GB2624865A

GB2624865A - Vehicle sill insert

Info

Publication number: GB2624865A
Application number: GB2217873.5A
Authority: GB
Inventors: Woolcock Tim Richard Martin; Carter Joe
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2022-11-29
Filing date: 2022-11-29
Publication date: 2024-06-05
Also published as: GB202217873D0

Abstract

A vehicle body is provided having a side sill 11-1, 11-2 with a sill insert 41 extending at least partway along a length of the side sill delimiting an elongate chamber 47 for receiving vehicle system components. Most preferably, insert 41 has a channel member 45 extending at least partway along a length of the sill, delimiting elongate chamber 47 and comprising a plurality of channel walls, and at least one locating member (59-n, Figure 3), for locating sill insert 41 in the side sill, on the exterior of at least one channel wall. The inserts may be resiliently deformable projecting cantilevers provided on opposing walls and may facilitate insertion of the insert in one longitudinal direction and inhibit or restrict removal in an opposite direction. Also provided are a sill insert assembly, a vehicle, a method of housing components and a sill insert. The components may be power cables or conduits such as refrigerant lines.

Description

VEHICLE SILL INSERT

TECHNICAL FIELD

The present disclosure relates to a vehicle sill insert. Aspects of the invention relate to a sill insert, a sill insert assembly, a vehicle body, a vehicle, and a method of housing one or more vehicle system components in a vehicle side sill.

BACKGROUND

Modern passenger vehicles are increasingly likely to be Battery Electric Vehicles (BEVs) which generally have a large battery pack positioned under the vehicle floor, between both the front and rear axle systems and between the vehicle side sills of the body. The battery pack is typically a relatively large vehicle component in order to deliver a good range. To ensure that the battery pack remains protected in any impact, the vehicle body sills need to be stiff and strong enough and to absorb energy in any side impact. Those requirements mean that the side sills typically has a section that is large in both height and width. Driver and passenger access to the vehicle requires the top of the sill section to be relatively low and there are a number of requirements relating to ground clearance that set the underside of the available space for these sill sections.

There is often the requirement for vehicle system components, such as electrical power cables or conduits, to connect one end of the vehicle to the other. Some of these may not be packaged within the vehicle cabin space for safety reasons. The voids formed in the side sills of the vehicle can be used to pass conduits, such as a refrigerant line, from one end of the vehicle to the other. A suitable route for the conduits may be provided in the vehicle body to enable the conduits to be inserted after the body has been constructed and painted. The conduits may be supported by foam blocks sub-assembled to the pipes that constrain and support them within the body section. The advantage of this arrangement is that available space for both battery pack and sill section is not compromised by non-structural pipes. However, this approach may not be suitable for vehicles that do not have a large aluminium extrusion or a smooth continuous pathway formed therein.

It is an aim of the present invention to address one or more of the disadvantages associated with the prior art.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a sill insert, a sill insert assembly, a vehicle body, a vehicle, and a method of housing one or more vehicle system components in a vehicle side sill as claimed in the appended claims According to an aspect of the present invention there is provided a vehicle body comprising a side sill having a sill insert installed therein, wherein the sill insert extends at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components.

The sill insert may comprise a channel member. The channel member may comprise at least one channel wall. Alternatively, the sill insert may comprise a partitioning member, for example comprising a single wall. The partitioning member could locate in one or more mounting channels formed in the vehicle side sill, for example.

According to another aspect of the present invention there is provided a sill insert configured to be installed in a vehicle side sill of a vehicle body as described above, the sill insert comprising: a channel member configured to extend at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components, the channel member comprising a plurality of channel walls; and at least one locating member configured to locate the sill insert within the vehicle side sill; wherein the at least one locating member is disposed on an exterior of at least one of the plurality of the channel walls.

The sill insert may extend in a longitudinal direction. At least in certain embodiments, the sill insert may extend along a length of the vehicle side sill. The channel member forms the elongate chamber within the vehicle side sill. The elongate chamber may be at least substantially free of interruptions or blockages. The elongate chamber may provide an uninterrupted route to facilitate installation of the one or more vehicle system components.

The vehicle side sill is formed in a body structure of a vehicle. The sill insert may be fitted after the body structure is assembled and optionally after painting of the body structure. The sill insert is particularly suitable for vehicles predominantly made from metal, such as aluminium or steel. The sill insert may help to protect anti-corrosion coatings (such as an e-coat, paint, cavity wax) provided inside the vehicle side sill. The sill insert may help to prevent these coatings being compromised, for example when the one or more vehicle system components is inserted into the vehicle side sill. The sill sections on even medium sized passenger cars are of significant length and the non-structural pipes can remain lightweight if they are supported at regular intervals along their length.

The sill insert is applicable, for example, where the related vehicle system is likely to be fitted only on a small proportion of vehicles. For example, the vehicle system may be an optional feature which is not fitted as standard to the vehicle or only in certain variants of a vehicle. The sill insert may be fitted only when required for installation of the related vehicle system components. These components and the sill insert may be omitted when the vehicle system is not installed. The sill insert may facilitate customisation of the body structure. This may reduce complexity during vehicle assembly. It will be understood that the sill insert is not limited in this respect and may, for example, be used for housing vehicle system components which are fitted as standard.

