Integrated trunk floor structure and mounting method thereof

Abstract

The invention discloses an integrated trunk floor structure and an installation method thereof. The integrated trunk floor structure comprises a trunk module used for loading a high-voltage electrical system integration module and a trunk metal plate frame, wherein the left side and the right side of the trunk metal plate frame are fixed to a left longitudinal beam and a right longitudinal beam of a vehicle body respectively. The trunk module is fixed below the trunk metal plate frame through a vehicle body mounting beam, the area, located over the trunk module, of the trunk metal plate frame is of a via hole structure, and the top face of the trunk module and the top face of the trunk metal plate frame jointly form a trunk floor; by means of the trunk floor formed by integrating the trunk module and the trunk metal plate frame, the Z-direction space of the trunk can be effectively improved. Through double optimization of space and weight, the practicability and economical efficiency of the vehicle are remarkably improved, the method is particularly suitable for the scene that new energy vehicles have high requirements for endurance and space, differential selling points can be formed through the space advantage and the lightweight technology in the market competition of vehicle enterprises, and the product competitiveness is enhanced.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle structure design, and in particular to an integrated luggage compartment floor structure and an installation method thereof. Background Art

[0002] In the development and production of modern vehicles, effective utilization of trunk space and overall lightweight design are crucial for improving vehicle practicality, fuel economy (or range), and handling. This is particularly true for models that locate modules such as the on-board charger (OBC), DC-DC converter (DCDC), and power distribution unit (PDU) in the trunk floor. Traditional design and placement methods present significant drawbacks.

[0003] Currently, various modules typically placed in the trunk area are typically mounted above the trunk using a transition bracket. This installation method creates additional space between the module and the trunk, significantly compressing the trunk's Z-direction clearance. For example, in the Ideal L9 model, this installation method uses approximately 160mm of Z-direction clearance due to the transition bracket (approximately 22mm) and the trunk module (approximately 138mm). This significantly reduces the trunk's ability to carry large items, reducing user convenience and satisfaction.

[0004] On the other hand, traditional solutions for trunk floor sheet metal design treat the trunk area sheet metal as a single unit, supporting components above the trunk area. While this design provides stable support, it also presents structural redundancy issues. The lack of optimized design between the trunk module and the trunk floor prevents efficient structural integration, resulting in the use of a large amount of sheet metal, increasing vehicle weight (and unnecessary production costs). This also limits further optimization of trunk space, making it difficult to meet the automotive industry's urgent needs for lightweighting and efficient space utilization.

[0005] Therefore, there is an urgent need for an innovative integrated design method for the trunk floor and trunk module, which can not only effectively solve the problem of excessive occupation of the trunk Z-direction space, but also achieve a lightweight design of the trunk floor sheet metal, thereby improving the overall performance and market competitiveness of the vehicle. Summary of the Invention

[0006] The purpose of the present invention is to address the deficiencies of the above-mentioned background technology and to provide an integrated trunk floor structure and its installation method that can effectively solve the problem of excessive occupation of the trunk Z-direction space and realize the lightweight design of the trunk floor sheet metal.

[0007] To achieve this objective, the integrated trunk floor structure designed in the present invention includes: a trunk module for loading a high-voltage electrical system integrated module and a trunk sheet metal frame fixed on both sides to the left and right longitudinal beams of the vehicle body respectively; the trunk module is fixed to the bottom of the trunk sheet metal frame via the vehicle body mounting beam, the area of ​​the trunk sheet metal frame directly above the trunk module is a through-hole structure, and the top surface of the trunk module and the top surface of the trunk sheet metal frame together constitute the trunk floor; the trunk floor formed by the integration of the trunk module and the trunk sheet metal frame can effectively improve the Z-direction space of the trunk.

[0008] Furthermore, the trunk module includes a loading box body for loading a high-voltage electrical system integrated module, the vehicle body mounting beam is detachably fixed on the loading box body, the vehicle body mounting beam is fixed under the trunk sheet metal frame, the through-hole structure is located directly above the top surface of the loading box body, and the top surface of the loading box body and the top surface of the trunk sheet metal frame together constitute the trunk floor.

[0009] Furthermore, a wiring harness interface is provided on the top of the loading box body.

[0010] Furthermore, the vehicle body mounting beam is an annular structure corresponding to the shape of the luggage box sheet metal frame, and the four sides of the vehicle body mounting beam can be detachably fixed to the loading box body.

