Floor structure for a motor vehicle body

Abstract

The invention relates to a floor structure for a motor vehicle body, comprising a vehicle floor (3) which is joined from a plurality of lightweight panels (13). In order to create a floor structure which is particularly easy to produce and can be readily scaled, the lightweight panels (13) are arranged one behind the other in the longitudinal direction of the vehicle such that the longitudinal extent of the panels runs in the transverse direction of the vehicle. The invention additionally relates to a method for producing such a floor structure.

Description

[0001] Floor structure of a motor vehicle body

[0002] The invention relates to a floor structure of a motor vehicle body according to the preamble of claim 1. Furthermore, the invention relates to a method for producing such a floor structure according to the preamble of claim 13.

[0003] Such a floor structure is already known, for example, from DE 199 17 177 B4 and comprises a vehicle floor which is composed of one or more lightweight panels.

[0004] The object of the present invention is to create a soil structure and an associated method by which the soil structure can be designed in a very flexible and scalable way.

[0005] This problem is solved according to the invention by a soil structure with the features of claim 1. Advantageous embodiments with favorable further developments of the invention are the subject of the dependent claims.

[0006] The floor structure according to the invention for a motor vehicle body comprises a vehicle floor which is made up of a plurality of lightweight panels.

[0007] To create a floor structure that is particularly easy to manufacture and readily scalable, the invention provides that the lightweight panels are aligned longitudinally in the transverse direction of the vehicle and arranged one behind the other in the longitudinal direction. This orientation of the lightweight panels in the transverse direction and their arrangement one behind the other in the longitudinal direction makes it possible, for example, to create corresponding derivatives or construction variants within a vehicle series in a simple yet rigid and stable manner, whose vehicle floor has a different length relative to the longitudinal direction of the vehicle.In particular, the possible use of different lightweight panels, which differ, for example, in their height in relation to the vehicle's vertical direction and / or their width in relation to the vehicle's longitudinal direction, or also in their respective shape, choice of material or wall thickness, thus enables a simple scalability of the floor structure or the vehicle floor.

[0008] The longitudinal extent of the respective lightweight panel means in particular that, for example, hollow chambers within the lightweight panels run in the transverse direction of the vehicle, or that the corresponding lightweight panels are dimensioned so that their longitudinal extent runs in the transverse direction of the vehicle.

[0009] In a further embodiment of the invention, it has proven advantageous if at least one of the lightweight panels has a different cross-sectional area in height compared to the other lightweight panels. This allows, for example, the corresponding lightweight panel to form a kind of crossbeam in order to specifically stiffen the vehicle floor in this area.

[0010] In a further embodiment of the invention, the respective lightweight panels have individual cover walls between which hollow chambers are formed. The cover walls are spaced apart from one another, and this spacing ensures an extremely rigid design of the respective lightweight panel or the vehicle floor as a whole. Furthermore, the hollow chambers can be used for a wide variety of functions, for example, for routing cables, conveying media, filling with insulating material and / or an energy-absorbing material, or the like.

[0011] Another advantageous embodiment of the invention provides that the respective lightweight panels are formed by extruded profiles with hollow chambers extending in the transverse direction of the vehicle. Such extruded profiles are particularly easy and cost-effective to manufacture.

[0012] Another advantageous embodiment of the invention provides that adjacent lightweight panels have a flange on their facing end faces and on their opposite broad sides, which is joined to the corresponding broad side of the adjacent lightweight panel to form a joint. This allows a plurality of lightweight panels to be arranged one behind the other in the longitudinal direction of the vehicle and joined on both sides of their broad sides, resulting in a particularly favorable connection between the respective lightweight panels. A further advantageous embodiment of the invention provides that a cross member element, designed as a hollow chamber profile, is provided at the front and / or rear end of the vehicle floor.Thus, the vehicle floor can transition particularly favorably into, for example, a front bulkhead or a rear floor by means of the respective cross member element, whereby the respective cross member element at the front or rear end of the vehicle floor gives the floor structure a special rigidity.