The sill insert may comprise a single locating member, for example extending in a longitudinal direction. Alternatively, the sill insert may comprise a plurality of the locating members. The locating members may be spaced apart from each other in a longitudinal direction.

The at least one locating member may be configured to facilitate insertion of the sill insert into the vehicle side sill in a first longitudinal direction. The at least one locating member may be configured to inhibit or restrict removal of the sill insert from the vehicle side sill in a second longitudinal direction. The first and second longitudinal directions may be opposite to each other.

The or each locating member may be resiliently deformable. In use, the or each locating member may engage a sidewall of the vehicle side sill. The or each locating member may be biased against the sidewall.

The at least one locating member may be configured to locate the sill insert within the vehicle side sill. The at least one locating member may be configured to resiliently locate the sill insert in one or more axis. The at least one locating member may be configured to locate the sill insert in one or more of the following: a longitudinal axis (X-axis), a transverse axis (Y-axis) and a vertical axis (Z-axis).

The or each locating member may be in the form of a cantilever. The or each locating member may be projecting at an acute angle relative to the exterior of the at least one of the plurality of the channel walls. The or each locating member may comprise a tab resiliently projecting at an angle from the sill insert.

The at least one locating member may be formed integrally with the channel member. For example, at least one locating member may be formed integrally with an associated channel wall. Alternatively, the at least one locating member may be fastened to the channel member. The at least one locating member may be formed separately and then fastened to the channel member, for example using a mechanical fastener.

The plurality of channel walls may comprise opposing first and second channel walls. The at least one locating member may comprise one or more first locating members disposed on the first channel wall. Alternatively, or in addition, the at least one locating member may comprise one or more second locating members disposed on the second channel wall. The first and second locating members may project outwardly in opposite directions.

The plurality of channel walls may comprise an upper channel wall. The at least one locating member may comprises at least one upper locating member disposed on the exterior of the upper channel wall.

The plurality of channel walls may comprise a lower channel wall. The at least one locating member may comprise at least one lower locating member disposed on the exterior of the lower channel wall. In a variant the lower channel wall may be free from the at least one locating member to facilitate installation of the sill insert in the vehicle side sill.

The sill insert may be formed of a plastics material. Altematively, the sill insert may be formed of a metal, for example aluminium or an aluminium alloy.

The channel member may comprise one or more live hinges to connect the channel walls to each other. The one or more live hinges may be formed integrally with the channel member, for example by forming obtuse corners in an extruded member. This arrangement may enable the channel member to be formed as a blank which may then be folded to form the channel member. The blank may be formed from a sheet member, for example by a pressing or a cutting operation. The sheet member may be extruded. The one or more live hinges may be formed integrally as the sheet member is extruded.

The channel member may comprise one or more fasteners for fastening channel walls to each other. For example, the one or more fasteners may comprise cooperating first and second interlocking components. The one or more fasteners may be formed integrally with the channel member. The one or more fasteners may facilitate formation of the channel member from a blank. The one or more fasteners may be configured to provide a self-clip function suitable for connecting adjacent walls of the channel member.

The channel member may be formed initially as a sheet member (blank) which is then folded to the desired shape or profile. The sheet member may comprise one or more live hinges. The live hinges may be formed integrally in the sheet member, for example to facilitate folding. The at least one locating member may be formed in the sheet member, for example by a cutting operation or a pressing process. At least in certain embodiments, there may be improved tool access to form the at least one locating member in the sheet member. The at least one locating member may be deformed relative to the associated channel wall, for example by a bending or folding operation. The sheet member may be folded to form the channel section after forming the at least one locating member.

First and second interlocking components may be formed on opposing edges of a sheet member for forming the channel member. The first and second interlocking components may lock together to retain the sheet member in the channel section.

The channel member may comprise a hollow section. The channel member may comprise a box section. The channel member may be rectangular or square in transverse section. The channel member may be polygonal in transverse section, for example triangular or trapezoidal. Alternatively, the channel member may be circular, elliptical or oval in transverse section. Other geometric profiles are also contemplated. For example, the channel member may comprise a stadium in transverse section.

The channel member may comprise or consist of one cell. Alternatively, the channel member may comprise a plurality of cells. For example, one or more internal walls may be provided in the channel member to form separate cells. The or each cell may extend along a length of the channel member.

The channel member may be open at a first end and/or a second end.

A first guide member may be removably mounted to a first end of the channel member. The first guide member may have a tapered profile to facilitate insertion of the sill insert into the vehicle side sill.

The sill insert may comprise at least one mounting flange for mounting the sill insert to the vehicle body. The at least one mounting flange may be configured to receive one or more mechanical fasteners. The sill insert may thereby be fastened to the vehicle body, for example to inhibit or restrict longitudinal movement. The at least one mounting flange may be provided at an end of the sill insert. The sill insert may comprise a first mounting flange disposed at a first end; and/or a second mounting flange disposed at a second end.