[0011] Furthermore, the body mounting beam includes a box body matching ring plate whose inner surface cooperates with the outer surface of the loading box body, and a body matching ring plate fixedly connected to the outer top surface of the box body matching ring plate and forming an integral structure with the box body matching ring plate. The body matching ring plate is fixed to the bottom surface of the trunk sheet metal frame.

[0012] Furthermore, a plurality of ear plates are arranged at intervals around the loading box body, each of the ear plates is provided with at least one threaded hole, and the matching ring plate of the box body is provided with a plurality of bolt through holes corresponding to the threaded holes at intervals along its circumferential direction, and the bolts pass through the bolt through holes and are threadedly connected to the threaded holes.

[0013] Furthermore, the box body matching ring plate includes a box body positioning ring plate for wrapping the top surface edges and the top edges of the side surfaces of the loading box body, and a connecting ring plate fixedly connected between the box body positioning ring plate and the vehicle body matching ring plate, and the connecting ring plate is provided with the bolt through holes spaced apart along its circumferential direction.

[0014] Furthermore, a sealing ring is provided between the box body positioning ring plate and the loading box body.

[0015] Furthermore, a method for installing an integrated trunk floor structure includes: fixing the body mounting beam to the trunk module, fixing the body mounting beam to the bottom surface of the trunk sheet metal frame, so that the area directly above the trunk module is the through-hole structure of the trunk sheet metal frame, and the top surface of the trunk module and the top surface of the trunk sheet metal frame together constitute the trunk floor.

[0016] Furthermore, the vehicle body mounting beam is detachably fixed to the luggage compartment module, and the vehicle body mounting beam is welded and fixed to the bottom surface of the luggage compartment sheet metal frame, so as to facilitate the removal and replacement of the luggage compartment module.

[0017] The beneficial effects of the present invention are:

[0018] 1. This invention secures trunk modules (such as OBC and DCDC) to the underside of the trunk sheet metal frame via body mounting beams. The top surfaces of the modules and the sheet metal frame directly form the trunk floor, eliminating transition brackets and the redundant space required by traditional mounting methods. This significantly increases the Z-direction space utilization of the trunk area and improves the loading capacity for large items. The trunk sheet metal frame utilizes a via structure directly above the module, eliminating overlap between the module top and the sheet metal frame. This allows the module top space to be directly incorporated into the trunk floor area, further freeing up vertical space in the trunk area and enhancing loading convenience. A sealing ring is provided between the box body positioning ring plate and the module to prevent dust and moisture from entering the module, enhancing the waterproof and dustproof performance of the high-voltage electrical system and ensuring driving safety.

[0019] 2. The present invention integrates the module and the sheet metal frame into a design, so that the module itself becomes part of the supporting structure. The sheet metal frame only needs to retain the necessary load-bearing area (such as the frame part outside the through-hole structure), reducing the use of unnecessary sheet metal materials, reducing the weight of the entire vehicle, and reducing production costs.

[0020] 3. The body mounting beam acts as a ring structure, connecting the module and the sheet metal frame at the same time, replacing the traditional complex installation method of multiple brackets, reducing the number of parts and assembly steps, and further reducing manufacturing complexity and weight.

[0021] 4. The release of trunk space directly improves the vehicle's loading capacity and meets users' needs for storage space. It is especially suitable for family cars or commercial scenarios, and improves user satisfaction.

[0022] 5. Reducing vehicle body weight can optimize vehicle fuel economy (or endurance), while reducing unsprung mass and improving handling stability, which is in line with the lightweight development trend in the automotive industry.

[0023] 6. The body mounting beam is detachably connected to the module (e.g., bolted) and welded to the sheet metal frame. When a module fails, it can be removed and replaced individually without disassembling the entire trunk structure, reducing maintenance costs and time.

[0024] In summary, the present invention significantly improves the practicality and economy of the vehicle through the dual optimization of space and weight. It is particularly suitable for scenarios where new energy vehicles have high requirements for endurance and space. It helps automobile companies to form differentiated selling points with "space advantages" and "lightweight technology" in market competition and enhance product competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the scope of protection of the present invention.

