Rear floor assembly for vehicle

Abstract

The present disclosure provides a rear floor assembly for a vehicle. A vehicle includes a monolithic rear floor assembly having a rear cross beam and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle. The side member has a wheel chamber section having a forward section and a rearward section. The forward section has a plurality of first ribs arranged contiguously in the longitudinal direction and each first rib having an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion. The rear section has a plurality of second ribs arranged contiguously in the longitudinal direction and each having a lower inverted U-shaped portion and an upper single rib portion extending upwardly from the inverted U-shaped rib portion.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a vehicle rear floor assembly. BACKGROUND

[0002] Vehicles traditionally have a frame and a body supported on the frame. Many light passenger vehicles today have a unibody construction in which the body and frame are formed together as a single assembly. The unibody construction typically includes a plurality of steel stampings that are welded together. SUMMARY

[0003] According to one embodiment, a vehicle includes a unitized rear floor assembly having a rear cross-car beam and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle. The side member has a wheelhouse section having a forward section and an aft section. The forward section has a plurality of first ribs arranged in succession in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion. The aft section has a plurality of second ribs arranged in succession in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upward from the inverted U-shaped rib portion.

[0004] According to another embodiment, a vehicle includes a rear floor assembly having a rear cross-car beam and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle. The first side member has a first section having a plurality of first Y-shaped ribs arranged in succession in the longitudinal direction and each in an upright orientation, and a second section having a plurality of second Y-shaped ribs arranged in succession in the longitudinal direction and each in an inverted orientation.

[0005] According to yet another embodiment, a vehicle includes a unitized cast rear floor assembly including a rear cross-car beam and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle. The side member has a wheelhouse section having a forward section and an aft section, wherein the forward section has a plurality of first ribs arranged in succession in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion. The aft section has a plurality of second ribs arranged in succession in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upward from the inverted U-shaped rib portion. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a perspective view of one embodiment of an example vehicle having a unitized rear floor assembly.

[0007] Figure 2 is a detailed view of a portion of the rear floor assembly of Figure 1 DETAILED DESCRIPTION

[0008] Embodiments of the present disclosure are described herein. It is to be understood, however, that the embodiments disclosed are merely examples, and other embodiments can take various forms and alternative forms. The drawings are not necessarily to scale; some features can be exaggerated or minimized for the purpose of clarity and illustration. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to employ the present application in a variety of ways.

[0009] As will be appreciated by one of ordinary skill in the art, the various features shown and described with reference to any one of the drawings can be combined with features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, various combinations and modifications of the features, consistent with the teachings of the present disclosure, can be desired for particular applications or implementations.

[0010] Referring to Figure 1 and Figure 2 , the vehicle 20 includes structural members that are part of the frame, body, or unibody of the vehicle. The structural members can provide strength, stiffness, and other desired attributes to the vehicle. One such structural member is the rear floor assembly 22. The vehicle can be a pickup truck having a unibody construction.

[0011] The rear floor assembly 22 includes a first side member 24 and a second side member 26, both of which extend in the longitudinal direction of the vehicle and are laterally spaced apart from each other. A front cross member 28 and a rear cross member 30 are joined to and extend between the side members 24, 26. In the illustrated embodiment, the rear floor assembly 22 has a unitized construction, meaning that all of the components are formed integrally with each other. For example, the rear floor assembly 22 can be a metal casting, such as a die casting or a high pressure die casting. In one or more embodiments, the metal casting is an aluminum casting. This unitized construction is in contrast to a traditional construction in which the rear floor assembly is formed from dozens of metal stampings that are welded to each other. By utilizing a casting, the rear floor assembly 22 is a single part, rather than an assembly of 70 to 100 individual parts that are welded together. This can reduce weight, complexity, and assembly time, while providing performance benefits such as strength, stiffness, etc.

[0012] ​The first side member 24 includes a front attachment 32 configured to engage with a side rail of the vehicle 20. For example, the front attachment 32 defines a plurality of holes for receiving fasteners for engaging the rear floor assembly 22 with a forward portion of the vehicle body or frame. The first side member 24 extends rearward from the front attachment 32 to a rear attachment 34 located near the intersection of the side member 24 and the rear rail 30. The rear attachment 34 defines a receiving area, such as the rectangular receiving area shown, for receiving a bumper tank or tubular member associated with a rear bumper or other structural component depending on the length of the vehicle. The attachment 34 can define fastener holes for connecting the rear floor assembly 22 with the bumper or extension member via fasteners, such as bolts.