According to a further aspect of the present invention there is provided a sill insert assembly comprising a sill insert as described herein and at least one insert locator configured to support the sill insert within the vehicle side sill. The at least one insert locator may be configured to locate the sill insert within the vehicle side sill. The at least one insert locator may be configured to locate the sill insert transversely within the vehicle side sill.

The at least one insert locator may comprise a tapered or stepped section for biasing the sill insert in a transverse direction.

According to a further aspect of the present invention there is provided a sill insert configured to be installed in a vehicle side sill, the sill insert being configured to extend at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components; wherein the sill insert comprises at least one locating member configured to locate the sill insert within the vehicle side sill. The sill insert may comprise or consist of a single wall configured to extend across the vehicle side sill to form the elongate chamber within the vehicle side sill. Alternatively, the sill insert may comprise a plurality of walls.

According to a further aspect of the present invention there is provided a vehicle body comprising a sill insert as described herein. The sill insert may be installed in a side sill of the vehicle body. First and second sill inserts may be installed in respective first and second side sills.

One or more vehicle system components may be disposed in the elongated chamber formed by the channel member. The one or more vehicle system components may comprise at least one conduit. The at least one conduit may comprise one or more of the following: a coolant conduit; a refrigerant conduit; a compressed air conduit; and a hydraulic fluid conduit.

Different vehicle system components may be disposed in the channel member. The vehicle system components may be disposed in separate cells formed in the channel member. For example, a first vehicle system component may be disposed in a first cell formed in the channel member; and a second vehicle system component may be disposed in a second cell formed in the channel member.

The vehicle body may comprise at least one insert locator configured to support the sill insert within the vehicle side sill. The at least one insert locator may be configured to locate the sill insert within the vehicle side sill. The at least one insert locator may be configured to locate the sill insert transversely within the vehicle side sill. The at least one insert locator may extend transversely across the vehicle side sill. The or each insert locator may, for example, comprise a support pin. The or each insert locator may optionally comprise a shank and/or a head.

The at least one insert locator may comprise a tapered section or a stepped section for biasing the sill insert in a transverse direction. The tapered or stepped section may facilitate insertion of the at least one insert locator.

The or each insert locator may be supported in first and second apertures formed in opposing walls of the vehicle side sill. The first and second apertures may have first and second diameters, respectively. The first diameter may be larger than the second diameter. A distal end of the insert locator may be inserted through the first aperture and located in the second aperture. The insert locator may comprise a shank for locating in the second aperture. This arrangement may facilitate insertion and/or alignment of the or each insert locator.

According to a further aspect of the present invention there is provided a vehicle comprising a vehicle body as described herein and/or one or more sill inserts as described herein.

According to a further aspect of the present invention there is provided a method of housing one or more vehicle system components in a vehicle side sill, the method comprising inserting a sill insert into the vehicle side sill from a first end of the vehicle side sill, such that the sill insert defines an elongate chamber within the vehicle side sill; the sill insert comprising at least one locating member configured to engage an interior of the vehicle side sill to locate the sill insert within the vehicle side sill; and disposing the one or more vehicle system components in the elongate chamber.

A first guide member may be removably located in a first end of the channel member. The first guide member may be provided to facilitate insertion of the sill insert into the vehicle side sill. The first guide member may comprise a tapered profile, for example tapered in a longitudinal direction. The tapered profile may comprise or consist of a conical or part-conical profile section, or a pyramid section. The first guide member may be located in the first end of the channel member prior to inserting the sill insert into the vehicle side sill. Once inserted into the vehicle side sill, the method may comprise removing the first guide member.

The method may comprise installing a plurality of insert locators along a length of vehicle side sill to support the sill insert. The insert locators may extend transversely across the vehicle side sill.

According to a still further aspect of the invention there is provided a sill insert configured to be installed in a vehicle side sill, the sill insert comprising a channel member configured to extend at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components, the channel member comprising a plurality of channel walls and at least one locating member configured to locate the sill insert within the vehicle side sill wherein the at least one locating member is disposed on an exterior of at least one of the plurality of the channel walls.

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 plan view of a vehicle having first and second vehicle side sills for receiving sill inserts in accordance with an embodiment of the present invention; Figure 2 shows a transverse section through the first vehicle side sill shown in Figure 1 with a sill insert and sill locators installed therein; Figure 3 shows a perspective view of the sill insert and the insert locators shown in Figure 2; Figure 4 shows an enlarged view of the sill insert shown in Figure 3; Figure 5 shows an enlarged view of the insert locators shown in Figure 3; Figure 6 shows a perspective view of a guide member installed in an end of the sill insert to facilitate insertion into the vehicle side sill; Figure 7 shows a perspective view of an interior region of the first vehicle side sill prior to installation of the sill insert; Figure 8 shows a perspective view of the interior region of the first vehicle side sill shown in Figure 7 after installation of the sill insert; Figure 9 shows a transverse section with perspective of the first vehicle side sill prior to installation of the sill insert; and Figure 10 shows a transverse section with perspective of the first vehicle side sill after installation of the sill insert and a vehicle system component.

