GB2566301A

GB2566301A - Sill assembly

Info

Publication number: GB2566301A
Application number: GB1714473.4A
Authority: GB
Inventors: Lakic Alex
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-09-08
Filing date: 2017-09-08
Publication date: 2019-03-13
Anticipated expiration: 2037-09-08
Also published as: GB201714473D0; GB2566301B; DE102018213721A1

Abstract

A sill assembly 2 for a vehicle comprises an inner extruded sill member 21 configured to be secured to a vehicle body and an outer extruded sill member 23 secured to the inner extruded sill member 21. The inner or outer sill members 21, 23 may each comprise a cavity which may each be divided by a reinforcement structure into at least two cavities. An outer side wall of inner member 21 and an inner side wall of outer member 23 may conform to each other’s shape, for example each may be substantially flat or each may comprise a step, and may also comprise openings which may be offset in a vertical or longitudinal direction. Inner member 21 may be connected to an underfloor, a battery pack or a side frame 30, and outer member 23 may be connected to a side frame reinforcement 40.

Description

SILL ASSEMBLY

TECHNICAL FIELD

The present disclosure relates to a sill assembly, particularly but not exclusively, to a sill assembly for a vehicle. In other aspects, the invention relates to a vehicle comprising the sill assembly and a method of providing a vehicle body with the sill assembly.

BACKGROUND

A conventional vehicle bodyshell comprises a variety of structural members such as a side sill (also known as a rocker). The sill fits at the base of the door openings and between the wheel wells. Vehicle sill assemblies are traditionally made from stamped metal panels, which are subsequently attached to the bottom of panels that form the remainder of the side frame structure of the bodyshell, and to the floor structure. Typically the sill box section is constructed of two main halves, an inner longitudinally elongate panel and an outer longitudinally elongate panel. The box section can contain further, smaller, longitudinal and transverse panels. On modern cars, side sills are an essential part of the survival cell, creating a passenger cabin area that protects occupants by limiting intrusion: that is to say deforming in a controlled, pre-defined sequence at high loads during accidents. Accordingly, sills play an essential role when it comes to passenger safety.

Traditionally, numerous stamped steel sheets are secured to each other by means of welding to create the desired sill structure. A known problem with this approach is that the traditional sill structures comprising steel sheets are comparatively heavy and difficult to manufacture. In view of this, newer sill structures have been proposed, which are generated as a single piece using an extrusion process. The process of extruding a single piece sill structure is described in prior art reference US 8,960,781 B2, for example, and leads to a lighter sill structure that can be produced quickly and easily.

One of the disadvantages of single piece extruded sill structures is an increased complexity in assembling the latter to the side frame and floor structure of the bodyshell. A number of access openings have to be introduced into the extruded sill structure in order to spot-weld or self-pierce-rivet it to the side frame and floor structure of the bodyshell. These access openings weaken the structure. Furthermore, the usual dimensional variability of the floor structure and side frame are greatly compounded by connecting them via a single component. The lack of an ostensibly planar dividing surface, normally present between the stamped main inboard and outboard panels of traditional sills, reduces the bodyshell’s tolerance to dimensional variability within its constituent parts. This leads to a less repeatable and accurate bodyshell shape and leaves residual assembly stresses locked into the bodyshell.

It is an aim of the present invention to address the disadvantages associated with the prior art. In particular, it is an object of the present invention to provide a sill assembly, which is quick and easy to manufacture and attach to the remaining structural members of the vehicle bodyshell. It is another object to provide a sill assembly with increased stiffness and strength.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a sill assembly, a vehicle and a method of providing a vehicle bodyshell with a sill assembly as claimed in the appended claims.

According to an aspect of the present invention, there is provided a sill assembly for a vehicle, the sill assembly comprising an inner extruded sill member configured to be secured to a vehicle body and an outer extruded sill member secured to the inner extruded sill member.

In other words, the sill assembly of the present invention is a two-part extruded sill structure. Two-part sill structures are advantageous as they allow the sill to be assembled to the vehicle without the need to leave a large number of open access holes in the box sections of the sill structure. Furthermore, a two-part structure allows tolerances in the longitudinal and vertical direction of the vehicle to be compensated. This is particularly advantageous in battery electric vehicles, where the sill is not only attached to the side panel of the vehicle body but also supports the battery pack.

As will be explained in more detail below, the inner extruded sill member is adapted to be assembled to panels of the side frame assembly and floor structure of the vehicle bodyshell and may subsequently be attached to the battery pack. Afterwards, the outer extruded sill is first connected to panels of a side frame reinforcement assembly (for example, the A-post and / or B-post reinforcements). These reinforcement panels are constituent parts of the side frame reinforcement assembly. Once the reinforcement panels are attached to the outer extruded sill member, the outer extruded sill member is connected to the inner extruded sill member, in a last mounting step allowing for tolerances to be compensated.

In another embodiment, the inner extruded sill member comprises opposite inner and outer side walls, the inner extruded sill member being secured to the vehicle floor structure along its inner wall, wherein the outer extruded sill member is secured to the outer side wall of the inner extruded sill member. To this end, the inner side wall of the inner extruded sill member may comprise a plurality of integrally extruded flanges configured to attach the inner extruded sill member to the vehicle floor structure. Such flanges can also be used to attach the inner extruded sill member to the side frame of the bodyshell.