[0013] The first side member 24 can curve upward from the front portion 40 to the rear portion 42 such that the front attachment 32 is lower than the rear attachment 34. The upward curvature provides clearance for the rear axle assembly 33 and suspension components. The first side member 24 can have an open tubular shape extending generally from the front portion 40 to the rear portion 42 of the floor assembly 22. For example, the side member 24 can include a top member 44, a bottom member 46, and a wall member 48 extending from the top member 44 to the bottom member 46. The top member 44, the bottom member 46, and the wall member 48 cooperate to define a cavity 50.

[0014] A plurality of reinforcing ribs are disposed within the cavity 50. The ribs structurally reinforce the side member 24 to increase stiffness and strength and limit deformation of the rear floor assembly 22 during use. The overall and cast construction of the rear floor assembly can be more brittle than a stamped construction, and the ribs reduce bending and other deformation. As we disclose in more detail below, the shape, spacing, and orientation of the ribs are strategically placed at various points of the side member 24 to increase resistance to bending and provide overall structural strength.

[0015] When a force (F) is applied to the bumper attachment 34, a moment (M) is created in the forward section 52 of the side member 24 due to the vertical offset between the lower front attachment 32 and the higher rear attachment 34. Strategic placement, shape, and orientation of the ribs are provided to counteract this moment to ensure optimal performance of the rear floor assembly 22. For example, the ribs provided in the forward section 52 can be different than the ribs provided in the rearward section 54. The different ribs provided in the forward section 52 and the rear section 54 counteract the moment (M) created by the force (F).

[0016] In the illustrated example, the side member 24 is curved to create a wheelhouse section 56 that includes a forward section 52 and an aft section 54. The forward section 52 has a plurality of first ribs 60 arranged in succession in the longitudinal direction of the vehicle. Each of the ribs 60 can have an overall Y-shape with an upright orientation. For example, the Y-shaped ribs 60 can include an upper U-shaped rib portion 62 and a lower single rib portion 64 extending downward from the U-shaped rib portion 60. The U-shaped rib portion 62 is upright oriented and has a pair of legs 66 and 68 joined by a bend 70. The lower rib portion 64 is joined near or at the midpoint of the bend 70. The legs 66, 68 can be straight, or can also have a slight curvature. The legs 66, 68 can be curved in the same direction (e.g., forward, as shown in the example).

[0017] The aft section 54 can have a plurality of second ribs 80 arranged in succession in the longitudinal direction of the vehicle. Each of the ribs 80 can have an overall Y-shape with an inverted orientation. (As used herein, "upright" and "inverted" do not require a vertical orientation, but also contemplate angled orientations, as shown in the figures. That is, a rib is oriented "upright" if it is angled less than 90 degrees straight up from the ground, and a rib is oriented "inverted" if it is angled less than 90 degrees straight down from the ground.) The ribs 80 can have a lower inverted U-shaped rib portion 82 and an upper single rib portion 84 extending upward from the inverted U-shaped rib portion. The U-shaped rib portion 82 is inverted oriented and has a pair of legs 86 and 88 joined by a bend 90. The upper rib portion 84 is joined near or at the midpoint of the bend 90. The legs 86, 88 can be straight, or can also have a slight curvature.

[0018] Accordingly, in the illustrated example, the ribs 60 of the forward section 52 are oriented opposite the ribs 80 of the rear section 54. In one or more embodiments, the ribs 60 are arranged one after another along the forward section 52 in the longitudinal direction of the vehicle, with all of the ribs being substantially the same size and shape and in the same orientation. At the transition point between the forward section 54 and the rear section 54, the ribs change orientation by about 180 degrees, with the ribs 80 being inverted and arranged one after another continuously along the longitudinal direction of the vehicle. All of the ribs 80 can be substantially the same size and shape and in the same orientation. The U-shaped rib portions provide more rigidity than a single rib portion, and by flipping them, the forward section 52 has different properties than the rear section 54. In doing so, the side member 24 can be tuned to counteract the moment (M). In addition to providing Y-shaped ribs in different sections in different orientations, the performance properties of the side member 24 can also be tuned by curving the overall shape of the ribs forward or rearward. In the illustrated example, both of the ribs 60 and 80 are curved forward toward the front 40 of the rocker assembly 22. The rigidity of the rear section 52 is further increased by adding additional longitudinal ribs 94 that intersect and join with each of the lower inverted U-shaped rib portions 82.

[0019] Each of the ribs 60 and 80 can join to the top member 44, the bottom member 46, and the wall member 48, and have a width that matches the width of the cavity 56, such that the ribs do not protrude outward from the cavity 56, i.e., the ribs are flush with or recessed into the cavity 50. For example, the upper U-shaped rib portion 62 joins to the top member 44, the lower rib portion 64 joins to the bottom member 46, and both the upper and lower portions 62 and 64 join to the wall member 48. Similarly, the upper rib portion 84 joins to the top member 44, the lower inverted U-shaped rib portion 82 joins to the bottom member 46, and both the upper and lower portions 84 and 82 join to the wall member 48.