DETAILED DESCRIPTION

A sill insert assembly 1 in accordance with an embodiment of the present invention is described herein with reference to the accompanying Figures. The sill insert assembly 1 is configured to be installed in a body 3 of a vehicle 5 to support one or more vehicle system components.

The vehicle 5 is described herein with reference to a longitudinal axis (X), a transverse axis (Y) and a vertical axis (Z).

As illustrated in Figure 1, the vehicle 5 is a motor vehicle. For example, the vehicle 5 may be an automobile, a utility vehicle or a sports utility vehicle. The vehicle 5 of the present embodiment is a battery electric vehicle (BEV), i.e., an all-electric vehicle. The vehicle 5 comprises a traction battery 13 and an inverter 15 operative to convert direct current (DC) supplied by the traction battery 13 to altemating current (AC). The vehicle 5 comprises a cabin 7 for vehicle occupants. The cabin 7 comprises regions 9-n, namely a front cabin region 9- 1 and a rear cabin region 9-2. The front cabin region 9-1 in the present embodiments contains a front row of seats (not shown): and the rear cabin region 9-2 contains a rear row of seats (not shown). It will be understood that the cabin 7 may comprise more than two rows of seats. For example, the rear cabin region 9-2 of the cabin 7 may include a third row of seats and/or one or more occasional seats.

The terminology NN-n or NN(n) of reference numerals (where NN is a numeral) is employed herein to refer to the same general element and to indicate that there are multiple specific, but different, embodiments of the general element. These may be specifically referred to by replacement of (n) or -n with specific numbers, as in: NN-1, -2, -3 etc, or NN(1), (2), (3) etc. Variation in usage herein and in the accompanying drawings between the form NN-n and NN(n) is of no consequence and NN-n in this description may refer to NN(n) shown in the drawings, and vice versa.

The body 3 forms a structural frame of the vehicle 5. The drivetrain and vehicle suspension (not shown) are typically mounted to the body 3. The body 3 comprises first and second vehicle side sills 11-1, 11-2. The first and second vehicle side sills 11-1, 11-2 extend longitudinally at each of laterally opposite sides of a lower portion of the body 3 of the vehicle 5, for example below door apertures (not shown) formed on each side of the body 3. The first and second vehicle side sills 11-1, 11-2 are hollow and each have a channel section comprising one or more cells extending longitudinally. The first and second vehicle side sills 11-1, 11-2 may each comprise or consist of an extruded member, for example extruded from aluminium or an aluminium alloy. Alternatively, or in addition, the first and second vehicle side sills 11-1, 11-2 may each comprise an assembly, for example comprising pre-formed sheet members fastened together.

The vehicle 5 comprises a plurality of vehicle systems, the vehicle systems each comprising one or more vehicle system components. At least some of the vehicle system components may be disposed in the first vehicle side sill 11-1 and/or the second vehicle side sill 11-2. As described herein, the sill insert assembly 1 is configured to support one or more of the vehicle system component(s) within the first vehicle side sill 11-1 and/or the second vehicle side sill 11-2. The sill insert assembly 1 is described herein in relation to supporting one or more vehicle system components within the first vehicle side sill 11-1. Alternatively, or in addition, the sill insert assembly 1 can be used to support one or more vehicle system components in the second vehicle side sill 11-2.

The first vehicle system 21 in the present embodiment is a heating, ventilation and air conditioning (HVAC) system operative to control the temperature of the air in the cabin 7. The first vehicle system components 23(n) include a compressor 23(1), an air conditioning (AC) condenser 23(2), and an evaporator 23(3). The first vehicle system 21 also comprises a plurality of conduits 23(n), for example to convey a refrigerant. The first vehicle system components 23(n) comprise at least a first air conditioning conduit 23(4) and a second air conditioning conduit 23(5). In the present embodiment, the first and second air conditioning conduits 23(4), 23(5) are configured to convey a refrigerant for the HVAC system. In the present embodiment, a chiller HVAC unit 23(6) is provided for the rear cabin region 9-2. The chiller HVAC unit 23(6) is provided at the rear of the vehicle 5, for example on either the left hand side or the right hand side of a load space or a row of seats in the rear of the cabin 7 (for example to a side of the seats in a third row).

As shown in Figure 1, the first and second air conditioning conduits 23(4), 23(5) extend in a longitudinal direction. The first and second air conditioning conduits 23(4), 23(5) in the present embodiment extend between the compressor 23(1) and the chiller HVAC unit 23(6). The first and second air conditioning conduits 23(4), 23(5) may, for example, be provided to enable independent front/rear climate control in the cabin 7. The first and second air conditioning conduits 23(4), 23(5) may provide a four-zone climate control in the cabin 7.

