HYBRID METAL COMPOSITE SUBSTRUCTURE FLOOR ARRANGEMENT FOR A VEHICLE

Abstract

A method for manufacturing a vehicle underbody floor assembly comprises (i) overmolding a composite preform and one or more metal sheets with an overmolding resin material to form a floor panel, wherein the floor panel comprises a metal section and a composite section, the metal section comprising a first flange extending along a first side of the floor panel and a second flange extending along a second side of the floor panel opposite the first side, and (ii) attaching a first end of a crossmember to the first flange and a second end of the crossmember to the second flange, wherein the crossmember comprises a metal layer and a fiber layer and the crossmember extends between the first end and the second end and at least partially over the composite section of the floor panel.

Description

INTRODUCTION

[0001] The information provided in this section serves the purpose of providing a general overview of the context of the disclosure. Neither the work of the inventors currently named, to the extent described in this section, nor those aspects of the description that could not otherwise qualify as prior art at the time of filing, are expressly or implicitly recognized as prior art against the present disclosure.

[0002] The present disclosure relates generally to a floor assembly for a vehicle, and in particular to an underbody floor panel that runs along and over a battery assembly for a hybrid or electric vehicle. The floor assembly provides a surface under or within a lower section of a vehicle's interior cabin. This surface can be used to mount seating assemblies and, generally, to separate the interior compartment from the underside of the vehicle and / or a battery assembly mounted beneath the vehicle's cabin. In this respect, the floor assembly must be robust, durable, and strong to accommodate its many applications. Furthermore, the floor assembly must be able to adequately withstand potential deformation and damage during an impact, such as a vehicle collision.This means the floor assembly can withstand the buckling of a vehicle's side sill during a side impact. In many cases, such as when the vehicle is an electric vehicle (EV), a battery assembly is positioned on the underside of the vehicle. Another consideration is preventing the floor assembly or side sill from penetrating the battery assembly during a vehicle collision.

[0003] Steel is a common material used in floor assemblies. However, the weight of steel can be excessive when used in floor assembly, as a significant amount is generally required to ensure the floor assembly is robust, durable, and strong enough to withstand its various applications. Based on the foregoing, and in the interest of reducing the overall vehicle weight, incorporating lighter materials into a vehicle floor while still providing sufficient robustness, durability, and strength is desirable. SUMMARY

[0004] One aspect of the disclosure provides a method for manufacturing a vehicle underbody floor assembly. The method comprises (i) overmolding a composite preform and one or more metal sheets with an overmolding resin material to form a floor panel, wherein the floor panel includes a metal section and a composite section, the metal section comprising a first flange extending along a first side of the floor panel and a second flange extending along a second side of the floor panel opposite the first side, and (ii) attaching a first end of a crossmember to the first flange and a second end of the crossmember to the second flange, wherein the crossmember comprises a metal layer and a fiber layer, and the crossmember extends between the first end and the second end and at least partially over the composite section of the floor panel.

[0005] Implementations of this aspect of the disclosure may include one or more of the following optional features. In certain examples, the method further includes pretreating the one or more metal sheets before overmolding.

[0006] In certain implementations, the one or more metal sheets are attached to the one or more metal sheets before overmolding.

[0007] In certain configurations, a seal is placed on one or more metal sheets during overmolding to prevent the overmolding resin material from flowing onto an upper section of the one or more metal sheets.

[0008] In certain examples, a first metal cap is located at the first end of the crossbeam, and a second metal cap is located at the second end of the crossbeam. Attaching the first end of the crossbeam to the first flange involves welding the first metal cap to the first flange, and attaching the second end of the crossbeam to the second flange involves welding the second metal cap to the second flange.

[0009] In certain implementations, the metal section of the base plate further includes an intermediate section located between the first and second flanges. A central section of the crossbeam, between the first and second ends of the crossbeam, is attached to this intermediate section of the metal part.

[0010] In certain configurations, the process further involves pultruding the fiber layer onto the metal layer to form the crossbeam. In certain other configurations, the metal layer is shaped before pultrusion to form the crossbeam. In some still further configurations, the metal layer and the fiber layer are shaped during pultrusion to form the crossbeam.