[0020] The forward section 52 can be shorter (in the longitudinal direction) than the rear section 54, resulting in the rear section 54 having more ribs 80. For example, there can be twice as many ribs 80 as ribs 60. In the illustrated embodiment, the height of the ribs is generally uniform due to the uniform spacing between the top member 44 and the bottom member 46. However, in other embodiments, the height of the ribs can vary based on the distance between the top member 44 and the bottom member 46. In yet other embodiments, the ribs can not extend completely from the top member 44 to the bottom member 46. The linear density (number of ribs for a given linear distance) can be uniform within each section 52, 54, or can vary. Furthermore, the linear density of the ribs 60 can be substantially the same as the ribs 80, as shown in the illustrated embodiment. However, in other embodiments, the linear density of the ribs can differ within different sections of the side member 24. For example, the linear density of the ribs 60 can be higher than the linear density of the ribs 80, or vice versa.

[0021] The side member 24 can also include structure for supporting a rear suspension. For example, an upwardly extending wall 100 can extend from the top member 44 along at least a portion of the wheelhouse section 56. The wall 100 can define a suspension mount 102. The suspension mount 102 can include one or more recesses or cavities formed in the wall 100 and holes for receiving fasteners.

[0022] While the foregoing describes exemplary embodiments, these embodiments are not intended to describe all possible forms of the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, features of various embodiments can be combined to form further embodiments of the present application that can not be explicitly described or illustrated. While various embodiments can have been described as providing advantages or being free from disadvantages, one of ordinary skill in the art will be able to discern that various embodiments can include one or more of the described features, or one or more of the described advantages, or one or more of the described disadvantages, and that no element, process, or method step described need be utilized in any particular embodiment. It will be appreciated that the features of the various embodiments can be combined with each other, such that the features are not mutually exclusive, and such that a particular feature can be combined with one more other features of a variety of embodiments, and such that a particular embodiment can combine a feature with one or more other features of the same or different embodiments. It will be appreciated that the scope of the disclosure is not limited to any particular embodiment described, and that the scope of the disclosure encompasses all embodiments falling within the scope of the claims.

[0023] According to the present invention, there is provided a vehicle having: a unitary rear floor assembly comprising: a rear cross beam; and a first side member joined to the beam and extending forwardly from the beam in a longitudinal direction of the vehicle, wherein the side member has a wheelhouse section having a forward section and an aft section, wherein the forward section has a plurality of first ribs arranged continuously in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downwardly from the U-shaped rib portion, and wherein the aft section has a plurality of second ribs arranged continuously in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upwardly from the inverted U-shaped rib portion.

[0024] According to an embodiment, the wheelhouse section includes a top member and a bottom member that cooperate to define a cavity, wherein the first ribs are disposed in the cavity, wherein the upper U-shaped rib portions are joined to the top member and wherein the lower rib portions are joined to the bottom member, and wherein the second ribs are disposed in the cavity, wherein the lower inverted U-shaped rib portions are joined to the bottom member and wherein the upper rib portions are joined to the top member.

[0025] According to an embodiment, the wheelhouse section includes a wall that extends upwardly from the top member and defines a suspension mount.

[0026] According to an embodiment, the wheelhouse section further has longitudinal ribs that intersect and join each of the lower inverted U-shaped rib portions.

[0027] According to an embodiment, the monolithic rear floor assembly is a casting that includes aluminum.

[0028] According to an embodiment, the wheelhouse section includes more second ribs than first ribs.

[0029] According to an embodiment, the wheelhouse section includes second ribs that are twice the first ribs.

[0030] According to an embodiment, the upper U-shaped rib portions are curved forwardly in the longitudinal direction.

[0031] According to an embodiment, the rear section is longer than the forward section.

[0032] According to an embodiment, the rear floor assembly further includes a second side member joined to the beam and extending forwardly from the beam in the longitudinal direction of the vehicle, wherein the second side member has a second wheelhouse section having a second forward section and a second rear section, wherein the second forward section has a plurality of first ribs arranged continuously in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downwardly from the U-shaped rib portion, and wherein the second rear section has a plurality of second ribs arranged continuously in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upwardly from the inverted U-shaped rib portion.

[0033] According to the present invention, there is provided a vehicle having a rear floor assembly comprising a rear cross-car beam and a first side member joined to the beam and extending forwardly therefrom in a longitudinal direction of the vehicle, the first side member having a first section with a first plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each upright in orientation, and a second section with a second plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each inverted in orientation.

[0034] According to an embodiment, the first section is forward of the second section.

[0035] According to an embodiment, the first section and the second section at least partially define a wheelhouse section of the side member.

[0036] According to an embodiment, the first side member includes a top member and a bottom member cooperating to define a cavity, and wherein the first plurality of ribs and the second plurality of ribs are disposed in the cavity and each joined to both the top member and the bottom member.