As described herein, at least a portion of the first air conditioning conduit 23(4) is routed through the first vehicle side sill 11-1. Alternatively, or in addition, at least a portion of the second air conditioning conduit 23(5) is routed through the second vehicle side sill 11-2.

The sill insert assembly 1 in accordance with the present embodiment will now be described with reference to Figures 2 to 9. The sill insert assembly 1 is configured to be installed in the first vehicle side sill 11-1 and/or the second vehicle side sill 11-2. For the sake of brevity, the sill insert assembly 1 is described herein with reference to the first vehicle side sill 11-1. A transverse cross section (YZ-plane) of the first vehicle side sill 111 is shown in Figure 2. The first vehicle side sill 11-1 comprises a first channel 31-1 extending in a longitudinal direction (substantially parallel to the longitudinal axis X of the vehicle 5). It will be understood that the sill insert assembly 1 can also be installed in the second vehicle side sill 11-2.

The sill insert assembly 1 comprises a sill insert 41 and a plurality of insert locators 43. The sill insert 41 is configured to be installed in the first vehicle side sill 11-1. The insert locators 43 are configured locate the sill insert 41 vertically and/or transversely within the first vehicle side sill 11-1. The sill insert 41 is located between the insert locators 43 and an inside wall of the first vehicle side sill 11-1. In the present embodiment, the insert locators 43 extend in a transverse direction across the first vehicle side sill 11-1. In the arrangement illustrated in Figure 2, the sill insert 41 is disposed on top of the insert locators 43. In an alternative arrangement, the sill insert 41 may be disposed under the insert locators 43. For example, the sill insert 41 may be located on a bottom wall of the first vehicle side sill 11-1 and the insert locators 43 disposed above the sill insert 41 to limit or prevent vertical movement. One or more of the insert locators 43 may extend vertically, for example to limit or inhibit lateral movement of the sill insert 41 in the first vehicle side sill 11-1.

The sill insert 41 comprises a channel member 45 configured to extend at least partway along a length of the first vehicle side sill 11-1. The channel member 45 is configured to delimit at least one elongate chamber 47 within the first vehicle side sill 11-1. The channel member 45 thereby partitions or sub-divides an interior of the first vehicle side sill 11-1. The at least one elongate chamber 47 is suitable for receiving one or more of the first vehicle system components 23(n). In the present embodiment, the at least one elongate chamber 47 is suitable for receiving the first air conditioning conduit 23(4) of the first vehicle system 21. The insert locators 43 are configured to extend transversely across a width of the first vehicle side sill 11-1. The insert locators 43 are spaced apart from each other in a longitudinal direction to provide support for the sill insert 41 along its length.

As shown in Figure 3, the channel member 45 comprises a box section having a first sidewall 51, a second sidewall 53, an upper wall 55 and a lower wall 57. The channel member 45 in the present embodiment comprises a single elongate cell. In a variant, the channel member 45 may comprise a plurality of elongate cells. For example, one or more internal walls (not shown) may be provided to partition the channel member 45 along its length. The internal walls may extend horizontally and/or vertically within the channel member 45. The internal walls may, for example, be located in guide channels formed in opposing walls of the channel member 45. The internal walls may be removable, for example to enable the sill insert 41 to be configured for different applications. The channel member 45 is formed from a sheet member (or a blank) comprising panels joined to each other by a live (integral) hinge 49. The sheet member is folded along the live hinges to form the sidewalls of channel member 45. The sheet member in the present embodiment comprises a fastener 50 (shown in Figure 4) having cooperating features to secure the channel member 45 in the assembled state. In the present embodiment, the fastener 50 comprises interlocking features. The fastener 50 is formed integrally with the sheet member in the present embodiment. The sheet member may, for example, be extruded from a plastics material. According to an aspect of the present invention there is provided a sheet member for forming the sill insert 41 described herein.

The channel member 45 in the present embodiment is open at each end. The channel member 45 may optionally comprise one or more access apertures (not shown) disposed along its length, for example formed in one or more of the first sidewall 51, the second sidewall 53, the upper wall 55 and the lower wall 57. The first vehicle side sill 11-1 may comprise one or more apertures for alignment with the one or access apertures formed in the channel member 45. The aperture(s) formed in the first vehicle side sill 11-1 may align with the one or more access apertures formed in the channel member 45 to provide access to the first vehicle system component 23(n) disposed therein.

As shown in Figures 3 and 4, the channel member 45 comprises a plurality of locating members 59(n) for locating the channel member 45 within the first vehicle side sill 11-1. The locating members 59(n) in the present embodiment are formed integrally with the channel member 45. The locating members 59(n) may be pre-formed, for example in a pressing or punching operation. The locating members 59(n) remain attached along one edge in a cantilever arrangement. Other techniques may be used to form the channel member 45 and/or the locating members 59(n). For example, the channel member 45 could comprise an extruded box section. The locating members 59(n) may be formed separately and then fastened to the channel member 45. The locating members 59(n) may be fastened to the channel member 45 using a suitable fastening technique, such as plastic welding, adhesive/bonding or a mechanical fastener. The channel member 45 in the present is formed from a plastic material. In a variant, the channel member 45 could be formed from metal.