The inner extruded sill member may comprise opposite upper and lower walls extending between the inner and outer side walls to define a first cavity running longitudinally through the inner extruded sill member. In other words, the inner sill member may define a boxed section, which may act as a crash resisting strut in the event of impacts from the front or rear. The boxed section may also act as a crash resisting beam in the event of impacts from the side. The boxed section may also act as a crash energy absorbing crush element in the event of impacts from the side. The first cavity may also be configured to receive electric wiring and/or fluid lines. This is particularly useful if the sill assembly is incorporated into a battery electric vehicle, in which case the inner extruded sill member is connected to - and runs adjacent to - the battery pack.

According to yet another embodiment, the inner extruded sill member comprises a first reinforcing structure, said reinforcing structure dividing the first cavity into at least two cavities. The additional reinforcing structure will further increase the stiffness of the inner extruded sill member. The reinforcing structure may also function as a sound or moisture barrier between the cavities of the inner extruded sill member that it separates.

In another embodiment, the outer side wall of the inner sill member comprises a first plurality of openings. As will be described in more detail below, this first plurality of openings can be used to attach the inner side wall of the inner extruded sill member to parts of the vehicle's side frame and floor structure. In other words, the first plurality of openings provides access to an inside surface of the inner side wall, and thus enables double sided joining techniques (for example spot welding or self-pierce riveting) to be employed. The first plurality of 3 openings may be constructed as bores, slots or any other form of opening that allows the respective tools to be inserted into the cavity of the inner extruded sill member.

The outer extruded sill member may comprise opposite inner and outer side walls, said inner side wall being configured to be secured to the inner extruded sill member. In particular, the inner side wall of the outer extruded sill member may be secured to the outer side wall of the inner extruded sill member. A shape of the outer side wall of the inner extruded sill member may conform to the shape of the inner side wall of the outer extruded sill member. The complimentary shape of the adjacent side walls of the inner and outer extruded sill members will simplify arranging the sill assembly on the vehicle bodyshell and align the two sill members correctly.

In an embodiment, the outer side wall of the inner extruded sill member and the inner side wall of the outer extruded sill member are substantially flat. Alternatively both extruded sill member feature substantially flat surfaces that are ostensibly parallel. According to this embodiment, the inner and outer sill members are freely moveable with respect to each other in the longitudinal and vertical direction of the vehicle, so as to compensate for and eliminate dimensional variability that can accumulate in the large multi-part subassemblies of a bodyshell. Alternatively, the outer side wall of the inner extruded sill member may define a first step and the inner side wall of the outer extruded sill member may define a second step, for example the first and second steps being substantially complementary. The complimentary stepped structure of the inner and outer side walls permits different dimensional requirements to be achieved on upper and lower regions of the extruded sill members. In some embodiments, the first and second steps may be vertically offset from one another to permit some vertical movement between the inner and outer extruded sill members when in position so as to compensate for and eliminate vertical variability that can accumulate in the large multi-part subassemblies of a bodyshell.

In another embodiment, the outer extruded sill member comprises opposite upper and lower walls extending between the inner and outer side walls to define a second cavity running longitudinally through the outer extruded sill member. Similar to the first cavity within the inner extruded sill member, the second cavity may be used to guide electrical wires or fluid lines and provide box sections with increased structural ability. The efficiency of the inner and outer sill members providing separate box sections, combined as an assembly, in performing the crash functions may be much greater than that of the individual members in isolation due to mutual stabilising and mutual reinforcing effects.

The outer extruded sill member comprises a second reinforcing structure, said second reinforcing structure dividing the second cavity into at least two cavities.

According to yet another embodiment, the inner side wall of the outer extruded sill member comprises a second plurality of openings. The second plurality of openings enables the car manufacturer to gain access to the second cavity of the outer extruded sill member in order to fix the outer side wall of the outer sill member to the rest of the vehicle bodyshell, particularly to the side frame reinforcement assembly. Similar to the first plurality of openings, the second plurality of openings may have any shape that allows tool access to the inside surface of the outer side wall.

If both the inner and outer extruded sill members are provided with openings, the first plurality of openings of the inner extruded sill member may be offset from the second plurality of openings of the outer extruded sill member. The first and second plurality of openings may be offset from each other along a longitudinal and/or a vertical direction of the sill assembly. Offsetting the first and second plurality of openings from each other will increase the strength and stiffness of the sill assembly. In particular, the outer side wall of the inner extruded sill member will be attached to the inner side wall of the outer extruded sill member in such a way that every first opening on the outer side wall of the inner extruded sill member is located adjacent to a solid part of the inner side wall of the outer extruded sill member. Conversely, each of the second plurality of openings on the inner side wall of the outer extruded sill member is arranged adjacent to a solid part of the outer side wall of the inner extruded sill member. Accordingly, weaker parts of the outer side wall of the inner extruded sill member are coupled to stronger, solid parts of the inner side wall of the outer extruded sill member, and vice versa, especially if an adhesive is used to secure a solid portion over an opening.