[0011] In certain examples, the composite preform comprises a first section having carbon fibers and a second section having glass fibers, the second section being in engagement with the one or more metal sheets.

[0012] Another aspect of the disclosure provides a vehicle underbody floor assembly. The vehicle underbody floor assembly comprises a floor plate and a crossmember. The floor plate includes a metal section and a composite section. The metal section is connected to the composite section by an overmolding resin material, the metal section having a first flange extending along a first side of the floor plate and a second flange extending along a second side of the floor plate opposite the first side. The crossmember has a first end attached to the first flange and a second end attached to the second flange, the crossmember comprising a metal layer and a fiber layer, and the crossmember extending between the first end and the second end and at least partially over the composite section of the floor plate.

[0013] Implementations of this aspect of the disclosure may include one or more of the following optional features. In certain examples, a first metal cap is arranged at the first end of the crossbeam and welded to the first flange, and a second metal cap is arranged at the second end of the crossbeam and welded to the second flange.

[0014] In certain implementations, the metal section of the base plate further includes an intermediate section located between the first flange and the second flange, and a central section of the crossbeam is attached to the intermediate section of the metal section between the first end and the second end of the crossbeam.

[0015] In certain configurations, the metal layer and the fiber layer are overmolded together using a pultrusion process.

[0016] In certain examples, the composite section contains a first section that has carbon fibers and a second section that has glass fibers, with the second section being bonded to the metal section.

[0017] A further aspect of the disclosure provides a vehicle. The vehicle includes a battery assembly and an underbody floor assembly. The underbody floor assembly extends at least partially over the battery assembly. The underbody floor assembly includes a base plate and a crossmember. The base plate comprises a metal section and a composite section. The metal section is connected to the composite section by an overmolding resin material, the metal section having a first flange extending along a first side of the base plate and a second flange extending along a second side of the base plate opposite the first side.The crossbeam has a first end attached to the first flange and a second end attached to the second flange, the crossbeam containing a metal layer and a fiber layer, and the crossbeam extending between the first end and the second end and at least partially over the composite section of the base plate.

[0018] Implementations of this aspect of the disclosure may include one or more of the following optional features. In certain examples, a first metal cap is arranged at the first end of the crossbeam and welded to the first flange, and a second metal cap is arranged at the second end of the crossbeam and welded to the second flange.

[0019] In certain implementations, the metal section of the base plate further includes an intermediate section located between the first flange and the second flange, and a central section of the crossbeam is attached to the intermediate section of the metal section between the first end and the second end of the crossbeam.

[0020] In certain configurations, the metal layer and the fiber layer are overmolded together using a pultrusion process.

[0021] In certain examples, the composite section contains a first section that has carbon fibers and a second section that has glass fibers, with the second section being bonded to the metal section. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings described here serve only to illustrate selected configurations and are not intended to limit the scope of this disclosure; they show: Fig. 1 a perspective view of a vehicle incorporating a vehicle underbody floor assembly, according to the present disclosure; Fig. 2 a perspective view of the vehicle underbody floor arrangement of Fig. 1; Fig. 3 A perspective view of a base plate of the vehicle underbody floor arrangement of Fig. 1; Fig. 4 a perspective view of several trusses according to the present disclosure; Fig. 5 a perspective view of one of the several trusses of Fig. 4; Fig. 6 a sectional view of one of the several trusses of Fig. 4, which is mounted on the base plate, Fig. 7 a perspective view of a first flange extending along a first side of the base plate of Fig. 3 runs, and a sill device according to the present disclosure; Fig. 8 a top view of a metal sheet attached to a composite preform, according to the present disclosure; Fig. 9A A top view of a seal arranged at a surface of the metal sheet attached to the composite preform of Fig. 8 is attached; Fig. 9B a sectional view of the metal sheet attached to the composite preform of Fig. 8 is attached in an overmolding tool according to the present disclosure; Fig. 10 a schematic diagram of a manufacturing process for a traverse according to the present disclosure; and Fig. 11 a flowchart of a procedure for producing the vehicle underbody floor arrangement of Fig. 1.