The locating members 59(n) are configured to engage an interior of the first vehicle side sill 11-1 to locate the channel member 45. When the sill insert 41 is located inside the first vehicle side sill 11-1, the locating members 59(n) may be spring biased against an interior of the first vehicle side sill 11-1. The locating members 59(n) are preferably resiliently deformable. The locating members 59(n) may, for example, be provided on the upper wall 55 and/orthe lower wall 57. Alternatively, or in addition, the locating member 59(n) may be provided on the first sidewall 51 and/or the second sidewall 53. In the present embodiment a plurality of first locating members 59(1) are provided on the upper wall 55; and a plurality of second locating members 59(2) are provided on the lower wall 57. The first locating members 59(1) project upwardly from the upper wall 55; and the second locating members 59(2) project downwardly from the lower wall 57. The first and second locating members 59(1), 59(2) are formed integrally with the respective upper and lower walls 55, 57.

In the present embodiment, each insert locator 43 extends transversely across the first vehicle side sill 11-1.

The insert locators 43 may be formed of plastic or metal. As shown in Figure 5, each insert locator 43 comprises a head 61, a shank 63 and a support pin 65. The shank 63 has a first diameter and the support pin 65 has a second diameter, the first diameter is larger than the second diameter. First and second apertures 67, 69 are formed in the opposing sidewalls of the first vehicle side sill 11-1 to receive the insert locators 43. The first and second apertures 67, 69 are sized to locate the shank 63 and the support pin 65. The first aperture 67 has a larger diameter than the second aperture 69. This arrangement may facilitate insertion of the insert locators 43, for example to enable the support pin 65 to be aligned with the second aperture. In use, the channel member 45 is supported on the support pins 65. In the present embodiment, the insert locators 43 comprise a tapered section 71 between the shank 63 and the support pin 65. The tapered section 71 tapers towards the support pin 65 and, in use, may help to bias the sill insert 41 towards the support pin 65. Alternatively, or in addition, each insert locator 43 comprises a step formed between the shank 63 and the support pin 65. The step may be formed between the shank 63 and the support pin 65. The step may form a face for engaging a sidewall of the channel member 45. The step may thereby limit lateral movement of the channel member 45 within the first vehicle side sill 11-1. The insert locators 43 may optionally comprise a retention feature (not shown), such as a clip, a tab or an anchor, for securing the insert locators 43 in position in the first vehicle side sill 11-1. Alternatively, or in addition, a fastening element, such as a nut or a locking pin, may be used to fasten the insert locators 43.

To facilitate insertion of the sill insert 41 into the first vehicle side sill 11-1, a first guide member 73 may be removably located on a first end of the channel member 45. As shown in Figure 6, the first guide member 73 comprises a head portion 75 which is tapered in a longitudinal direction. The head portion 75 of the first guide member 73 may, for example, comprise or consist of a cone or a pyramid. The first guide member 73 comprises a mounting section 77 which locates inside the channel member 45. The first guide member 73 comprises a handle 79. The handle 79 comprises a longitudinal protrusion in the present embodiment.

The installation of the sill insert assembly 1 in the first vehicle side sill 11-1 will now be described. A perspective side view of the first vehicle side sill 11-1, with side panels omitted and without the sill insert assembly 1 installed is shown in Figure 7. The same view of the first vehicle side sill 11-1 with the sill insert assembly 1 installed is shown in Figure 8. The plurality of first and second apertures 67, 69 are pre-formed in the sidewalls of the first vehicle side sill 11-1 to enable insertion of the insert locators 43. The insert locators 43 are located in the first and second apertures 67,69 formed along the length of the first vehicle side sill 11-1. The first guide member 73 is mounted on the first end of the channel member 45. The sill insert 41 is then inserted into the first vehicle side sill 11-1 from a first end. The sill insert 41 is displaced in a longitudinal direction along the insert locators 43. The tapered sections 71 of the insert locators 43 help to guide the channel member 45 as it is inserted into the first vehicle side sill 11-1. The first and second locating members 59(1), 59(2) cooperate with the upper wall of the first vehicle side sill 11-1 and the insert locators 43 to locate the channel member 45. The first guide member 73 is then removed from the first end of the channel member 45. The sill insert 41 may optionally be secured to limit or restrict longitudinal movement relative to the first vehicle side sill 11-1.

The first vehicle system component 23(n) may be pre-installed in the sill insert 41. For example, the first vehicle system component 23(n) may be installed in the channel member 45 prior to locating the sill insert 41 in the first vehicle side sill 11-1. In the present embodiment, this comprises locating the first air conditioning conduit 23(4) or (5) in the channel member 45. The first air conditioning conduit 23(4)1(5) and the sill insert 41 are then installed together. Alternatively, the first vehicle system component 23(n) may be installed after installation of the sill insert 41. For example, the first vehicle system component 23(n) may be installed in the channel member 45 after locating the sill insert 41 in the first vehicle side sill 11-1. The first vehicle system component 23(n) may be inserted into the channel member 45 after installation of the sill insert 41. It will be understood that one or more first vehicle system components 23(n) may be located in the sill insert 41.