In another embodiment, the inner and outer extruded sill members comprise opposite inner and outer side walls, said inner extruded sill member comprising a first mounting flange extending above or below its outer side wall, said outer extruded sill member comprising a second mounting flange configured to be secured to the first mounting flange, said second mounting flange extending above or below the inner side wall of the outer extruded sill 5 member. As such, the inner and outer extruded sill members may be attached to each other along their respective mounting flanges, in addition to the surfaces of their inner/outer side walls. The first and second mounting flanges may extend above the corresponding side walls of the inner and outer extruded sill members such that the latter are attached to each other longitudinally along their top and bottom edges.

The first and second mounting flanges may be secured to each other by gluing, welding, riveting, bolting or combinations thereof. Of course, any other method of mounting the flanges together that achieves the desired bond between the inner and outer extruded sill members is also feasible. The outer side wall of the inner extruded sill member may be attached to the inner side wall of the outer extruded sill member in the same way. However, due to limited access to the inner/outer side walls of the extruded sill members during assembly, gluing, screwing or friction welding may be a preferred method of attachment.

In another embodiment, the inner extruded sill member is configured to be secured to a vehicle floor structure. The inner extruded sill member may be secured to a battery pack of a vehicle. The outer extruded sill member may be configured to be secured to the lower portions of side frame reinforcement assembly. As will be described in more detail below, this arrangement will provide the manufacturer with the ability to easily align the side frame and the floor structure of the vehicle bodyshell, before making final permanent connections between the outer extruded sill member and the inner extruded sill member of the sill assembly.

The inner and outer extruded sill members may be fabricated from aluminium, and aluminium alloys, steel, or any extrudable or drawable material of appropriate strength and stiffness

In another embodiment, the inner extruded sill member comprises opposite inner and outer side walls, said inner extruded sill member comprising an attachment flange extending above or below the inner wall, said attachment flange being configured to secure the inner extruded sill member to a vehicle body. Similar to the first and second mounting flanges, the attachment flange may be glued, riveted, welded, screwed or bolted to remaining parts of the vehicle, be it the side frame, floor structure or the battery pack.

In yet another embodiment, the assembly comprises a trim panel configured to be secured to the outer extruded sill member. In particular, the trim panel may be secured to the outer side wall of the outer extruded sill member in order to cover the outer extruded sill member and provide the sill assembly with a high quality finish and I or desired curvature that the sill assembly does not otherwise alone exhibit.

In another aspect of the present invention there is provided a vehicle comprising the sill assembly described hereinbefore.

In yet another aspect, there is provided a method of providing a vehicle bodyshell with a sill assembly, the method comprising

i) securing an extruded inner sill member to a vehicle bodyshell;

ii) securing an extruded outer sill member to the inner sill member.

As will be appreciated, the inner and outer extruded sill members are extruded in separate steps and secured to the vehicle I each other at different times. This aspect significantly reduces the manufacturing costs and time needed to provide a sill assembly on a vehicle body.

The steps i) - ii) may be separated by intermediate steps whereby the inner and I or outer sill members attach to (or have attached to them) other components, either to realise the special strength and quality of joining available within an isolated prior step (subassembly) or as a matter of convenience.

In another embodiment, the inner extruded sill member is secured to a lower portion of a vehicle bodyshell side frame and/or to the floor structure. The outer extruded sill member may be secured to a lower portion of a side frame reinforcement assembly prior to securing the outer extruded sill member to the inner extruded sill member.

In another embodiment, after the outer extruded sill member is secured to the side frame reinforcement assembly, the side frame reinforcement assembly is secured to the vehicle body side frame assembly prior to securing the outer extruded sill member to the inner extruded sill member.

A plurality of first openings may be introduced into the inner extruded sill member between extruding the inner sill member and securing the latter to the vehicle body, wherein a plurality of second openings may be introduced into the outer extruded sill member between extruding the outer extruded sill member and securing the latter to the inner extruded sill member. The inner and outer extruded sill members are aligned prior to securing the outer extruded sill member to the inner extruded sill member such that the first and second plurality of openings are offset from each other.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a schematic view of a vehicle according to an embodiment of the present invention;

Figure 2 shows an exploded view of parts of a vehicle bodyshell comprising a sill assembly according to the an embodiment of the present invention;

Figure 3 shows a schematic perspective view of inner and outer extruded sill assemblies;

Figure 4a and 4b show schematic cross-sections of the inner and outer extruded sill assemblies shown in Figure 3;

Figures 4c and 4d show schematic cross-sections of an embodiment of the sill assembly according to the present invention, attached to respective parts of a vehicle body;

Figure 5 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention, attached to respective parts of a vehicle body;

Figure 6 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention, attached to respective parts of a vehicle body;

Figure 7 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention, attached to respective parts of a vehicle body;

Figure 8 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention, attached to respective parts of a vehicle body;

Figure 9 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention, attached to a bodyshell floor structure;

Figure 10 shows a schematic perspective view of an embodiment of the sill assembly according to the present invention;

Figure 11 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention; and

Figure 12 shows a flow diagram regarding an embodiment of the method according to the present invention.

DETAILED DESCRIPTION

Turning to Figure 1, there is shown a vehicle according to an embodiment of the present invention. The vehicle 1 comprises a sill assembly 2 arranged between a front wheel well 4 and a rear wheel well 6.