[0023] In all drawings, corresponding reference symbols denote corresponding parts. DETAILED DESCRIPTION

[0024] Exemplary configurations are now described in more detail with reference to the accompanying drawings. Exemplary configurations are provided to ensure that this disclosure is thorough and fully conveys its scope to those skilled in the art. Specific details, such as examples of specific components, devices, and methods, are presented to provide a precise understanding of the configurations of this disclosure. It is evident to those skilled in the art that specific details need not be used, that exemplary configurations can be embodied in many different forms, and that the specific details and exemplary configurations are not intended to limit the scope of the disclosure.

[0025] The terminology used here serves only to describe certain exemplary configurations and is not intended to be restrictive. As used here, the singular articles "a," "an," and "the" may be intended to include the plural forms unless the context clearly indicates otherwise. The terms "includes," "comprise," "contain," and "exhibit" are inclusive and therefore establish the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more further features, steps, operations, elements, components, and / or groups thereof.The procedural steps, processes, and operations described herein are not intended to necessarily require their execution in the specific order discussed or illustrated, unless explicitly identified as such. Additional or alternative steps may be employed.

[0026] When an element or layer is described as "attached to," "intervening with," "connected to," "attached to," or "coupled to" another element or layer, it may be directly attached to, intervening with, connected to, attached to, or coupled to that other element or layer, or there may be intermediate elements or layers. Conversely, when an element is described as "directly attached to," "directly intervening with," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there need not be any intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" or "directly between," "adjacent" or "directly adjacent," etc.).As used herein, the expression “and / or” includes all combinations of one or more of the associated listed elements.

[0027] The terms "first," "second," "third," etc., can be used here to describe different elements, components, areas, layers, and / or sections. These elements, components, areas, layers, and / or sections are not intended to be limited by these terms. These terms can only be used to distinguish one element, component, area, layer, or section from another. Terms such as "first," "second," and other numerical terms do not imply any sequence or order unless clearly indicated by the context.Thus, a first element, a first component, a first area, a first layer or a first section discussed below can be referred to as a second element, a second component, a second area, a second layer or a second section without deviating from the instructions of the exemplary configurations.

[0028] In this application, including the definitions below, the term "module" may be replaced by the term "circuit". The term "module" may refer to, be part of, or include an application-specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field-programmable gate array (FPGA); a processor (shared, dedicated, or a group) that executes code; a working memory (shared, dedicated, or a group) that stores code executed by a processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-a-chip.

[0029] The term "code," as used above, can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" includes a single processor that executes some or all of the code from multiple modules. The term "group processor" includes a processor that, in combination with additional processors, executes some or all of the code from multiple modules. The term "shared memory" includes a single memory that stores some or all of the code from multiple modules. The term "group memory" includes memory that, in combination with additional memory, stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium."The term "computer-readable medium" encompasses non-transient electrical and electromagnetic signals that propagate through a medium and can therefore be considered a physical, non-transient storage medium. Non-restrictive examples of non-transient storage include physical computer-readable media such as non-volatile memory, magnetic storage, and optical storage.

[0030] The devices and methods described in this application can be partially or completely implemented by one or more computer programs executed by one or more processors. The computer programs contain processor-executable instructions stored on at least one non-transient, computer-readable physical medium. The computer programs may also contain and / or access stored data.

[0031] A software application (i.e., a software resource) can refer to computer software that causes a computing device to perform a task. In certain examples, a software application may be called an "application," an "app," or a "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0032] Non-transient memory can be physical devices used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by a computing device. Non-transient memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electronically erasable programmable read-only memory (EEPROM) (which is typically used, for example, for firmware such as boot programs).Examples of volatile memory include, but are not limited to, write / read memory (RAM), dynamic write / read memory (DRAM), static write / read memory (SRAM), phase change memory (PCM), and disks or tapes.