[0013] Another advantageous embodiment of the invention provides for sill elements along the outer sides of the vehicle floor, which are designed as hollow chamber profiles. These sill elements can preferably themselves be designed as extruded profiles or the like. The sill elements thereby achieve a particularly favorable stiffness of the vehicle floor or the floor structure as a whole with respect to the longitudinal direction of the vehicle. The sill elements can be fixed, in particular joined, to the end faces or to the top or bottom faces of the respective broad sides of the lightweight panels of the vehicle floor.

[0014] A further advantageous embodiment of the invention provides that openings are recessed within the vehicle floor. This allows, for example, targeted weight savings in the area of ​​the vehicle floor. Furthermore, openings can be created to, for example, provide access to a battery housing located beneath the vehicle floor.

[0015] In this context, it has proven advantageous if the opening is formed by a gap between two lightweight panels running in the transverse direction of the vehicle and overlapping. In other words, instead of a single lightweight panel, two lightweight panels are arranged one behind the other in the longitudinal direction, spaced apart to form the opening. This allows for the creation of the opening in a particularly simple manner.

[0016] Furthermore, it is advantageous if the respective opening is spanned by a longitudinal beam structure or similar stiffening element. This allows any weakening caused by the opening to be compensated for in a particularly simple and reliable manner. Finally, it has proven advantageous if at least one of the lightweight panels is designed to be universally applicable to a number of floor structure variants, and at least one lightweight panel is designed specifically for a particular floor structure variant. By strategically using universally applicable and variant-specific lightweight panels at appropriate locations on the vehicle floor or floor structure, corresponding scalability of the vehicle floor or floor structure can thus be easily achieved.

[0017] The advantages mentioned above for the soil structure according to the invention are also to be understood as advantages of the method for producing such a soil structure.

[0018] Further features of the invention will become apparent from the claims, the figures, and the description of the figures. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the description of the figures and / or shown in the figures alone, are not only usable in the combinations specified, but also in other combinations or on their own.

[0019] The invention will now be explained in more detail with reference to a preferred embodiment and the drawings. The drawings show:

[0020] Fig. 1a, b, c, d shows a perspective top view and bottom view of a floor structure of a motor vehicle body with a vehicle floor made of a plurality of lightweight panels, in which the lightweight panels are oriented with their longitudinal extent in the transverse direction of the vehicle and are arranged one behind the other in the longitudinal direction of the vehicle, as well as respective partial perspective views in the area of ​​the front and rear ends of the vehicle floor.

[0021] Fig. 2a, b respective sectional views, namely the floor structure along a cutting plane running in the longitudinal direction of the vehicle or in the vertical direction of the vehicle, Fig. 3 further partial sectional views of the vehicle floor along a cutting plane running in the longitudinal direction of the vehicle or in the vertical direction of the vehicle,

[0022] Fig. 4 shows three schematic and perspective sectional views through a plurality of lightweight panels, by means of which a length scaling of the vehicle floor can be implemented.

[0023] Fig. 5 shows respective sectional views through the floor structure along corresponding cutting planes running in the longitudinal direction of the vehicle or in the vertical direction of the vehicle, in which respective vehicle floors scaled in length according to Fig. 4 are used.

[0024] Fig. 6 shows a partial top view of a vehicle floor formed from a plurality of lightweight panels, within which respective openings are recessed.

[0025] Figs. 7a, 7b respective cross-sectional views along a cutting plane extending in the vehicle's vertical direction or in the vehicle's transverse direction through the floor structure according to the invention,

[0026] Figs. 8a, 8b show partial sectional views along corresponding cutting planes running in the longitudinal direction of the vehicle or in the vertical direction of the vehicle in the area of ​​a respective cross member at the front or rear end of the vehicle floor and

[0027] Figs. 9a, 9b show a perspective exploded view and a perspective view of a body according to the invention, which comprises several sub-modules in the form of the vehicle floor according to Figs. 1a to 8b, a front structure, a rear structure and respective side sills, which are joined together in one clamping operation.

[0028] Figures 1a and 1b show, in perspective top and bottom views respectively, the body of a motor vehicle, comprising a front structure 1 and a rear structure 2, between which a vehicle floor 3 extends. The front structure 1 extends longitudinally to the rear of the vehicle up to a front bulkhead 4, which divides the front structure 1 from a passenger compartment 5. Within the area of ​​the front structure 1, longitudinal members / engine mounts 6 and upper longitudinal members 7 at the level of each fender bank are visible, extending rearward to the respective front door pillars 8, which laterally frame the front bulkhead 4.