[0026] Figure 1 A structural perspective view of the assembly of the luggage compartment module and the vehicle body mounting beam in the present invention;

[0027] Figure 2 This is a structural perspective diagram of the luggage compartment module of the present invention;

[0028] Figure 3 This is a structural perspective diagram of the vehicle body mounting beam of the present invention;

[0029] Figure 4 is a perspective view of the luggage compartment floor structure of the present invention;

[0030] Figure 5 A bottom view of the luggage compartment floor structure of the present invention;

[0031] Among them, 1 is the trunk module (1.1 is the loading box, 1.2 is the wiring harness interface, 1.3 is the ear plate, 1.4 is the threaded hole), 2 is the trunk sheet metal frame, 3 is the body mounting beam (3.1 is the box matching ring plate, 3.2 is the body matching ring plate, 3.3 is the bolt through hole), 4 is the box positioning ring plate, 5 is the connecting ring plate, and 6 is the sealing ring. DETAILED DESCRIPTION

[0032] The technical solutions (including preferred technical solutions) of the present invention are further described in detail below by way of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. In the description of the present invention, it should be understood that the directions or positional relationships indicated by the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention.

[0033] The present invention designs an integrated luggage compartment floor structure and an installation method thereof.

[0034] like Figure 1 As shown in FIG5 , in certain embodiments, the integrated trunk floor structure includes a trunk module 1 for loading a high-voltage electrical system integrated module and a trunk sheet metal frame 2 fixed on the left and right longitudinal beams of the vehicle body respectively; the trunk module 1 is fixed to the bottom of the trunk sheet metal frame 2 by a vehicle body mounting beam 3, and the area of ​​the trunk sheet metal frame 2 directly above the trunk module 1 is a through-hole structure, and the top surface of the trunk module 1 and the top surface of the trunk sheet metal frame 2 together constitute the trunk floor.

[0035] Example 1

[0036] A specific embodiment of the assembly structure of the luggage compartment module 1 and the vehicle body mounting beam 3 is provided:

[0037] like Figure 1 As shown in FIG. 2 , the luggage compartment module 1 includes a loading box body 1.1 for loading a high-voltage electrical system integrated module. A plurality of ear plates 1.3 are arranged at intervals around the loading box body 1.1. A threaded hole 1.4 is provided on each ear plate 1.3. A wiring harness interface 1.2 is provided on the top of the loading box body 1.1.

[0038] like Figure 1As shown in Figure 3, the body mounting beam 3 is an annular structure corresponding to the shape of the luggage box sheet metal frame 2. It includes a body-matching ring plate 3.1, whose inner surface mates with the outer surface of the loading box 1.1, and a body-matching ring plate 3.2, fixedly connected to the outer top surfaces of the body-matching ring plate 3.1 and integrally formed with the body-matching ring plate 3.1. The body-matching ring plate 3.2 is fixed to the bottom surface of the luggage box sheet metal frame 2. The body-matching ring plate 3.1 includes a body-positioning ring plate 4, which wraps around the top and side edges of the loading box 1.1, and a connecting ring plate 5, fixedly connected between the body-positioning ring plate 4 and the body-matching ring plate 3.2. The connecting ring plate 5 is provided with bolt holes 3.3 spaced apart along its circumference. Bolts pass through the bolt holes 3.3 and are threaded into the threaded holes 1.4. A sealing ring 6 is provided between the body-positioning ring plate 4 and the loading box 1.1.

[0039] Example 2

[0040] Based on the above-mentioned integrated trunk floor structure, a method for installing the integrated trunk floor structure is provided: the vehicle body mounting beam 3 is fixed to the trunk module 1 by multiple bolts, and the vehicle body mounting beam 3 is welded and fixed to the bottom surface of the trunk sheet metal frame 2, so that the area directly above the trunk module 1 forms the through-hole structure of the trunk sheet metal frame 2, so that the top surface of the trunk module 1 and the top surface of the trunk sheet metal frame 2 together form the trunk floor.