[0033] These computer programs (also known as programs, software, software applications, or code) contain machine instructions for a programmable processor and may be implemented in a high-level procedural and / or object-oriented programming language and / or in assembly / machine language. As used here, the terms "machine-readable medium" and "computer-readable medium" refer to a computer program product, a non-transient computer-readable medium, a device, and / or a device (e.g., magnetic disks, optical disks, memory, programmable logic devices (PLDs)) used to provide machine instructions and / or data to a programmable processor, which includes a machine-readable medium that receives machine instructions as a machine-readable signal.The term "machine-readable signal" refers to a signal that is used to provide machine instructions and / or data to a programmable processor.

[0034] Various implementations of the systems and techniques described herein can be realized in digital electronics and / or an optical circuit arrangement, an integrated circuit arrangement, specially designed ASICs (application-specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations may include an implementation in one or more computer programs that are executable and / or interpretable in a programmable system comprising at least one programmable processor, which may be specialized or general-purpose and is coupled to receive data and instructions from and send data and instructions to a storage system, at least one input device, and at least one output device.

[0035] The processes and logic operations described in this application can be performed by one or more programmable processors, also referred to as data processing hardware, which execute one or more computer programs to perform functions by working on input data and generating outputs. The processes and logic operations can also be performed by a special-purpose logic circuit arrangement, such as an FPGA (field-programmable gate array) or an ASIC (application-specific integrated circuit). Processors suitable for executing a computer program include, by way of example, general-purpose microprocessors, special-purpose microprocessors, and one or more processors of any type of digital computer. Generally, a processor receives instructions and data from read-only memory and / or read / write memory.The essential elements of a computer are a processor for executing instructions and one or more storage devices for storing instructions and data. Generally, a computer also includes, or is functionally coupled to, the ability to receive data from and / or send data to one or more mass storage devices for storing data, such as magnetic, magneto-optical, or optical media. However, a computer does not necessarily have to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and storage devices, such as semiconductor memory devices (e.g., EPROM, EEPROM, and flash memory devices); magnetic media (e.g., internal hard drives or removable media); magneto-optical media; and CD-ROM and DVD-ROM media.The processor and memory can be supplemented or incorporated by a logic circuit arrangement for a specific purpose.

[0036] To provide interaction with a user, one or more aspects of the disclosure may be implemented in a computer that has a display device, such as a CRT (cathode ray tube), an LCD (liquid crystal display), or a touchscreen for displaying information to the user, and optionally a keyboard and pointing device, such as a mouse or trackball, with which the user can provide input to the computer. Other types of devices may also be used to provide interaction with a user; for example, feedback provided to the user may be any form of sensory feedback, such as...Visual, auditory, or haptic feedback; and input can be received from the user in any form, including auditory, verbal, or tactile input. Additionally, a computer can interact with a user by sending documents to and receiving documents from a device used by the user; for example, by sending web pages to an internet browser in a user's client device in response to requests received from the internet browser.

[0037] With reference to Fig. 1, Fig. 2 to Fig. 3. A vehicle 10 contains a vehicle underbody floor assembly 100. The vehicle underbody floor assembly 100 is configured to provide the vehicle 10 with a rigid structure and to provide a durable and strong surface for passengers or components in an inner chamber of the vehicle 10. For example, components supported by and / or mounted to the vehicle underbody floor assembly 100 may include seating assemblies, consoles, instrument panels, and the like. Furthermore, the vehicle underbody floor assembly 100 separates the inner chamber from the exterior of the vehicle 10. A battery assembly 200 may be positioned on the underside of the vehicle 10 adjacent to the vehicle underbody floor assembly 100. In this respect, the vehicle underbody floor assembly 100 keeps the battery assembly 200 outside the inner chamber.Furthermore, the vehicle underbody floor arrangement 100 provides a structural support for the vehicle 10 that is inclined to the body, which can protect the integrity of the battery arrangement 200 and resist buckling of the vehicle body and frame, such as during an impact on the vehicle 10, like a side collision.

[0038] The vehicle underbody floor assembly 100 includes a floor panel 120. The floor panel 120 contains one or more metal sections 122 and one or more composite sections 124. As discussed further below, the metal sections 122 and the composite sections 124 are joined together or formed as a single unit to provide a unified floor panel 120. In this respect, the floor panel 120 is a hybrid of both the one or more metal sections 122 and the one or more composite sections 124. The one or more metal sections 122 provide an interface for welding, assembly, etc., and also contribute to the strength, durability, and stiffness of the floor panel 120. The one or more metal sections 122 may contain steel, a steel alloy, aluminum, or a similar material.The one or more composite sections 124 contribute to a reduction in the weight of the base plate 120 compared to when the base plate 120 contains only and exclusively the one or more metal sections 122. This is due to the one or more composite sections 124 having a lower density compared to the density of the one or more metal sections 122.