[0029] The rear body structure 2 essentially comprises rear longitudinal members 9, which extend inside the respective wheel arches 10 over the rear wheels and connect at their front ends to the rear ends of the respective side sills 11, which extend over the entire length of the vehicle floor 3 between the front and rear wheel arches 10. Between the rear longitudinal members 9 are also respective body-in-white structural components, such as cross members of a rear floor structure 12.

[0030] Figures 1c and 1c show partial perspective views of the front and rear ends of the vehicle floor 3. Longitudinal structures 31, which are designed like a central tunnel or exhibit a similar stiffening behavior, are further explained in connection with Figures 6, 7a, and 7b.

[0031] Figures 2a and 2b each show a sectional view along a section plane extending in the longitudinal direction and vertical direction of the vehicle, respectively, of the floor structure according to Figures 1a and 1b. Furthermore, Figure 3 shows partial sectional views of the vehicle floor 3, also along a section plane extending in the longitudinal direction and vertical direction of the vehicle. Figure 4 additionally illustrates the scaling possibilities of the vehicle floor 3 using three schematic sectional views, which will be explained in more detail below.

[0032] In conjunction with Figures 1a to 4, it is evident that the vehicle floor 3 is formed from a plurality of lightweight panels 13, which are oriented longitudinally in the transverse direction of the vehicle and arranged one behind the other in the longitudinal direction of the vehicle. As can be seen particularly in Figures 2a to 4, in the present embodiment the respective lightweight panels 13 are designed as extruded profiles, with respective cover walls 14, 15, between which respective hollow chambers, subdivided by webs 16, are formed. The extruded profiles or hollow chambers 17 of the lightweight panels 13 therefore also extend longitudinally in the transverse direction of the vehicle.

[0033] In particular, Fig. 4 shows that a plurality of lightweight panels 13, extending transversely and approximately horizontally, are arranged one behind the other to form the vehicle floor 3 of a corresponding length, depending on the derivative or construction variant of the respective vehicle series being created. Experience has shown that the vehicle floor 3, which is also referred to as the main floor or floor center, is longer in a 4- or 5-door sedan than, for example, in a three-door coupe or convertible.

[0034] As can be seen particularly in Fig. 4, the vehicle floor 3 is therefore scalable in length with respect to the longitudinal direction of the vehicle by arranging a different number of lightweight panels 3 one behind the other in the longitudinal direction of the vehicle. While, for example, six lightweight panels 13 are used in the lower embodiment according to Fig. 4, nine lightweight panels 13 are used in the middle embodiment and seven lightweight panels 13 in the uppermost embodiment.

[0035] Figure 4 also shows that the respective lightweight panels 13 can assume different shapes or forms in cross-section. While some lightweight panels 13 have a uniform thickness with, for example, only one row of hollow chambers 17, there are also lightweight panels 13h which, for example, have a larger cross-section with two rows of hollow chambers 17 arranged one above the other. These lightweight panels 13h serve, for example, as crossbeams or seat crossbeams.

[0036] Furthermore, Fig. 4 shows individual lightweight panels 13ü, each with openings 18 in one of the cover walls 14. These openings 18 can serve various purposes, for example, for fastening corresponding components or parts, or for routing components, lines, cables, or the like within the hollow chambers 17, or for at least partially housing components within the respective lightweight panel 13ü.

[0037] By using uniform lightweight panels 13 that are both cross-model and intended for several derivatives or model variants of a vehicle series, as well as model variant-specific lightweight panels 13 that are intended only for one or more derivatives or model variants of a vehicle series, it is thus possible, as shown in Fig. 4, to easily assemble a desired vehicle floor 3 of the corresponding length, for example to obtain a vehicle floor 3 for a longer vehicle, such as a sedan, or for a shorter vehicle, such as a coupe or a convertible.

[0038] The respective lightweight panels 13 can be connected to each other, for example, by appropriate joining connections, by mechanical connecting means or by means of other components, for example support components, such as the side sills 11.

[0039] Another connection option can be seen in conjunction with Figs. 3 and 4 with Figs. 8a and 8b, in which respective sectional views of the front and rear ends of the vehicle floor are shown along a respective cutting plane running in the longitudinal direction of the vehicle or in the vertical direction of the vehicle.

