System for absorbing and distributing side impact energy utilizing a side sill assembly with a collapsible sill insert

1. An energy absorbing and distributing side impact system for a vehicle, comprising:

a pair of side sill assemblies, said pair of side sill assemblies comprising a left hand side sill assembly and a right hand side sill assembly, wherein each of said side sill assemblies further comprises a side sill insert, wherein said side sill insert is captured between an inner side sill wall and an outer side sill wall, wherein said side sill insert further comprises a reacting portion and a collapsible portion, wherein said reacting portion is adjacent to said inner side sill wall and wherein said collapsible portion is adjacent to said outer side sill wall;

a plurality of vehicle cross-members interposed between said inner side sill walls of said left hand side sill assembly and said right hand side sill assembly, wherein each of said plurality of vehicle cross-members is mechanically coupled to said inner side sill walls of said left hand side sill assembly and said right hand side sill assembly; and

wherein said side sill insert is captured between a substantially horizontal inner side sill wall and a pair of insert guide members, wherein a first insert guide member of said pair of insert guide members extends from an inner surface of said inner side sill wall, and wherein a second insert guide member of said pair of insert guide members extends from an inner surface of said outer side sill wall, and wherein said substantially horizontal inner side sill wall is interposed between and is coupled to said inner surface of said inner side sill wall and said inner surface of said outer side sill wall.

2. The energy absorbing and distributing side impact system of claim 1 , wherein said side sill insert is held in place between said inner side sill wall and said outer side sill wall using a plurality of mechanical fasteners.

3. The energy absorbing and distributing side impact system of claim 2 , wherein said plurality of mechanical fasteners are selected from the group consisting of rivets and bolts.

4. The energy absorbing and distributing side impact system of claim 1 , wherein said side sill insert is held in place between said inner side sill wall and said outer side sill wall using a plurality of spot welds.

5. The energy absorbing and distributing side impact system of claim 1 , wherein said side sill insert is held in place between said inner side sill wall and said outer side sill wall using an adhesive.

6. The energy absorbing and distributing side impact system of claim 1 , further comprising:

a pair of rear torque boxes, said pair of rear torque boxes comprising a left hand rear torque box mechanically coupled to said left hand side sill assembly and a right hand rear torque box mechanically coupled to said right hand side sill assembly; and

a pair of front torque boxes, said pair of front torque boxes comprising a left hand front torque box mechanically coupled to said left hand side sill assembly and a right hand front torque box mechanically coupled to said right hand side sill assembly;

wherein each of said side sill inserts has a rectangularly-shaped cross section, and wherein each of said sill inserts extends longitudinally within each of said side sill assemblies from a first side sill assembly end portion proximate to one of said pair of front torque boxes to a second side sill assembly end portion proximate to one of said pair of rear torque boxes.

7. The energy absorbing and distributing side impact system of claim 6 , wherein each of said side sill inserts further comprises a vertical internal wall interposed between an upper sill insert wall and a lower sill insert wall, said vertical internal wall separating said reacting portion from said collapsible portion.

8. The energy absorbing and distributing side impact system of claim 7 , wherein said reacting portion is substantially square-shaped.

9. The energy absorbing and distributing side impact system of claim 7 , wherein said collapsible portion further comprises a pair of diagonal structural members, wherein said pair of diagonal structural members cross to form an x-shape, and wherein each diagonal structural member of said pair of diagonal structural members extends between said upper sill insert wall and said lower sill insert wall.

10. The energy absorbing and distributing side impact system of claim 7 , wherein said collapsible portion further comprises a first pair of diagonal structural members and a second pair of diagonal structural members, wherein said first pair of diagonal structural members cross to form a first x-shape, wherein said second pair of diagonal structural members cross to form a second x-shape, and wherein each structural member of said first and second pair of diagonal structural members extends between said upper sill insert wall and said lower sill insert wall.

11. The energy absorbing and distributing side impact system of claim 10 , wherein said first pair of diagonal structural members is configured to collapse and deform prior to said second pair of diagonal structural members during a side impact collision, wherein said first pair of diagonal structural members is closer to said outer side sill wall than said second pair of diagonal structural members.

12. The energy absorbing and distributing side impact system of claim 1 , further comprising:

a pair of rear torque boxes, said pair of rear torque boxes comprising a left hand rear torque box mechanically coupled to said left hand side sill assembly and a right hand rear torque box mechanically coupled to said right hand side sill assembly; and

at least one rear torque box cross-member interposed between said left hand rear torque box and said right hand rear torque box, wherein said at least one rear torque box cross-member is mechanically coupled to both said left hand rear torque box and said right hand rear torque box;

wherein said left hand rear torque box is welded to said left hand side sill assembly and said right hand rear torque box is welded to said right hand side sill assembly, and wherein said at least one rear torque box cross-member is welded to both said left hand rear torque box and said right hand rear torque box.

13. The energy absorbing and distributing side impact system of claim 1 , further comprising a pair of front torque boxes, said pair of front torque boxes comprising a left hand front torque box mechanically coupled to said left hand side sill assembly and a right hand front torque box mechanically coupled to said right hand side sill assembly, wherein said left hand front torque box is welded to said left hand side sill assembly and said right hand front torque box is welded to said right hand side sill assembly.

14. The energy absorbing and distributing side impact system of claim 1 , further comprising:

a pair of front torque boxes, said pair of front torque boxes comprising a left hand front torque box mechanically coupled to said left hand side sill assembly and a right hand front torque box mechanically coupled to said right hand side sill assembly; and

a toe board cross-member interposed between said left hand front torque box and said right hand front torque box;

wherein said toe board cross-member is mechanically coupled to both said left hand front torque box and said right hand front torque box.

15. The energy absorbing and distributing side impact system of claim 1 , wherein said left hand side sill assembly and said right hand side sill assembly are each comprised of a material selected from the group consisting of aluminum extrusions, aluminum alloy extrusions and steel extrusions.

16. The energy absorbing and distributing side impact system of claim 1 , wherein said side sill insert is fabricated from an aluminum alloy.