[0039] Furthermore, the one or more composite sections 124 also contribute to the strength, durability, and stiffness of the base plate 120. The illustrative examples show the base plate 120 containing four of the one or more metal sections 122 and three of the one or more composite sections 124. However, it must be acknowledged that the base plate 120 may contain fewer or more of the one or more metal sections 122 and the one or more composite sections 124 without departing from the context of this disclosure.

[0040] The base plate 120 can have a shape, contour, or profile that accommodates a vehicle structure beneath the vehicle body (e.g., the battery assembly 200) and / or a vehicle structure within the vehicle 10's cabin. For example, the base plate 120 can include a central raised section to accommodate the mounting of the battery assembly 200 beneath the vehicle 10. That is to say, the base plate 120 can include minor elevations, protrusions, bumps, etc., which may vary depending on the vehicle 10 in which the base plate 120 is incorporated and on the tooling used during its manufacture. Furthermore, the one or more metal sections 122 include a first flange 122a and a second flange 122b.The first flange 122a extends along a first side 126 of the base plate 120, and the second flange 122b extends along a second side 128 of the base plate 120, opposite the first side 126. Both the first flange 122a and the second flange 122b project from the base plate 120 in a manner that may be shaped to correspond to a sill 300 incorporated on the frame of the vehicle 10. In this respect, a sill assembly 300 is configured on the vehicle 10 to couple to the first flange 122a, and another sill assembly 300 is configured on the vehicle 10 to couple to the second flange 122b. The first flange 122a and the second flange 122b may, for example,The first flange 122a and the second flange 122b are metallic, being mounted to the respective inner sections 302 of each of the sill assemblies 300 contained on the vehicle 10 by means of welding, adhesive bonding, or mechanical fasteners. Mounting the first flange 122a and the second flange 122b to the respective inner sections 302 of each of the sill assemblies 300 imparts rigidity to the floor plate 120 and thus to the vehicle underbody floor assembly 100. In other words, because the flanges 122a and 122b of the floor plate 120 are mounted to the respective sill assemblies 300 of the vehicle 10, the floor plate 120 can absorb load transfer from the sill assemblies 300, such as during a side-impact collision.

[0041] The one or more metal sections 122 of the base plate 120 may also include one or more intermediate sections 122c arranged between the first flange 122a and the second flange 122b. In the illustrated examples, the base plate 120 includes two of the one or more intermediate sections 122c. However, it should be acknowledged that the base plate 120 may contain more or fewer of the one or more intermediate sections 122c without departing from the context of this disclosure. The one or more intermediate sections 122c provide a metal interface for welding, joining, or otherwise attaching further components included in the vehicle 10 to the vehicle underbody floor assembly 100. In other words, welding on the one or more intermediate sections 122c is possible due to their metal structure.Furthermore, the intermediate sections 122c of the vehicle underbody floor assembly 100 provide additional strength and durability.

[0042] With continued reference to Fig. 1- Fig. 3 and with reference to Fig. 4- Fig. 7 The vehicle underbody floor assembly 100 also includes one or more crossbeams 140. Each of the one or more crossbeams 140 rests against an upper surface of the floor plate 120 and extends at least partially between the first side 126 of the floor plate 120 and the second side 128 of the floor plate 120. While the illustrated examples show four crossbeams 140 included in the vehicle underbody floor assembly 100, it should be acknowledged that the vehicle underbody floor assembly 100 may contain fewer or more of the one or more crossbeams 140 without departing from the context of this disclosure. The one or more crossbeams 140 provide mechanical support and stiffness to the vehicle underbody floor assembly 100 and further protect the vehicle underbody floor assembly 100 from deformation, e.g., during a side impact or vehicle collision.For example, side impact loads can be transferred via the sill device 300 and the flange 122a, 122b and along one or more of the crossbeams 140 during a side impact. Furthermore, the one or more crossbeams 140 incorporate a combination of a metal material and a fiber material such as glass fibers or carbon fibers, details of which are explained below.

