Composite Vehicle Floor with Foam Core
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Solution Overview
Problem
Current vehicle front floor designs, primarily made of metal or composite parts, face challenges in meeting impact test requirements, are complex to assemble, and result in high material density leading to poor energy performance and increased manufacturing costs.
Innovation Solution
A single-piece composite front floor with a recessed design and local reinforcement, incorporating a foam core and cut reinforcing fibers, which reduces assembly complexity and weight while maintaining structural integrity during frontal impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple metal or composite parts are assembled to create the front floor, then the structural integrity and impact resistance are improved, but the assembly complexity and manufacturing time increase significantly
Solution Approach 1:
The patent merges multiple separate floor parts (side panels, central tunnel, cross members) into a single monolithic composite structure. This single-piece construction eliminates the need for assembly operations while maintaining the structural integrity required for impact resistance, directly resolving the contradiction between strength and assembly complexity
2Strength
If metal materials are used for the front floor, then the structural strength and rigidity are improved, but the vehicle weight increases leading to poor energy performance
Solution Approach 1:
The patent employs composite materials (such as fiber-reinforced plastics) to replace traditional metal materials in the front floor construction. These composite materials provide equivalent or superior structural rigidity and strength while significantly reducing the weight, thereby improving the vehicle's energy performance without compromising safety
3Strength
If hollow bodies are used in the floor structure, then the impact force absorption is improved, but the manufacturing complexity and assembly requirements increase
Solution Approach 1:
The patent integrates the hollow body structures directly into the monolithic composite floor during the molding process, eliminating the need for separate manufacturing and assembly of hollow impact-absorbing elements. This approach maintains impact force absorption capabilities while significantly simplifying the manufacturing process
4Reliability
If multiple parts are assembled to meet impact test requirements, then the safety performance is improved, but the production cost and manufacturing time increase
Solution Approach 1:
The patent combines multiple safety-critical floor components into a single molded part, which maintains the ability to meet impact test requirements while eliminating time-consuming assembly operations. This directly improves productivity without compromising safety performance
Data Source
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AI summary
- The invention relates to a front floor (10) of a motor vehicle comprising a main panel (20) made of composite material (30), having an upper face (22) and an lower face (24), the panel (20) comprising a front edge (26) intended to be positioned towards the front of the vehicle, and a central tunnel (28), characterized in that the main panel (20) has on each side of the central tunnel (28) at least: o a recess (50) extending from the front edge (26) of the main panel (20) to a transverse wall (52); o a local reinforcement (70) forming a single piece with the main panel (20) capable of increasing the rigidity of the main panel (20), and made of a composite material (30) enclosing a foam core (80).