As can be derived from Figure 2, the sill assembly is formed as a two-part extrusion. An inner extruded sill member 21 is configured to be attached to a vehicle bodyshell side frame assembly 30. The vehicle bodyshell side frame assembly 30 may be of conventional construction, comprising, for example, panels partially or substantially defining an A-pillar 32, a B-pillar 34, a C-pillar 36 and a roof rail 38. The inner extruded sill member 21 is configured to be mounted to the A-pillar 32 at its front end, to the B-pillar at a central location, and to the C-pillar at its rear end.

Also with reference to Figure 2, the inner extruded sill member is also configured to be attached to a vehicle bodyshell floor structure 70. The vehicle bodyshell floor structure 70 may be of a conventional construction, comprising, for example, panels defining a front outrigger member 72, seat mounting crossmembers 73 and 74, heelboard crossmember 75, rear outrigger member 76 and a floor panel ΊΊ. The inner extruded sill member 21 is configured to be mounted to the front outrigger member 72 at its front end, to the seat crossmembers 73 and 74 at its mid portion, to the heelboard crossmember 75 and rear outrigger 76 at its rear end, and to the floor panel 77 along the majority of its length.

An outer extruded sill member 23 is configured to be attached to a vehicle bodyshell side frame reinforcement assembly 40. In particular, the outer extruded sill member 23 may be attached to the bottom end of the side frame reinforcement assembly 40. The side frame reinforcement assembly 40 may be of conventional structure, comprising, for example, panels partially or substantially defining an A-pillar 42, a B-pillar 44, a C-pillar 46, and a roof rail 48.

According to the method of the present invention, the inner extruded sill member 21 is extruded separately from the outer extruded sill member 23, the inner extruded sill member 21 is then attached to the vehicle bodyshell side frame 30 and/or the floor structure 70. The outer extruded sill member 23 is attached to the side frame reinforcement assembly 40 thereafter, which is then mounted to the vehicle body side frame 30. Once the reinforcement assembly 40, the side frame assembly 30, and the floor structure 70 have been aligned with and secured to each other, the outer extruded sill member 23 may be secured to the inner extruded sill member 21. It will be appreciated that forming the sill assembly as a two-part extruded structure enables the manufacturer to align the vehicle body side frame assembly 30, the side frame reinforcement assembly 40 and the floor structure more easily and build a more dimensionally consistent and dimensionally repeatable bodyshell.

In an alternative variation, the inner extruded sill member 21 is not connected to any of the panels of the vehicle body side frame assembly 30. Rather, the sill member may exclusively be retained by a connection to the underfloor structure 70.

Figure 3 shows a schematic, perspective view of the inner and outer extruded sill members 21, 23 being connected to the B-pillars 34, 44, of their respective side frame assembly 30/reinforcement panel assembly 40. The inner extruded sill member 21 comprises an inner side wall 211 opposite an outer side wall 213. The inner side wall 211 is adapted to be mounted on the vehicle side frame assembly 30, for example, the B-pillar 34. The outer side wall 213 is adapted to be secured to the outer extruded sill member 23.

The inner extruded sill member 21 further comprises an upper wall 215, opposite a lower wall 217. The upper and lower walls 215, 217 extend between and connect the inner and outer side walls 211, 213. Together, the side walls 211, 213 and the upper and lower walls 215, 217 define a first cavity 219 extending in a longitudinal direction of the inner extruded sill member 21. The first cavity 219 may be used to receive electric wiring and/or fluid lines of the vehicle.

A first plurality of openings 218 is provided on the outer side wall 213 of the inner extruded sill member 21. The first plurality of openings 218 allows access to an inside surface of the inner side wall 211 in order to introduce fastening means for attaching the inner extruded sill member 21 to the vehicle body side frame assembly 30. The fastening means may, therefore, be those requiring double sided access and will be introduced through the first plurality of holes 218 together with corresponding fastening tools.

The outer extruded sill member 23 comprises an inner side wall 231, which is arranged opposite to an outer side wall 233. The inner side wall 231 is adapted to be secured to the outer side wall 213 of the inner extruded sill member 21 for connection of the two extruded parts of the sill assembly 2 according to the present invention. The outer side wall 233 of the outer extruded sill member 23 is configured to be mounted on the vehicle bodyshell side frame reinforcement assembly 40, in the example of Figure 3 the B-pillar 44.

The outer extruded sill member 23 further comprises an upper wall 235, opposite a lower wall 237. The upper and lower walls 235, 237 extend between and connect the side walls

231, 233. Together, the side walls 231, 233 and the upper and lower walls 235, 237 define a second cavity 239 extending in a longitudinal direction of the outer extruded sill member 23.

A second plurality of openings 238 is provided on the inner side wall 231. Similar to the first plurality of openings 218, the second plurality of openings 238 allow access to the inside surface of the outer side wall 233 for mounting the outer extruded sill member 23 to the side frame reinforcement assembly 40. It will be appreciated that the amount and location of the first and second plurality of openings 218, 238 may vary depending on the stability requirements of the sill assembly and the number and location of joints to the side frame assembly 30 and side frame reinforcement assembly 40. It is, however, advantageous to arrange for the first plurality of openings 218 not to coincide or overlap with the second plurality of openings 238 (i.e. to offset the first and second plurality of openings), as will be described in more detail below.