[0043] Each of the one or more crossbeams 140 can be continuous and unseparated between the first side 126 of the base plate 120 and the second side 128 of the base plate 120. Alternatively, each of the one or more crossbeams 140 can be separated and contain two or more sections between the first side 126 of the base plate 120 and the second side 128 of the base plate 120. Regardless of the configuration, each of the one or more crossbeams 140 extends over both the one or more metal sections 122 and the one or more composite sections 124 of the base plate 120. The one or more crossbeams 140 comprise a first end 142 and a second end 144 opposite the first end 142. The first end 142 is positioned on the first side 126 of the base plate 120 and the second end 144 is positioned on the second side 128 of the base plate 120.For example, the first end 142 and the second end 144 of the crossbeams 140 can be mounted or attached (e.g. by welding or adhesive or mechanical fasteners) to one or both of the flanges 122a, 122b, with a section of the crossbeam 140 optionally mounted or attached to the intermediate section 122c.

[0044] Each of the one or more crossbeams 140 is fitted with a first metal cap 146 and a second metal cap 148. The first metal cap 146 is attached to the first end 142 of each of the one or more crossbeams 140. The first metal cap 146 is also attached to the first flange 122a of the base plate 120. In this respect, each of the one or more crossbeams 140 is firmly attached to the base plate 120 at the first flange 122a. Since the first flange 122a and the first metal cap 146 are metallic, and the one or more crossbeams 140 are at least partially metallic, the first metal cap 146 can be welded to the first end 142 of each of the one or more crossbeams 140. Furthermore, the first metal cap 146 is generally shaped to match the shape of the first flange 122a.

[0045] Similarly to what was described above, the second metal cap 148 is attached to the second end 144 of each of the one or more crossbeams 140. The second metal cap 148 is also attached to the second flange 122b of the base plate 120. In this respect, each of the one or more crossbeams 140 is firmly attached to the base plate 120 at the second flange 122b. Since the second flange 122b and the second metal cap 148 are metallic, and the one or more crossbeams 140 are partially metallic, the second metal cap 148 can be welded to the second end 144 of each of the one or more crossbeams 140. Furthermore, the second metal cap 148 is generally shaped to match the shape of the second flange 122b.

[0046] The one or more crossbeams 140 also include a central section 150 that runs between the first end 142 and the second end 144. The central section 150 is attached to the one or more intermediate sections 122c of the base plate 120 at one or more attachment points 130, for example, by welding, gluing, bolting, or a similar method. Attaching the central section 150 to the base plate 120, the first metal cap 146 at the first end 142 on the base plate 120, and the second metal cap 148 at the second end 144 on the base plate 120 provides a firm and unshaken rigid attachment of the one or more crossbeams 140 to the base plate 120. This improves the stiffness, overall strength, and durability of the vehicle underbody floor assembly 100.

[0047] As in Fig. As shown in Figure 5, the one or more crossbeams 140 can comprise a metal layer 152 and a fiber layer or composite layer 154. The metal layer 152 is located outside the fiber layer 154 and couples to the base plate 120 at the one or more attachment points 130. In other words, with the crossbeam 140 mounted to the base plate 120, the fiber layer 154 is positioned between the metal layer 152 and the base plate 120, with a section of the metal layer 152 extending beyond the fiber layer 154 and along the base plate 120 for attachment. Since the one or more intermediate sections 122c are contained within the one or more metal sections 122, the one or more crossbeams 140 can be welded to the one or more intermediate sections 122c of the base plate 120.With the metal layer 152, which is arranged on the outside of the crossbeam 140, vehicle components such as seats can be mounted along the crossbeams 140. The fiber layer 154 can be completely concealed by the metal layer 152 and the base plate 120 when the one or more crossbeams are attached to the base plate 120. Configuring the one or more crossbeams 140 with the metal layer 152 and the fiber layer 154 provides sufficient durability and rigidity while simultaneously reducing the weight of the vehicle underbody floor assembly 100.

