Aluminum MPV Upper Body Modular Design
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Solution Overview
Problem
Conventional upper vehicle bodies for MPVs and VANs are heavy, prone to corrosion, and have high manufacturing costs due to complex processes and numerous components, making them unsuitable for energy conservation and lightweight requirements.
Innovation Solution
A modular upper vehicle body composed of aluminum alloy stamped sheets and extruded profiles with cavities, using various connection methods such as screwing, welding, and gluing to achieve strength, rigidity, and reduced weight, while simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional steel plates are used for manufacturing upper vehicle bodies, then sufficient strength and rigidity can be achieved, but the body becomes too heavy to meet energy conservation and emission reduction requirements
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, which has a lower density and weight. This parameter change allows the vehicle body to meet energy conservation requirements while maintaining sufficient strength through optimized structural design of the modular components
Solution Approach 2:
The patent uses composite material construction by combining aluminum alloy stamped sheets with aluminum alloy extruded profiles having cavities. This composite approach creates a lightweight structure that achieves both weight reduction and sufficient mechanical strength through the synergistic combination of different aluminum alloy components
2Duration of action of stationary object
If conventional steel plates with stamping and welding processes are used, then manufacturing capability is achieved, but the risk of corrosion increases and service life is reduced
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, which has inherent corrosion resistance compared to steel. This material parameter change reduces the risk of corrosion and extends the service life of the vehicle body without requiring complex protective coatings
Solution Approach 2:
The patent divides the vehicle body into multiple modular components (front end module, front module, front quarter modules, rear quarter modules, back module, and crossmember modules) that can be independently manufactured and assembled. This segmentation allows each module to be optimized for corrosion resistance and makes it easier to replace individual components if corrosion occurs, thereby extending overall service life
3Ease of manufacture
If conventional manufacturing processes with numerous components are used, then sufficient structural integrity can be achieved, but manufacturing costs increase due to complicated processes
Solution Approach 1:
The patent divides the vehicle body into standardized modular components that can be independently manufactured using optimized processes and then assembled together. This segmentation simplifies manufacturing by allowing parallel production of modules, reduces inventory complexity, and lowers overall manufacturing costs while maintaining structural integrity through proper connection design
Solution Approach 2:
The patent designs the modular components with universal connection interfaces and standardized dimensions, allowing the same types of modules to be used in different positions and configurations. This universality simplifies the manufacturing process, reduces the number of unique tooling requirements, and lowers manufacturing costs while ensuring consistent structural quality across the entire vehicle body
Data Source
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AI summary
The invention discloses an upper vehicle body for an MPV or VAN, which comprises: a front end module (1), a front module (2), two front quarter modules (3) spaced apart from each other in a left-right direction, two rear quarter modules (4) spaced apart from each other in the left-right direction, a front windshield upper crossmember module (5), a front top crossmember module (6), a support crossmember module (7), a rear top crossmember module (8), and a back module (9). All of the modules are formed by aluminum alloy extruded profiles with cavities and aluminum alloy stamped sheets in combination so that the entire upper vehicle body is made of aluminum alloy material, different connecting methods are adopted appropriately between different modules so that the upper vehicle body possesses sufficient strength and rigidity, and the modules are shaped separately and independently so that modular production and assemble can be achieved. Moreover, structural design of key components of the upper vehicle body is optimized so that the upper vehicle body has an integral frame-type structure with high strength and rigidity.