Figure 4a shows a schematic cross-section along line A-A shown in Figure 3. The inner extruded sill member 21 is connected to the vehicle side frame assembly 30 by fastening means 51, 52 achieved using double-sided access for the joining tool, particularly selfpiercing rivets. The rivets are introduced into the first cavity 219 of the inner extruded sill member 21 via the first plurality of openings 218 and protrude through the inner side wall 211 and into the respective part of the vehicle bodyshell side frame assembly 30 (which in turn is supported by the die of the joining tool). Of course, other fastening means, such as double-sided spot welds may be used instead of the self-piercing rivets depicted in Figure 4a.

Figure 4b shows a schematic cross-section along line B-B of Figure 3. The second plurality of openings 238 act as access bores for double-sided fastening means 54 and 55. The double-sided fastening means 54 and 55 attach the outer extruded sill member 23 to a corresponding part of the side frame reinforcement assembly 40, in this example the B-pillar 44. The second plurality of openings 238 extend through the inner side wall 231 of the outer extruded sill member 23 and allow access to the inner surface of the outer side wall 233. This provides access for the fastening means 54 and 55 and the required tool.

Figures 4c and 4d show cross-sections of the inner and outer extruded sill members 21, 23 of the embodiment in Figures 4a and 4b mounted together as a sill structure according to an embodiment of the present invention. Figure 4c shows a cross-section along line A-A. The inner and outer extruded sill members 21, 23 are attached to each other along their corresponding outer/inner side walls. In particular, the outside surface of the outer side wall 213 of the inner extruded sill member 21 is connected to the outside surface of the inner side wall 231 of the outer extruded sill member 23. The inner and outer extruded sill members 21, 23 of this example are attached to each other by means of a self-tapping screw 61. Alternatively and additionally, it is also feasible to attach the inner and outer extruded sill members 21,23 in other ways, such as gluing.

A third plurality of openings 80 may be provided in the outer side wall 233 of the outer extruded sill member 23 to provide access to an inside surface of the inner side wall 231 of the outer extruded sill member 23. It will be appreciated that the plurality of third openings are offset from the first and second plurality of openings 218, 238 described hereinbefore. A fourth plurality of openings 82 may be provided along the side frame reinforcement assembly 40 and aligned with the third plurality of openings 80.

From Figure 4c, it will also be appreciated that the plurality of first openings 218 are offset from the plurality of second openings 238. Figure 4c shows that some of the first plurality of openings 218 are arranged next to a solid part (i.e. a part with no openings) of the inner side wall 231 of the outer extruded sill member 23. This arrangement provides the sill assembly of the present invention with increased strength and stiffness.

Figure 4d shows a cross-section of the sill assembly along line B-B. Similar to the illustration of Figure 4c, there is a self-tapping screw 62 shown between the outer side wall 213 of the inner extruded sill member 21 and the inner side wall 231 of the outer extruded sill member

23. It will be understood that a number of self-tapping screws are provided between the inner and outer extruded sill members 21,23, along the longitudinal direction of the sill assembly.

Figure 4d shows two of the second plurality of openings 238 arranged next to a solid section of the outer side wall 213 of the inner extruded sill member 21. In other words, the plurality of first and second openings 218, 238 of the embodiment shown in Figures 4c and 4d are offset from each other in a longitudinal direction of the sill assembly. Additionally or alternatively, it is also feasible to offset the first and second plurality of openings in a vertical direction.

It should be appreciated that the inner and outer extruded sill members 21, 23 are mounted to their respective vehicle body parts before being secured to each other. This will help nullify compounded dimensional variability accumulated during earlier assembly stages in the manufacture of the vehicle bodyshell side frame assembly 30, the floor structure 70 or the side frame reinforcement assembly 40 respectively.

Figure 5 shows an embodiment of the sill assembly according to the present invention. Parts of the sill assembly of Figure 5 that correspond to parts of the sill assembly shown in Figures 4c and 4d are labelled with identical reference signs. The sill assembly according to the embodiment of Figure 5 differs from the embodiment shown in Figure 4c in that the sill assembly comprises mounting flanges protruding from the top walls 215, 235 of the inner and outer extruded sill members 21,23. In particular, a first mounting flange 212a protrudes from the upper wall 215 of the inner extruded sill member 21, particularly along outer side wall 213. In other words, the mounting flange 212a is an extension of side wall 213 that protrudes over the upper wall 215 of the inner extruded sill member 21. A corresponding, second mounting flange 232a protrudes from the upper wall 235 of the outer extruded sill member 23 along the inner side wall 231. The second mounting flange 232a is an extension of the inner side wall 231 of the outer extruded sill member 23 and protrudes over the upper wall 235. In this embodiment, the first and second mounting flanges 212a, 232a have a similar height and thickness to facilitate spot welding 63 or other joining methods to be applied therebetween.

Figure 6 shows an embodiment of the sill assembly, which is similar to the embodiment shown in Figure 5. Parts of Figure 6 that correspond to parts shown in Figure 5 are labelled with identical reference signs. In contrast to the embodiment in Figure 5, the embodiment of Figure 6 shows first and second mounting flanges 212b, 232b protruding over the lower walls 217, 237 of the inner and outer extruded sill members 21, 23. The first and second mounting flanges 212b, 232b are extensions of the side walls 213, 231 and extend below the lower walls 217, 237. Again, the first and second mounting flanges 212b, 232b have corresponding shapes and sized in order to facilitate spot welding 64 or other joining methods to be applied therebetween.