[0048] With reference to Fig. Sections 8-10 comprise a method 400 for manufacturing the base plate 120, comprising overmolding a composite preform 402 with one or more metal sheets 404. The composite preform 402 can be made of a uniform composite material. Alternatively, the composite preform 402 can include a first section 402a comprising carbon fibers and a second section 402b comprising glass fibers. The second section 402b is configured to engage with the one or more metal sheets 404 to prevent corrosion that may occur if the metal sheet comes into contact with carbon fibers. The metal sheets 404 can be positioned at respective holes or recesses of the composite preform 402 and / or the metal sheets 404 can be arranged at least partially along an upper surface of the composite preform 402. Furthermore, the one or more metal sheets 404 can be pretreated before the overmolding begins.Pretreatment can be carried out by means of laser ablation, plasma or something similar to improve the adhesion capabilities of one or more metal sheets 404 to a resin material and the composite preform 402 during overmolding.

[0049] The one or more metal sheets 404 are attached to the composite preform 402 before overmolding ( Fig. 8) The attachment of the one or more metal sheets 404 to the composite preform 402 prevents unwanted movement of the one or more metal sheets 404 relative to the composite preform during overmolding. The attachment of the one or more metal sheets 404 can be achieved in various ways. For example, the one or more metal sheets 404 can be tacked to the composite preform 402 or bonded to it in some other way. In another example, the composite preform 402 can contain several pockets 406 (which are formed, for example, from a fabric or polymer fiber material such as polyester or nylon stitches or the like) that are bonded to the composite preform 402. The one or more metal sheets 404 are configured to fit into the several pockets 406 and secure the one or more metal sheets 404 relative to the composite preform 402.

[0050] A seal 408 can be arranged on a surface of one or more metal sheets 404 before overmolding ( Fig. 9A). The seal 408 is positioned at or near a circumference 410 of the one or more metal sheets 404 and is configured to seal and prevent an upper section 412 of the one or more metal sheets 404 from contacting or coupling to an overmolding resin material 414 during overmolding. In other words, the seal 408 prevents the overmolding resin material 414 from leaking onto the upper section 412 of the one or more metal sheets 404 during overmolding. In this respect, the upper section 412 is kept clear of the overmolding resin material 414 to provide a metal interface and allow welding. In other words, it prevents welding from occurring in sections of the one or more metal sheets 404 that contain the overmolding resin material 414.For example, the upper section 412 can ultimately be welded to a component in the vehicle 10 that couples to one or more metal sheets 404.

[0051] An overmolding tool 416 contains an upper tool 416a and a lower tool 416b ( Fig. 9B). The composite preform 402, the one or more metal sheets 404, and the seal 408 are positioned in a cavity 418 of the overmolding tool 416 between the upper tool 416a and the lower tool 416b. The overmolding resin material 414 is fed into the cavity 418 and overmolds the one or more metal sheets 404 to form the composite preform 402, thereby forming the base plate 120. That is, the overmolding resin material 414 can flow over and along the composite preform 402 and / or at least partially impregnate or saturate the composite preform 402, and the overmolding resin material 414 can flow over and along a section of the metal sheets 404 such that, due to cooling, the metal sheets 404 are fixed in relation to the composite preform 402. The composite preform 402, the metal sheets 404 and / or the cavity of the overmolding tool 416 can define the shape or contour of the base plate 120.

[0052] With reference to Fig. Document 11 comprises a process 500 for manufacturing one or more crossbeams 140 by pultruding the fiber layer 154 onto the metal layer 152 to form the one or more crossbeams 140. Prior to pultrusion, dry fibers 502, such as composite fibers, and fabrics 504 are passed through a resin bath 506. The resin bath 506 forms the dry fibers 502 and the fabrics 504 in the fiber layer 154. The metal layer 152 and the fiber layer 154 then pass through a heating device 508. After the metal layer 152 and the fiber layer 154 have passed through the heating device 508, drawbars 510 pultrude the metal layer 152 and the fiber layer 154 together to form the one or more crossbeams 140. In one example, the metal layer 152 is formed before pultrusion in the drawing bars 510, e.g. by means of punching.In another example, the metal layer 152 and the fiber layer 154 are formed simultaneously during the pultrusion process. For example, the metal layer 152 and the fiber layer 154 can be embossed or roll-formed after the fiber layer 154 has been pultruded onto the metal layer 152. After pultrusion, the one or more crossbeams 140 are then cut by a cutting tool 512 to configure and resize them to fit the base plate 120.