[0041] In summary, the present invention aims to address the issues of excessive Z-direction space occupation and lightweight floor sheet metal in a luggage compartment through an integrated design. The core solution is to integrate the luggage compartment module 1 with the luggage compartment sheet metal frame 2 via a body mounting beam 3, so that the module's top surface and the sheet metal frame's top surface together form the luggage compartment floor. Furthermore, a through-hole structure is employed in the sheet metal frame area directly above the module to free up space and optimize the structure. The luggage compartment module 1 comprises a loading box 1.1 (for loading the high-voltage electrical module), a wiring harness interface 1.2, and four peripheral lugs 1.3. The lugs 1.3 have threaded holes 1.4 for connection to the body mounting beam. The body mounting beam 3 is an annular structure that corresponds in shape to the luggage compartment sheet metal frame 2 and consists of a box-matching ring plate 3.1 and a body-matching ring plate 3.2. The box-matching ring plate 3.1 includes a box-positioning ring plate 4 that wraps around the top and side edges of the loading box 1.1, and a connecting ring plate 5. The connecting ring plate 5 has bolt holes 3.3 that are secured to the lugs 1.3 through threaded holes 1.4. The body matching ring plate 3.2 and the box body matching ring plate 3.1 are integrally formed and welded to the bottom surface of the trunk sheet metal frame 2, connecting the module to the sheet metal frame. A sealing ring 6 is provided between the box body positioning ring plate 4 and the loading box body 1.1 to prevent dust and moisture from intruding into the module and ensure electrical safety. The left and right sides of the trunk sheet metal frame 2 are fixed to the left and right longitudinal beams of the vehicle body. The area directly above the trunk module 1 is designed as a through-hole structure, so that the top surface of the module is flush with the top surface of the sheet metal frame, together forming the trunk floor, eliminating the spatial overlap in traditional designs. The body mounting beam 3 is connected to the trunk module 1 with bolts, which facilitates separate removal and replacement of the module in the event of a failure; the welded connection to the sheet metal frame ensures structural rigidity, taking into account both maintenance convenience and assembly stability.

[0042] This design eliminates the traditional transition bracket (approximately 22mm) and redundant mounting space, freeing up approximately 160mm of free space in the Z direction. This improves the loading capacity of large items, significantly enhancing vertical space utilization in the Ideal L9 trunk. The through-hole structure allows the module's top space to be directly integrated into the trunk's usable area, avoiding structural overlap and further improving space utilization. The sheet metal frame eliminates the need for integral support, retaining only the necessary load-bearing areas. This reduces material usage, lowers vehicle weight, and reduces fuel and power consumption. The integrated mounting structure reduces the number of components (e.g., eliminating the transition bracket), simplifies the assembly process, and reduces manufacturing costs. The flush design of the module with the floor ensures uniform load distribution on the trunk floor, improving loading stability. The sealing ring design ensures that the electrical module is waterproof and dustproof, enhancing safety. The modular design allows for individual replacement and repair, reducing repair costs compared to traditional solutions without disassembling the entire trunk structure. By optimizing both space and weight, this design is suitable for new energy vehicles (such as pure electric and hybrid vehicles) with demanding range and space requirements, significantly improving vehicle practicality and affordability. Its integrated design provides an innovative paradigm for car trunk structures, helping automakers to form differentiated competitiveness with "space advantage + lightweight technology" and promote the development of the automotive industry towards efficient space utilization and low carbonization.

[0043] It should be noted that the description of the above technical solutions is illustrative only. This specification may be embodied in various forms and should not be construed as limiting the technical solutions set forth herein. Rather, these descriptions are provided to ensure that the disclosure of the present invention is thorough and complete and to fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solutions of the present invention are limited only by the scope of the claims.

[0044] When “including,” “having,” and “comprising” are used in this specification, another part or other parts may also be included, and the terms used may generally be singular but may also represent plural forms.

[0045] When describing positional relationships, for example, when the position sequence is described as "on," "above," "below," and "next," unless words or terms such as "just" or "directly" are used, situations where they are not in contact or in contact can also be included. If a first element is mentioned as being "on" a second element, it does not mean that the first element must be above the second element in the figure. The upper and lower parts of the components will change depending on the angle and orientation of observation. Therefore, in the drawings or in actual constructions, if it is mentioned that the first element is "on" a second element, it can include situations where the first element is "below" the second element as well as situations where the first element is "above" the second element. When describing temporal relationships, unless "just" or "directly" is used, situations where steps are not continuous can be included when describing "after," "subsequently," "followed," and "before." The features of the various embodiments of the present invention can be combined or spliced ​​with each other in part or in whole, and can be implemented in various different configurations as can be fully understood by those skilled in the art. The embodiments of the present invention can be implemented independently of each other, or can be implemented together in a mutually dependent relationship.