At least in certain embodiments, the sill insert 41 may be inserted into the body 3 after assembly and painting. In use, the sill insert 41 is operative to support and protect the vehicle system component(s) 23(n) installed therein.

A transverse section of the first vehicle side sill 11-1 is shown in Figure 9 prior to installation of the sill insert by way of example. The vehicle side sill 11-1 includes internal components, such as sill reinforcement members and backing nuts. These internal components may make it difficult to insert system components, such as the first and second air conditioning conduits 23(4), 23(5), which may flex or bend as they are inserted into the vehicle side sill 11-1. A transverse section of the sill insert 41 is shown in Figure 10 by way of example. The sill insert 41 has an interior which is substantially free of projections which may obstruct or impede insertion of system components, such as the first and second air conditioning conduits 23(4), 23(5). In the illustrated arrangement, the sill insert 41 comprises a plurality of locating members 59(3) on the first and second sidewalls 51, 53. The locating members 59(3) may be provided on one or both of the first and second sidewalls 51, 53.

The locating members 59(3) may be provided in addition to or instead of the first and second locating members 59(1), 59(2).

As shown in Figure 10, the sill insert 41 in this arrangement is located on one or more support members 81.

The one or more support members 81 may, for example, be formed integrally with the body structure. In the present embodiment, the or each support member 81 comprises a metal tab or arm which is folded from a structural wall 83 mounted inside the vehicle side sill 11-1. The one or more support members 81 may be used in addition to, or instead of, the sill locators 43 (not shown in Figure 10).

One or more component locating members 85 may be provided inside the sill insert 41 to locate the first vehicle system component 23(n). The component locating members 85 may, for example comprise a resiliently deformable member, for example an expanded foam member. The component locating members 85 may be configured, in use, to reduce or inhibit transverse and/or vertical movement of the first vehicle system component 23(n) within the sill insert 41. The component locating members 85 may be spaced apart from each other in a longitudinal direction. The component locating members 85 may be configured to engage an interior of one or more of the walls 57, 59,61, 63 of the channel member 45 defining the insert 41.

The sill insert assembly 1 has been described with reference to the installation of first vehicle system components 23(n) of a first vehicle system 21. Alternatively, or in addition, the sill insert assembly 1 may be used in conjunction with a second vehicle system 25 comprising one or more second vehicle system components 27(n). By way of example, the second vehicle system 25 may comprise an electric drive system operative to propel the vehicle 5. The second vehicle system components 27(n) may comprise at least one electric drive motor 27(1) and one or more power cables 27(2). The one or more power cables 27(2) provide an electrical connection between the traction battery 13, the inverter 15 and the at least one electric drive motor 27(1). A portion of one or more of the power cables 27(2) may be routed through the first vehicle side sill 11-1 and/or the second vehicle side sill 11-2. The power cable 27(2) may be routed through the sill insert 41. The sill insert 41 may comprise first and second channels for the first and second vehicle system components 23(n), 27(n).

It will be understood that the sill insert assembly 1 may be used in conjunction with other vehicle system components. By way of example, the vehicle system components may comprise one or more of the following: a coolant conduit and a compressed air conduit (for an air suspension or tyre inflation). Alternatively, or in addition, the vehicle system component(s) may comprise one or more hydraulic fluid conduits, for example associated with a vehicle braking system and/or a suspension systems. Other vehicle system component(s) are contemplated.

It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

It will be understood that more than one sill insert 41 may be installed in each vehicle side sill 11-1, 11-2. For example, first and second sill inserts 41 may be installed in the first vehicle side sill 11-1. The first and second sill inserts 41 may be configured to receive first and second vehicle system components 23(n), 27(n) respectively. The first and second sill inserts 41 may be installed alongside each other; or one above the other.

The sill insert 41 has been described herein as having a single-cell arrangement arranged to form a single internal channel. In a variant, the sill insert 41 may comprise a multi-cell arrangement arranged to form a plurality of internal channels. The sill insert 41 may comprise one or more internal walls or webs configured to form a plurality of internal channels. For example, the sill insert 41 may comprise a first internal wall configured to form first and second internal channels. The one or more internal walls may extend between opposing walls of the sill insert 41.

The sill insert 41 illustrated herein is rectilinear. It will be understood that the sill insert 41 may be non-linear. For example, one or more curves may be formed in the sill insert 41. The one or more curves may be formed at least substantially to match the profile of the side sill 11-1, 11-2 of the vehicle 5. Alternatively, the sill insert 41 may be deformable. For example, the sill insert 41 may comprise at least one concertina section suitable for conforming to the profile of the side sill 11-1, 11-2 of the vehicle 5.