[0040] For example, Fig. 8b shows how the lightweight panel 13 is joined to the lightweight panel 13H, which in this case is designed as a cross member or heel element 32, at which the vehicle floor 3 transitions into a rear floor at its rear end. It is evident that the two lightweight panels 13 and 13H each have a projecting flange 21 or 22 on their respective facing end faces 19, 20 and on their opposite broad sides or cover walls 14, 15. These flanges are connected to the corresponding cover wall 14, 15 of the adjacent lightweight panel 13, 13H by forming a flange connection 23, 24.For example, an adhesive bond or adhesive connection can be provided between the respective flange 21, 22 and their associated cover wall 14, 15. Likewise, a corresponding adhesive bond can be present between the respective end faces 19, 20 of the two lightweight panels 13, 13H.

[0041] Furthermore, it is evident that this type of double-shear connection with the two flange connections 23, 24 is suitable for compensating for tolerances in the longitudinal direction of the vehicle, depending on the relative spacing of the two end faces 19, 20. It is also evident that the two flange connections 23, 24, spaced apart at the level of the respective cover wall 14, 15, create a connection between the two lightweight panels 13, 13H, allowing the entire vehicle floor to be subjected to tensile or compressive loads, for example, in the plane of the respective cover wall 14, 15. The sandwich-like, double-walled design of the respective lightweight panel 13, 13H in the joining area thus provides a particularly stiff and stable connection between the respective lightweight panels.The two-section connection of the respective lightweight panels 13, 13H shown here can of course be applied to all lightweight panels, such as those shown in connection with Fig. 4.

[0042] Alternatively, the two lightweight panels 13, 13H can also be joined together by gas metal arc welding in the area of ​​the flange connections 23, 24. Furthermore, it is conceivable to use flow-drill screws or semi-tubular rivets in addition to the adhesive bond.

[0043] From Figs. 2a to 3 it can also be seen that the present sandwich floor or vehicle floor 3 is scalable both via the height of the respective lightweight panels 13, their profile design or division of the hollow chambers 17 as well as via the wall thickness of the respective cover walls 14, 15 or webs 16.

[0044] Thus, as can be seen, for example, in Fig. 3, individual lightweight panels 13H with a different height profile can be exchanged according to arrow 25, for example depending on the vehicle weight or other conditions. Likewise, individual lightweight panels 13H can be exchanged depending on the corresponding seat connection or other conditions according to arrow 26.

[0045] Figure 5, which shows the floor structure in three sectional views along a respective section plane running in the longitudinal direction of the vehicle and in the vertical direction of the vehicle, illustrates the different lengths of the vehicle floors as shown in Figure 4. It is also particularly evident that a cross member element 27, 28 in the form of a corresponding lightweight profile or a lightweight panel / extruded profile is arranged at the front and rear ends of the vehicle floor 3. This respective cross member element 27, 28 is connected to the respective lightweight panels 13 of the vehicle floor 3 in the manner described in connection with Figures 8a and 8b. The front cross member element 27 creates, in particular, a transition from the vehicle floor 3 to the front wall 4, which can be formed, for example, as a sheet metal forming part, a cast component, or also from lightweight panels.The connection of the corresponding crossbeam element 27 to the front wall 4 can be effected, for example, by a joining connection or by mechanical fasteners. The respective front longitudinal beams / engine mounts 6 are also supported and fastened to the front crossbeam element 27.

[0046] The rear crossmember element 28, at which the vehicle floor 3 transitions into a rear floor 29, is also designed as an extruded profile or multi-chamber profile or lightweight panel. The height of this crossmember element 28 can be variable. The crossmember element 28 is connected to the rear floor 29, which can be formed, for example, from a sheet metal forming part, a metal casting component, or several lightweight panels, via joining connections and / or mechanical fasteners.