[0037] According to an embodiment, the assembly further comprises a second side member joined to the rear cross-car beam and extending forwardly therefrom in the longitudinal direction of the vehicle, and wherein the second side member has a first section with a first plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each upright in orientation, and a second section with a second plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each inverted in orientation.

[0038] According to an embodiment, the first section is forward of the second section.

[0039] According to an embodiment, the second section has a longitudinal rib intersecting and joined to each of the second Y-shaped ribs.

[0040] According to an embodiment, the rear floor assembly is an aluminum casting.

[0041] According to the invention, there is provided a vehicle having a unitarily formed die cast rear floor assembly comprising a rear cross beam and a first side member joined to the beam and extending forwardly therefrom in a longitudinal direction of the vehicle, wherein the side member has a wheelhouse section having a forward section and an aft section, wherein the forward section has a first plurality of ribs arranged continuously in the longitudinal direction and each having an upper U-shaped rib portion and a lower single rib portion extending downwardly from the U-shaped rib portion, and wherein the aft section has a second plurality of ribs arranged continuously in the longitudinal direction and each having a lower inverted U-shaped portion and an upper single rib portion extending upwardly from the inverted U-shaped rib portion.

[0042] According to an embodiment, the first side member comprises a top member and a bottom member cooperating to define a cavity, and wherein the first and second pluralities of ribs are disposed in the cavity and each joined to both the top and bottom members.

Claims

1. A vehicle comprising: a unitary rear floor assembly comprising: a rear cross-car beam, and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle, wherein the side member has a wheelhouse section having a forward section and a rear section, wherein the forward section has a plurality of first ribs arranged continuously in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion, and wherein the rear section has a plurality of second ribs arranged continuously in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upward from the inverted U-shaped rib portion.

2. The vehicle of claim 1, wherein the wheelhouse section includes a top member and a bottom member that cooperate to define a cavity, wherein the first ribs are disposed in the cavity, wherein the upper U-shaped rib portions are joined to the top member and wherein the lower rib portions are joined to the bottom member, and wherein the second ribs are disposed in the cavity, wherein the lower inverted U-shaped rib portions are joined to the bottom member and wherein the upper rib portions are joined to the top member.

3. The vehicle of claim 2, wherein the wheelhouse section includes a wall extending upward from the top member and defining a suspension mount.

4. The vehicle of claim 1, wherein the wheelhouse section further has longitudinal ribs that intersect and join each of the lower inverted U-shaped rib portions.

5. The vehicle of claim 1, wherein the unitary rear floor assembly is a casting including aluminum.

6. The vehicle of claim 1, wherein the wheelhouse section includes more second ribs than first ribs.

7. The vehicle of claim 1, wherein the wheelhouse section includes twice as many second ribs as first ribs.

8. The vehicle of claim 1, wherein the upper U-shaped rib portions are curved forward in the longitudinal direction.

9. The vehicle of claim 1, wherein the rear section is longer than the forward section.

10. The vehicle of claim 1, wherein the rear floor assembly further includes a second side member joined to the beam and extending forward from the beam in the longitudinal direction of the vehicle, wherein the second side member has a second wheelhouse section having a second forward section and a second rear section, wherein the second forward section has a plurality of first ribs arranged continuously in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion, and wherein the second rear section has a plurality of second ribs arranged continuously in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upward from the inverted U-shaped rib portion.

11. A vehicle comprising: a rear floor assembly comprising: a rear cross-car beam, and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle, the first side member having a first section with a first plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each upright oriented, and a second section with a second plurality of Y-shaped ribs arranged continuously in the longitudinal direction and each inverted oriented.

12. The vehicle of claim 11, wherein the first section is forward of the second section.

13. The vehicle of claim 11, wherein the first section and the second section at least partially define a wheelhouse section of the side member.

14. The vehicle of claim 11, wherein the first side member includes a top member and a bottom member that cooperate to define a cavity, and wherein the first and second pluralities of ribs are disposed in the cavity and each joined to both the top and bottom members.

15. A vehicle comprising: an integrally formed, die cast rear floor assembly comprising: a rear cross-car beam, and a first side member joined to the beam and extending forward from the beam in a longitudinal direction of the vehicle, wherein the side member has a wheelhouse section with a forward section and a rear section, wherein the forward section has a first plurality of ribs arranged continuously in the longitudinal direction and each first rib has an upper U-shaped rib portion and a lower single rib portion extending downward from the U-shaped rib portion, and wherein the rear section has a second plurality of ribs arranged continuously in the longitudinal direction and each second rib has a lower inverted U-shaped portion and an upper single rib portion extending upward from the inverted U-shaped rib portion.

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