture an inner side sill 1 is indicated, in the right half of the picture an outer side sill 3. The inner side sill 1 and the outer side sill 3 together form a frame structure of a side sill for a vehicle. The side sill extends from a rear wheel arch to a front wheel arch, with the 1 a section transverse to this direction of extension is shown. Between the inner side sill 1 and the outer side sill 3, a reinforcement unit is introduced, which comprises an essentially horizontally inserted upper cover plate 5 and a likewise essentially horizontally inserted lower cover plate 7. The upper cover plate 5 and the lower cover plate 7 are connected to one another at a joint 9 by welding or gluing. The 1 The joint 9 shown is also connected to the outer side sill 3 by gluing or welding. The inner side sill 1 is connected to the respective cover plate 5, 7 by a respective flange 11, again by gluing or welding. An intermediate element 13 is also arranged between the upper cover plate 5 and the lower cover plate 7, in this example in a double wave shape. The intermediate element 13 is joined to the upper cover plate 5 and the lower cover plate 7 at respective contact points, again preferably by gluing or welding. In the example of the 1 Both the upper cover plate 5 and the lower cover plate 7 have transverse beads 15, which, however, do not touch the intermediate element 13. The glued or welded contact points of the intermediate element 13 with the upper cover plate 5 or the lower cover plate 7 are therefore not in the area of the beads 15, but in the area of the non-beaded material sections of the cover plates 5, 7. An angle plate 17 is part of the reinforcement unit and extends from a surface of the upper cover plate 5 to the inner side sill 1. The angle plate 17 essentially protrudes perpendicularly from the flat surface of the upper cover plate 5.

2 shows the side sill arrangement of the 1 in pure cross-section without perspective. Here, the shape of the intermediate element 13, which is made by double corrugation, is particularly visible, which contributes in particular to energy absorption in the event of a collision and stabilizes the cover plates 5, 7, as well as the angle plate 17.

3 shows the core of another side sill arrangement, showing the joint 9 between the upper cover plate 5 and the lower cover plate 7. The beads 15 are provided in a transverse direction, ie transverse to the longitudinal extension of the side sill. The intermediate element 13 comprises a double corrugated sheet with an extension direction in the longitudinal direction.

4 shows the core of another side sill arrangement, in which a variable spacing distribution of the beads 15 in the upper cover plate 5 and in the lower cover plate 7 is provided along the side sill longitudinal direction. Thus, a different reinforcement is achieved by introducing round beads 15.

5 shows the core of another side sill arrangement with an expanding angle between the lower cover plate 7 and the upper cover plate 5, so that the intermediate element 13, designed as a simple wave, has larger amplitudes in increasing transverse direction.

6 shows a further side sill arrangement with an intermediate element 13, which is designed as a double wave that extends in the longitudinal direction of the side sill. Again, the beads 15 are arranged irregularly on the lower cover plate 7 and the upper cover plate 5.

7 shows a further side sill arrangement including the inner side sill 1 and the outer side sill 3. Here, the intermediate element 13 is designed as a simple shaft and has perforations to save weight.

8 shows a reinforcement unit of another side sill arrangement with a variation in the beads 15, which extend in the longitudinal direction of the side sill. Additional transverse bead sections are incorporated in the beads 15.

9 shows a reinforcement unit of a further side sill arrangement with a variation in the beads 15, which extend in the longitudinal direction of the side sill. In this case, further impressions or recesses of the first type are provided in the beads 15.

10 shows a reinforcement unit of a further side sill arrangement with a variation in the beads 15, which extend in the longitudinal direction of the side sill. In this case, further impressions or recesses of a second type are provided in the beads 15.

11 shows a reinforcement unit of a further side sill arrangement with a variation in the beads 15, which extend in the longitudinal direction of the side sill. In this case, further impressions or recesses of a third type are provided in the beads 15.

12 shows a reinforcement unit of a further side sill arrangement with a variation in the beads 15, which extend in the longitudinal direction of the side sill. In this case, further impressions or recesses of a fourth type are provided in the beads 15.

13 to 15 show examples of an upper cover plate 5 and/or a lower cover plate 7, on each of which beads 15 are provided in an unevenly distributed arrangement. In the 13 The distance between the beads 15, which are designed as transverse beads, varies. In the 14 The width of the beads 15 designed as transverse beads varies - for example, a widening and a deepening of the beads 15 is provided at the level of a seat cross member, since these can absorb more energy in the event of a crash. In the 15 Both the widths and the distances between the beads 15 vary.

list of reference symbols

1

inner side sills

3

outer side skirts

5

upper cover plate

7

lower cover plate

9

joint

11

flange

13

intermediate element

15

beads

17

angle plate

Claims (9)

Side sill arrangement for a vehicle, comprising an inner side sill (1), an outer side sill (3), and a reinforcement unit arranged between the inner side sill (1) and the outer side sill (3), wherein the reinforcement unit has an upper cover plate (5) and a lower cover plate (7), wherein the upper cover plate (5) and the lower cover plate (7) are connected to one another at at least one joint (9) by welding or gluing, and wherein an intermediate element (13) is arranged between the upper cover plate (5) and the lower cover plate (7), and wherein beads (15) are introduced into the cover plates (5, 7), which do not touch the intermediate element (13), and wherein beads (15) of at least two pairs of beads (15) have different distances and/or have different sizes. Side sill arrangement according to claim 1 , wherein the upper cover plate (5) and the lower cover plate (7) are each connected to the inner side sill (1) and/or to the outer side sills (3) are connected by a respective flange (11). Side sill arrangement according to one of the preceding claims, wherein the reinforcement unit has an angle plate (17) which is applied to the upper cover plate (5) or the lower cover plate (7) with a first angle plate element and protrudes from a flat upper side or flat lower side of the connected cover plate (5,7) and is connected to the inner side sill (1) or to the outer side sill (3) with a second angle plate element. Side sill arrangement according to one of the preceding claims, wherein the intermediate element (13) is joined to the upper cover plate (5) and the lower cover plate (7) by at least one of: laser welding, spot welding, projection welding, gluing. Side sill arrangement according to one of the preceding claims, wherein the intermediate element (13) comprises one of the following: - roll-profiled corrugated sheet in single or double design; - cold-formed or hot-formed corrugated sheet in single or double design; - honeycomb structure; - tube; - particle foam; Side sill arrangement according to one of the preceding claims, wherein at least one of the beads (15) is designed as a transverse bead. Side sill arrangement according to one of the preceding claims, wherein at least one of the beads (15) is designed as a longitudinal bead. Side sill arrangement according to one of the preceding claims, wherein the at least one joint (9) is designed by means of a welded connection. Vehicle with a side sill arrangement according to one of the preceding claims.

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