[0046] Finally, it should be noted that the above embodiments are merely representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments and is susceptible to numerous variations. Any simple modifications, equivalent variations, and modifications to the above embodiments based on the technical essence of the present invention shall be deemed to fall within the scope of protection of the present invention.

Claims

1. An integrated luggage compartment floor structure, characterized by: It comprises a trunk module (1) for loading a high-voltage electrical system integrated module and a trunk sheet metal frame (2) fixed on the left and right longitudinal beams of a vehicle body respectively; the trunk module (1) is fixed below the trunk sheet metal frame (2) via a vehicle body mounting beam (3); the area of ​​the trunk sheet metal frame (2) located directly above the trunk module (1) is a through-hole structure; the top surface of the trunk module (1) and the top surface of the trunk sheet metal frame (2) together constitute a trunk floor; The luggage compartment floor formed by integrating the luggage compartment module (1) and the luggage compartment sheet metal frame (2) can effectively improve the Z-direction space of the luggage compartment.

2. The integrated luggage compartment floor structure according to claim 1, wherein: The luggage compartment module (1) comprises a loading box body (1.1) for loading a high-voltage electrical system integrated module, the vehicle body mounting beam (3) is detachably fixed to the loading box body (1.1), the vehicle body mounting beam (3) is fixed below the luggage compartment sheet metal frame (2), the through-hole structure is located directly above the top surface of the loading box body (1.1), and the top surface of the loading box body (1.1) and the top surface of the luggage compartment sheet metal frame (2) together constitute the luggage compartment floor.

3. The integrated luggage compartment floor structure according to claim 2, wherein: A wiring harness interface (1.2) is provided on the top of the loading box body (1.1).

4. The integrated luggage compartment floor structure according to claim 2, wherein: The vehicle body mounting beam (3) is an annular structure corresponding in shape to the luggage box sheet metal frame (2), and the four sides of the vehicle body mounting beam (3) are detachably fixed to the loading box body (1.1).

5. The integrated luggage compartment floor structure according to claim 4, wherein: The vehicle body mounting beam (3) comprises a box body matching ring plate (3.1) whose inner surface matches the outer surface of the loading box body (1.1) and a vehicle body matching ring plate (3.2) fixedly connected to the outer top surfaces of the box body matching ring plate (3.1) and forming an integral structure with the box body matching ring plate (3.1); the vehicle body matching ring plate (3.2) is fixed to the bottom surface of the luggage box sheet metal frame (2).

6. The integrated luggage compartment floor structure according to claim 5, wherein: A plurality of ear plates (1.3) are arranged at intervals around the loading box body (1.1), each ear plate (1.3) is provided with at least one threaded hole (1.4), and a plurality of bolt through holes (3.3) corresponding to the threaded holes (1.4) are arranged at intervals along the circumference of the box body matching ring plate (3.1), and bolts pass through the bolt through holes (3.3) and are threadedly connected to the threaded holes (1.4).

7. The integrated luggage compartment floor structure according to claim 6, wherein: The box body matching ring plate (3.1) comprises a box body positioning ring plate (4) for wrapping the top edges and the top edges of the side surfaces of the loading box body (1.1), and a connecting ring plate (5) fixedly connected between the box body positioning ring plate (4) and the vehicle body matching ring plate (3.2), wherein the connecting ring plate (5) is provided with the bolt through holes (3.3) at intervals along its circumferential direction.

8. The integrated luggage compartment floor structure according to claim 7, wherein: A sealing ring (6) is provided between the box body positioning ring plate (4) and the loading box body (1.1).

9. A method for installing the integrated luggage compartment floor structure according to any one of claims 1 to 8, characterized in that: It includes: The vehicle body mounting beam (3) is fixed to the trunk module (1), and the vehicle body mounting beam (3) is fixed to the bottom surface of the trunk sheet metal frame (2), so that the area directly above the trunk module (1) is the through-hole structure of the trunk sheet metal frame (2), and the top surface of the trunk module (1) and the top surface of the trunk sheet metal frame (2) together constitute the trunk floor.

10. The method for installing an integrated luggage compartment floor structure according to claim 9, wherein: The vehicle body mounting beam (3) is detachably fixed to the luggage compartment module (1), and the vehicle body mounting beam (3) is welded and fixed to the bottom surface of the luggage compartment sheet metal frame (2), so as to facilitate the removal and replacement of the luggage compartment module (1).

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