[0053] With reference to Fig.Section 11 comprises a method 600 for manufacturing the vehicle underbody floor assembly 100. In operation 602, the one or more metal sheets 404 are pretreated to improve adhesion to the composite preform 402. In operation 604, the one or more metal sheets 404 are attached to the composite preform 402. The attachment of the one or more metal sheets 404 to the composite preform 402 can be achieved by tack welding or by fastening them to the multiple pockets 406. In operation 606, the one or more metal sheets 404, which are attached to the composite preform 402, are inserted into the cavity 418 of the overmolding tool 416. The overmolding resin material 414 is then fed into the cavity 418 of the overmolding tool 416 during operation 608, whereby the one or more metal sheets 404 are overmolded to form the composite preform 402, thereby forming the base plate 120.In Operation 610, the one or more crossbeams 140 are formed by pultruding the fiber layer 154 onto the metal layer 152. In Operation 612, the first end 142 of the one or more crossbeams 140 is attached to the first flange 122a of the base plate 120 by welding at the first metal cap 146. Similarly, the second end 144 of the one or more crossbeams 140 is attached to the second flange 122b of the base plate 120 by welding at the second metal cap 148.

[0054] Several implementations have been described. However, it should be understood that various modifications can be made without deviating from the concept and scope of the disclosure. Accordingly, further implementations fall within the scope of the following claims.

[0055] The preceding description is provided for illustrative and descriptive purposes only. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not restricted to that particular configuration but are, where applicable, interchangeable and may be used in any chosen configuration, even if not specifically shown or described. They may also be varied in many ways. Such variations are not to be considered a deviation from the disclosure, and it is intended that all such modifications are included within the scope of the disclosure.

Claims

[1] Method for manufacturing a vehicle underbody floor assembly, the method comprising: Overmolding a composite preform and one or more metal sheets with an overmolding resin material to form a base plate, wherein the base plate comprises a metal section and a composite section, and the metal section comprises a first flange extending along a first side of the base plate and a second flange extending along a second side of the base plate opposite the first side; and Attaching a first end of a crossbeam to the first flange and a second end of the crossbeam to the second flange, wherein the crossbeam contains a metal layer and a fiber layer and the crossbeam extends between the first end and the second end and at least partially over the composite section of the base plate. [2] Method according to claim 1, further comprising pretreating the one or more metal sheets before overmolding. [3] Method according to claim 1, wherein the one or more metal sheets are attached to the one or more metal sheets before overmolding. [4] Method according to claim 1, wherein during overmolding a seal is arranged on the one or more metal sheets to prevent the overmolding resin material from flowing onto an upper section of the one or more metal sheets. [5] Method according to claim 1, wherein a first metal cap is arranged at the first end of the crossbeam and a second metal cap is arranged at the second end of the crossbeam, the attachment of the first end of the crossbeam to the first flange comprises welding the first metal cap to the first flange and the attachment of the second end of the crossbeam to the second flange comprises welding the second metal cap to the second flange. [6] Method according to claim 1, wherein the metal section of the base plate further comprises an intermediate section arranged between the first flange and the second flange, and a central section of the crossbeam is attached to the intermediate section of the metal section between the first end and the second end of the crossbeam. [7] Method according to claim 1, further comprising pultruding the fiber layer onto the metal layer to form the traverse. [8] Method according to claim 7, wherein the metal layer is shaped prior to pultrusion to form the traverse. [9] Method according to claim 7, wherein the metal layer and the fiber layer are shaped during pultrusion to form the traverse. [10] Method according to claim 1, wherein the composite preform comprises a first section having carbon fibers and a second section having glass fibers and the second section engages with the one or more metal sheets.

Images