In another embodiment, which is not shown in any of the drawings, a combination of the first and second mounting flanges 212a, 232a, 212b, 232b shown in Figures 5 and 6 may be provided to improve the stability of the connection between the inner and outer extruded sill members 21,23.

Figure 7 shows an embodiment that helps to improve the connection between the inner and outer extruded sill members 21, 23 with their respective parts of the vehicle bodyshell. Parts of Figure 7 that correspond to parts of the previous illustrations are labelled with identical reference signs. In this embodiment, the inner and outer extruded sill members 21, 23 both comprise attachment flanges extending above the upper walls 215, 235 of the respective extruded sill members. A first attachment flange 214 is an extension of the inner side wall 211 of the inner extruded sill member 21 and protrudes over the upper wall 215. The first attachment flange 214 facilitates spot welding 65 between the inner extruded sill member 21 and the corresponding vehicle bodyshell side frame 30.

A second attachment flange 234 extends above the upper wall 235 of the outer extruded sill member 23. The second attachment flange 234 is an extension of the outer side wall 233 of the outer extruded sill member 23 and protrudes from the upper wall 235 thereof. The second attachment flange 234 facilitates spot welding 66 between an outer surface of the outer extruded sill member 23 and its corresponding side frame reinforcement panel 40. In an embodiment not depicted in any of the drawings, attachment flanges may alternatively or additionally be arranged below the lower wall 217, 237 of the inner and outer extruded sill members 21,23.

It should be understood that the spot-welds 63, 64, 65, and 66 are described by way of example only, and any other appropriate joining method, such as self-pierce riveting, gluing, etc. are equivalently feasible.

Figure 8 shows a schematic cross-section of an embodiment of the sill assembly according to the present invention. The embodiment of Figure 8 mostly corresponds to the embodiment shown in Figure 4c. Parts in Figure 8 that correspond to parts in Figure 4c are labelled with identical reference signs. In addition to the parts shown in Figure 4c, the embodiment of Figure 8 shows reinforcement structures in each of the inner and outer extruded sill members 21,23. A first reinforcement structure 216 is arranged within the first cavity 219 of the inner extruded sill member 21. The first reinforcement structure 216 extends between the upper and lower walls 215, 217 and divides the inner cavity 219 into two substantially separate chambers. The reinforcing structure 216 further increases structural stability of the inner extruded sill member 21. A plurality of openings 218a are provided within the reinforcing structure 216. The plurality of openings 218a correspond to the plurality of first 15 openings 218 of the inner extruded sill member 21 and are aligned with the latter. This will again facilitate introduction of the fastening means 51, 52 when the inner extruded sill member 21 is mounted to the vehicle body side panel 30 and I or floor structure 70.

A second reinforcing structure 236 is provided within the second cavity 239 of the outer extruded sill member 23. The second reinforcing structure 236 extends between the upper and lower walls 235, 237 of the outer extruded sill member 23 and divides the second cavity 239 into two substantially separate chambers. Although not shown in Figure 8, the second reinforcing structure 236 also comprises openings, which are aligned with the second plurality of openings 238 of the outer extruded sill member 23. The skilled practitioner will understand that the shape and orientation of the reinforcing structures 216, 236 is not limited to the vertical wall design shown in Figure 8. Rather, it is also feasible to construct additional or alternative reinforcing structures that extend in any other direction or exhibit a curved/undulating shape.

Turning to Figure 9, there is shown a schematic cross-section of an embodiment of the sill assembly according to the present invention. The embodiment of Figure 9 mostly corresponds to the embodiment shown in Figure 4c. Parts in Figure 9 that correspond to parts in Figure 4c are labelled with identical reference signs. In addition to the parts shown in Figure 4c, the inner extruded sill member 21 of the embodiment of Figure 9 includes a sideways projecting flange portion 211a. The sideways projecting flange portion 211a extends substantially perpendicular to the inner side wall 211 of the inner extruded sill member 21. The sideways projecting flange portion 211a extends from an outside surface of the inner side wall and is arranged to connect the inner extruded sill member 21 with a corresponding part of the floor structure 70. In this particular example, the sideways projecting flange portion 211a is connected to the floor structure by means of spot weld 67, however other attachment means such as gluing or riveting are equivalently feasible.

In the embodiment of Figure 9, another part of the inner side wall 211 is directly connected to the seat mounting cross-member 73 of the floor structure 70. The inner side wall 211 is connected to the seat mounting cross-member 73 via fastening means 54, particularly selfpiercing rivets. The rivets are introduced into the first cavity 219 of the inner extruded sill member 21 via the first plurality of openings 218 and protrude through the inner side wall 211 and into a flange section of the seat mounting cross-member 73. Consequently, the inner extruded sill member 21 of this embodiment is exclusively connected to the floor 16 structure 70. The vehicle side frame assembly 30 and the side frame reinforcement assembly 40 may, therefore, both be secured to the outer extruded sill member 23, before the latter is attached to the inner extruded sill member 21.