[0047] Figure 6, which shows a partial top view of the vehicle floor 3, illustrates that three openings 30 can be provided within the vehicle floor. These openings 30 are formed by maintaining a corresponding gap between two lightweight panels 13 that overlap each other in the transverse direction of the vehicle. In other words, in the area of ​​each opening 30, two lightweight panel sections 13t are provided by means of a continuous lightweight panel 13, which have the same width in the longitudinal direction of the vehicle. This provides a simple way to create a corresponding opening 30, for example, in areas that are subject to little stress or that are necessary to access a corresponding area below the vehicle floor, for example, to provide access to a battery housing for an electric drive system.In combination with Figs. 1a and 1b, Fig. 6 and Figs. 7a and 7b, which show respective cross-sectional views along a section plane running in the vehicle's vertical direction or in the vehicle's transverse direction through the floor structure according to the invention, it becomes particularly clear how the front and rear longitudinal structures 31 are designed.

[0048] The front longitudinal structure 31, which, according to Fig. 1a, connects to a pedal base 37 of the front bulkhead 4, comprises two profile elements 33 extending towards each other in the longitudinal direction of the vehicle. These profile elements are designed as extruded profiles extending in the longitudinal direction of the vehicle. In the connection area to the pedal base 37, additional, essentially triangular profile elements 34 are attached to the upper side of the respective profile elements 33, providing additional stiffening. The two profile elements 34 are also connected to each other via at least one transverse element 35.

[0049] The longitudinal structure 31, or the respective profile elements 33, which span the openings 18 in a bridge-like manner, also connect the corresponding lightweight panels 13 on their upper sides. The longitudinal structures 31 serve, in particular in the longitudinal direction of the vehicle, to stiffen the vehicle floor 3.

[0050] In the longitudinal structure 31 shown in Fig. 1d, respective profile elements 36 are provided, which in particular serve as corner stiffeners between the lightweight panels 13 of the vehicle floor 3 and the extruded profile 13 designed as a heel element 32. The profile elements 36 are also designed as extruded profiles.

[0051] Figures 7a and 7b show, in particular, the respective side sills and their connection to the vehicle floor 3. Figure 7a shows a cross-section through the floor structure in the area of ​​the longitudinal structure 31. Figure 7b shows a cross-section through the floor structure in the area of ​​a raised lightweight panel 13h, which in this case is designed as a seat cross member.

[0052] Furthermore, it becomes clear that the vehicle floor 3, or rather its lightweight panels 13, butt-jointly connect to the respective side sills 11 and are connected to the corresponding side sill 11, for example, via a weld seam in both the area of ​​the upper cover wall 14 and the lower cover wall 15. The side sills 11 are, for example, composed of profile elements, which are designed as extruded profiles running horizontally in the longitudinal direction of the vehicle.

[0053] Figures 9a and 9b show a perspective exploded view and a perspective view of the body according to the invention, which comprises several sub-modules in the form of the vehicle floor 3 - formed from the plurality of lightweight panels 13, lightweight beams 13h or similar lightweight structural elements - the front body structure 1, the rear body structure 2 and the side sills 11, which are joined together in one clamping operation.

[0054] The exploded view in Fig. 9a shows that the front crossmember element 27 is designed as a component of the front-end structure 1. The crossmember element 27 extends between the respective rear structural elements, for example, the ends 60 of the engine mounts / longitudinal members 6, which, after assembly, connect to the inside of the laterally corresponding side sills 11, as is particularly illustrated in Fig. 9b. The crossmember element 27 is, for example, welded or similarly joined to the rear ends 60 of the engine mounts / longitudinal members 6.

[0055] The rear cross member element 28 is designed as a component of the rear vehicle structure 2 and is welded or joined, for example, to the front ends of the longitudinal members 9 and / or to other structural elements of the rear vehicle structure 2.

[0056] To connect the individual sub-modules 1, 2, 3, 11, they are aligned / positioned and fixed relative to each other in a common clamping setup within a suitable production system. Subsequently, the sub-modules 1, 2, 3, 11 are joined together, in particular by welding. Here, the crossbeam elements 27 and 28 of the front body structure 1 and the rear body structure 2, respectively, are connected to each other, for example, by welding. The vehicle floor 3, or its lightweight structural elements 13, are joined to the side sills 11, for example, by welding. Here, the side sills 11 are joined to a corresponding laterally facing 61, 62, 63 of the lightweight panels 13, lightweight beams 13h, or similar lightweight structural elements of the vehicle floor 3, the front body structure 1, and / or the rear body structure 2.Furthermore, the rear ends 60 of the front engine mounts / longitudinal members 6 are also joined externally to the inner sides of the side sills 11. This creates a very rigid and stable connection of the sub-modules 1, 2, 3, 11 in the desired manner. Due to the joint clamping of all sub-modules 1, 2, 3, 11, they can also be joined together very quickly. The preferably uniformly wide sub-modules 1, 2, 3 also allow for a joint seam, preferably a straight weld seam, between the side sills 11 and the sub-modules 1, 2, 3.