The sill insert 41 is configured to be relatively easily insertable into a vehicle sill by being relatively stiff longitudinally so that it can be manoeuvred and manipulated during insertion to avoid catching internal components of the space within the side sill. The provision of removable guide 75 facilitates the insertion process. During insertion of the sill insert into a vehicle side sill, the locating members periodically engage insert locators 43, 85, as the case may be, or internal walls of the side sill. The locating members 59(n) may thus also facilitate insertion of the sill insert by resiliently biasing the insert transversely to the longitudinal direction of its insertion to keep the sill insert central within the intended insertion space in the side sill. When inserted, sill insert 41 is configured to provide a relatively smooth channel through which more flexible vehicle components 23, 27 may be threaded without being snagged by internal components of the space within the side sill.

It will be appreciated that various changes and modifications can be made to the present disclosed examples without departing from the scope of the present application as defined by the appended claims. Whilst endeavouring in the foregoing specification to draw attention to those features believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

CLAIMS1. A vehicle body comprising a side sill having a sill insert installed therein, wherein the sill insert extends at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components.
2. A sill insert configured to be installed in a vehicle side sill of a vehicle body as claimed in claim 1, the sill insert comprising: a channel member configured to extend at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components, the channel member comprising a plurality of channel walls; and at least one locating member configured to locate the sill insert within the vehicle side sill; wherein the at least one locating member is disposed on an exterior of at least one of the plurality of the channel walls.
3. A sill insert as claimed in claim 2, wherein the at least one locating member is configured to facilitate insertion of the sill insert into the vehicle side sill in a first longitudinal direction; the at least one locating member optionally being configured to inhibit or restrict removal of the sill insert from the vehicle side sill in a second longitudinal direction, the first and second longitudinal directions being opposite to each other.
4. A sill insert as claimed in claim 2 or 3, wherein the or each locating member is resiliently deformable and is configured to locate the sill insert in one or more of: a longitudinal axis, a transverse axis and a vertical axis of the sill insert
5. A sill insert as claimed in any one of claims 2, 3 or 4, wherein the or each locating member is in the form of a cantilever; the or each locating member projecting at an acute angle relative to the exterior of the at least one of the plurality of the channel walls.
6. A sill insert as claimed in any one of claims 2 to 5, wherein the plurality of channel walls comprise opposing first and second channel walls; and the at least one locating member comprises at least one of: one or more first locating members disposed on the first channel wall; and optionally one or more second locating members disposed on the second channel wall.
7. A sill insert as claimed in any one claims 2 to 6, wherein the plurality of channel walls comprise an upper channel wall; and the at least one locating member comprises at least one upper locating member) disposed on the exterior of the upper channel wall; and/or wherein the plurality of channel walls comprise a lower channel wall; and the at least one locating member comprises at least one lower locating member) disposed on the exterior of the lower channel wall.
8. A sill insert as claimed in any one claims 2 to 7, wherein the channel member comprises a box section and comprises one or more live hinges to connect the channel walls of the box section to each other.
9. A sill insert as claimed in any one of claims 2 to 8, wherein a first guide member is removably mounted to a first end of the channel member, the first guide member having a tapered profile to facilitate insertion of the sill insert into the vehicle side sill.
10. A sill insert assembly comprising a sill insert as claimed in any one of claims 2 to 9 and at least one insert locator configured to support the sill insert within the vehicle side sill.
11. A sill insert assembly as claimed in claim 10, wherein the at least one insert locator is configured to locate the sill insert transversely within the vehicle side sill and wherein the at least one insert locator comprises a tapered or stepped section for biasing the sill insert in a transverse direction.
12. A vehicle body comprising a sill insert as claimed in any one of claims 2 to 9, or a sill insert assembly as claimed in claim 10 or 11, the sill insert being installed in a side sill of the vehicle body.
13. A vehicle body as claimed in claim 12, wherein said one or more vehicle system components, is disposed in the elongate chamber formed by the channel member.
14. A vehicle comprising a vehicle body as claimed in any one of claims 1, 12 or 13 and/or one or more sill inserts as claimed in any one of claims 2 to 9 and/or a sill insert assembly as claimed in claim 10 01 11.
15. A method of housing one or more vehicle system components in a vehicle side sill, the method comprising inserting a sill insert into the vehicle side sill from a first end of the vehicle side sill, such that the sill insert defines an elongate chamber within the vehicle side sill; the sill insert comprising at least one locating member configured to engage an interior of the vehicle side sill to locate the sill insert within the vehicle side sill; and disposing the one or more vehicle system components in the elongate chamber.
16. A sill insert configured to be installed in a vehicle side sill, the sill insert comprising: a channel member configured to extend at least partway along a length of the vehicle side sill to delimit an elongate chamber within the vehicle side sill for receiving one or more vehicle system components, the channel member comprising a plurality of channel walls; and at least one locating member configured to locate the sill insert within the vehicle side sill; wherein the at least one locating member is disposed on an exterior of at least one of the plurality of the channel walls.