A perspective view of an embodiment of the sill assembly according to the present invention is shown in Figure 10. Parts of Figure 10 that correspond to parts described hereinbefore are labelled with identical reference signs. The inner extruded sill member 21 comprises inner and outer side walls 211, 213 and two reinforcing structures 216 (vertical reinforcement), 216-1 (horizontal reinforcement) extending therebetween, separating the first cavity 219 into three substantially separate cavities. Cavity 240 may be used to attach the inner extruded sill member 21, and thus the sill assembly 2, to a battery pack of an electric vehicle.

An attachment flange 214 extends above the upper wall 215 of the inner extruded sill member 21. In other words, the attachment flange 214 is an extension of the inner side wall 211 of the inner extruded sill member 21. The inner wall 211 and the attachment flange 214 are configured to be connected to a vehicle bodyshell side frame as described hereinbefore.

On the opposite, outer side wall 213, mounting flanges 212a and 212b extend above and below the upper and lower walls 215, 217 of the inner extruded sill member 21. Corresponding second mounting flanges 232a, 232b extend above and below the upper and lower walls 235, 237 of the outer extruded sill member 23 and are an extension of the inner side wall 231. The first mounting flanges 212a, 212b are attached to the second mounting flanges 232a, 232b by means of self-pierce riveting, spot welding or gluing. In the embodiment of Figure 9, the upper mounting flange 212a of the inner extruded sill member 21 comprises a plurality of tap-like flange sections or crenellations, which are secured to a continuous upper mounting flange 232a of the outer extruded sill member 23.

The outer extruded sill member 23 comprises two reinforcement structures 236 (vertical reinforcement), 236-1 (horizontal reinforcement) extending between the inner and outer side walls 231,233 thereof and separating the second cavity 239 into three substantially separate cavities.

Figure 11 shows a cross-section of an embodiment of the sill assembly according to the present invention. Parts of Figure 11 that correspond to parts described hereinbefore are labelled with identical reference signs. Similar to the embodiment of Figure 10, the variant shown in Figure 11 comprises a variety of horizontal and vertical reinforcement structures 216-1, 216-2, 216-3, 236-1 and 236-2. The reinforcement structures 216-1,216-2 and 216-3 of the inner extruded sill member 21 divide the first cavity into four substantially separate cavities. The reinforcement structures 236-1 and 236-2 divide the outer extruded sill member 23 into three substantially separate cavities.

The outer side wall 213 of the inner extruded sill member 21 defines a first step 213a. The inner side wall 231 of the outer extruded sill member 23 defines a second step 231a. In other words, the outer side wall 213 of the inner extruded sill member 21 and the inner side wall 231 of the inner extruded sill member 23 are step-shaped. The first and second steps 213a, 231a have complimentary shapes such that the latter may be brought into engagement when the inner and outer extruded sill members 21, 23 are connected to each other. As illustrated in Figure 11, the first and second steps 213a, 231a may be vertically offset from one another to create a gap there between when in position that permits some vertical movement between the inner and outer extruded sill members so as to compensate for and eliminate vertical variability that can accumulate in the large multi-part subassemblies of a bodyshell. Such a complimentary stepped structure of the inner and outer side walls permits different dimensional requirements to be achieved on upper and lower regions of the extruded sill members, whilst enabling vertical variability to be compensated for.

A flow chart showing an embodiment of the method of providing a vehicle body with a sill assembly is depicted in Figure 12. In a first step, S101, the inner extruded sill member 21 is secured to a lower portion of the vehicle body side frame assembly 30 and/or the vehicle floor structure 70. In step S102, the outer extruded sill member 23 is secured to a lower portion of the side frame reinforcement assembly 40. Steps S101 and S102 may be performed substantially simultaneously (as illustrated in Figure 12) or may be performed a different times. Once steps S101 and S102 are completed, the side frame reinforcement assembly 40 is brought into contact with the vehicle side frame assembly 30, and may be secured to the vehicle side frame assembly, in step S103. At this point, the first and second extruded sill members 21 and 23 are aligned but not yet secured to each other.

In a final step, S104, the outer extruded sill member 23 is secured to the inner extruded sill member 21. In particular, the inner side wall 231 of the outer extruded sill member 23 is secured to the outer side wall 213 of the inner extruded sill member 21. Connecting the inner and outer extruded sill members 21 and 23 in a final step allows tolerances of the side frame assembly 30 and the side frame reinforcement assembly 40 to be to be compensated.

Claims

1. A sill assembly (2) for a vehicle, the sill assembly (2) comprising:

an inner extruded sill member (21) configured to be secured to a vehicle body;

an outer extruded sill member (23) secured to the inner extruded sill member (21).

2. The sill assembly (2) of claim 1, wherein the inner extruded sill member (21) comprises opposite inner and outer side walls (211, 213), the inner extruded sill member (21) being secured to the vehicle body along its inner side wall (211), and wherein the outer extruded sill member (23) is secured to the outer side wall (213) of the inner extruded sill member (21).

3. The sill assembly (2) of claim 2, wherein the inner extruded sill member (21) comprises opposite upper and lower walls (215, 217) extending between the inner and outer side walls (211,213) to define a first cavity (219) running longitudinally through the inner extruded sill member (21).

4. The sill assembly (2) of claim 3, wherein the first cavity (219) is configured to receive electric wiring and/or fluid lines.