[0057] Finally, as part of joining the sub-modules 1, 2, 3, 11, further structural elements such as components 33, 34 or fastening shoes 64 for B-pillars can also be joined.

[0058] Reference symbol list

[0059] Front structure Rear structure Vehicle floor Front wall Passenger compartment Longitudinal members / engine mounts Longitudinal members Door pillars Longitudinal members Wheel arches Side sills Floor structure Lightweight panels Cover wall Cover wall Web Hollow chamber Opening Front face Front face Flange Flange Joint connection Joint connection Arrow Arrow Cross member element Cross member element Rear floor Opening Longitudinal structure Heel element Profile elements Profile elements Cross element

[0060] Profile elements

[0061] pedal floor

[0062] End

[0063] Front

[0064] Front

[0065] Front

[0066] Mounting shoe

Claims

Patent claims 1. Floor structure of a motor vehicle body, comprising a vehicle floor (3) which is composed of a plurality of lightweight panels (13), characterized in that the lightweight panels (13) are arranged one behind the other with their longitudinal extent extending in the transverse direction of the vehicle and in the longitudinal direction of the vehicle.

2. Floor structure according to claim 1, characterized in that at least one of the lightweight panels (13) is different from the other lightweight panels. (13) has a different height cross-section.

3. Floor structure according to claim 1 or 2, characterized in that a cross member element (27, 28) extending in the transverse direction of the vehicle with a larger vertical cross-section is formed by at least one lightweight panel.

4. Floor structure according to one of the preceding claims, characterized in that the respective lightweight panels (13) have respective cover walls (14, 15) between which hollow chambers (17) are formed.

5. Floor structure according to claim 4, characterized in that the lightweight panels (13) are formed by extruded profiles with hollow chambers (17) extending in the transverse direction of the vehicle.

6. Floor structure according to claim 4 or 5, characterized in that adjacent lightweight panels (13) are joined at their mutually facing end faces (19, 20) and on their opposing broadsides a respective, projecting have a cover wall (14, 15) which is joined to the corresponding cover wall (14, 15) of the adjacent lightweight panel.

7. Floor structure according to one of the preceding claims, characterized in that a cross member element (27, 28) is provided at the front and / or rear end of the vehicle floor (3), which is designed as a hollow chamber profile.

8. Floor structure according to one of the preceding claims, characterized in that sill elements are provided along the outer sides of the vehicle floor (3), which are designed as hollow chamber profiles.

9. Floor structure according to one of the preceding claims, characterized in that respective openings (18, 30) are recessed within the floor structure.

10. Floor structure according to claim 9, characterized in that the respective opening (18, 30) is formed by a gap between two lightweight panels (13) extending in the transverse direction of the vehicle in overlapping fashion.

11. Floor structure according to claim 9 or 10, characterized in that the respective opening (18, 30) is spanned by a longitudinal beam structure.

12. Floor structure according to one of the preceding claims, characterized in that at least one of the lightweight panels (13) is designed to be versatile across construction variants for a plurality of construction variants of floor structures and at least one lightweight panel is designed to be specific to a construction variant of the floor structure.

13. Method for producing a floor structure of a motor vehicle body in which a plurality of lightweight panels (13) are joined to form a vehicle floor (3), characterized in that the lightweight panels (13) are arranged one behind the other in the longitudinal direction of the vehicle with their longitudinal extent extending in the transverse direction of the vehicle.

14. Method according to claim 13, characterized in that the floor structure is composed of at least one lightweight panel designed across multiple construction variants for a plurality of construction variants of floor structures and at least one lightweight panel (13) designed specifically for one construction variant of the floor structure.

15. Method according to claim 13 or 14, characterized in that adjacent lightweight panels (13) are joined by means of respective projecting cover walls (14, 15) arranged on their mutually facing end faces (19, 20) and on their opposite broad sides.

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