5. The sill assembly (2) of claim 3 or 4, wherein the inner extruded sill member (21) comprises a first reinforcing structure (216), said reinforcing structure dividing the first cavity (219) into at least two cavities.

6. The sill assembly (2) of any of claims 2 to 5, wherein the outer side wall (213) of the inner extruded sill member (21) comprises a first plurality of openings (218).

7. The sill assembly (2) of any of claims 1 to 6, wherein the outer extruded sill member (23) comprises opposite inner and outer side walls (231, 233), said inner side wall (231) being configured to be secured the inner extruded sill member (21).

8. The sill assembly (2) of claim 7 in combination with claim 2, wherein a shape of the outer side wall (213) of the inner extruded sill member (21) conforms to the shape of the inner side wall (231) of the outer extruded sill member (23).

9. The sill assembly (2) of claim 8, wherein the outer side wall (213) of the inner extruded sill member (21) and the inner side wall (231) of the outer extruded sill member (23) are substantially flat.

10. The sill assembly (2) of claim 8, wherein the outer side wall (213) of the inner extruded sill member (21) defines a first step (213a) and the inner side wall (231) of the outer extruded sill member (23) defines a second step (231a).

11. The sill assembly (2) of any of claims 7 to 10, wherein the outer extruded sill member (23) comprises opposite upper and lower walls (235, 237) extending between the inner and outer side walls (231,233) to define a second cavity (239) running longitudinally through the outer extruded sill member (23).

12. The sill assembly (2) of claim 11, wherein the outer extruded sill member (23) comprises a second reinforcing structure (236), said second reinforcing structure dividing the second cavity (239) into at least two cavities.

13. The sill assembly (2) of any of claims 7 to 12, wherein the inner side wall (231) of the outer sill member comprises a second plurality of openings (238).

14. The sill assembly (2) of claim 6 in combination with claim 13, wherein the first plurality of openings (218) are offset from the second plurality of openings (238).

15. The sill assembly (2) of claim 14, wherein the first and second plurality of openings (218, 238) are offset from each other along a longitudinal direction of the sill assembly (2).

16. The sill assembly (2) of claim 14 or 15, wherein the first and second plurality of openings (218, 238) are offset from each other along a vertical direction of the sill assembly (2).

17. The sill assembly (2) of any of claims 1 to 16, wherein the inner and outer extruded sill members (21, 23) comprise opposite inner and outer side walls (211, 213, 231, 233), said inner extruded sill member (21) comprising a first mounting flange (212a, 212b) extending above and/or below its outer side wall (213), said outer extruded sill member (23) comprising a second mounting flange (232a, 232b) configured to be secured to the first mounting flange (212a, 212b), said second mounting flange (232a, 232b) extending above and/or below the inner side wall (231) of the outer extruded sill member (23).

18. The sill assembly (2) according to claim 17, wherein the first mounting flange (212a, 212b) is secured to the second mounting flange (232a, 232b) by any of gluing, welding, riveting, bolting, or combinations thereof.

19. The sill assembly (2) of any of claims 1 to 18, wherein the inner extruded sill member (21) is configured to be secured to a vehicle underfloor structure.

20. The sill assembly (2) of any of claims 1 to 19, wherein the inner extruded sill member (21) is configured to be secured to a battery pack of a vehicle.

21. The sill assembly (2) of any of claims 1 to 20, wherein the inner and outer extruded sill members (21,23) are fabricated from aluminium, aluminium alloys, or steel.

22. The sill assembly (2) of any of claims 1 to 21, wherein the inner extruded sill member (21) comprises opposite inner and outer side walls (211, 213), said inner extruded sill member (21) comprising an attachment flange (214) extending above or below the inner side wall, said attachment flange (214) being configured to secure the inner extruded sill member (21) to a vehicle body.

23. The sill assembly (2) of any of claims 1 to 22, wherein the sill assembly comprises a trim panel configured to be secured to the outer extruded sill member (23).

24. The sill assembly (2) of any of claims 1 to 23, wherein the inner extruded sill member (21) is configured to be secured to a lower portion of a vehicle body side frame assembly (30).

25. The sill assembly (2) of any of claims 1 to 24, wherein the outer sill member (23) is configured to be secured to a lower portion of a side frame reinforcement assembly (40).

26. A vehicle (1) comprising the sill assembly (2) of any of claims 1 to 25.

27. A method of providing a vehicle body with a sill assembly, the method comprising:

i) securing an extruded inner sill member to a vehicle bodyshell;

ii) securing an extruded outer sill member to the inner sill member.

28. The method of claim 27, wherein in step i), the inner sill member is secured to a lower portion of a vehicle body side frame assembly and/or a floor structure.

29. The method of claim 27 or claim 28, wherein the outer sill member is secured to a lower portion of a side frame reinforcement assembly prior to step ii).

30. The method of claim 29, wherein, after the outer sill member is secured to the side frame reinforcement assembly, the vehicle side reinforcement assembly is secured to the vehicle body side frame assembly prior to step ii).

31. The method of any of claims 27 to 30, wherein a plurality of first openings are introduced into the inner sill member between steps i) and ii), wherein a plurality of second openings are introduced into the outer sill member between steps iii) and iv), and wherein the inner and outer sill members are aligned prior to step iv) such that the first and second plurality of openings are offset from each other.