Composite Monocoque Structure for Vehicle Load Bearing
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Solution Overview
Problem
Existing monocoque structures for high-powered super sports cars are complex, requiring numerous components and a lengthy production process, making them difficult to modify for different vehicle configurations and increasing production time, weight, and cost.
Innovation Solution
A vehicle structure composed of a reduced number of highly integrated components made from composite materials, such as carbon fibre reinforced polymers, with a simplified tooling process and assembly methods like gluing and co-bonding, eliminating the need for fastening elements like screws, allowing for easier adaptation to various car types by modifying fewer components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monocoque structures are made up of numerous separately cast components assembled using known fastening technologies, then structural rigidity and load-bearing capacity are achieved, but device complexity and production time increase significantly
Solution Approach 1:
The patent merges multiple separately cast components into a single monolithic shell structure made of composite material. The shell is designed as one integrated component that performs multiple structural functions simultaneously, eliminating the need for numerous separate parts and their associated fastening elements.
Solution Approach 2:
The single shell structure serves multiple functions: it provides structural rigidity, acts as a load-bearing monocoque, defines the vehicle interior space, and serves as a mounting platform for other vehicle components. This multi-functionality is achieved through the integrated design of the shell itself.
2Reliability
If monocoque structures are made up of numerous separately cast components, then structural integrity is maintained, but production time and manufacturing complexity increase
Solution Approach 1:
The manufacturing process is simplified by producing a single monolithic shell instead of assembling multiple separate components. This reduces the number of manufacturing steps, eliminates intermediate assembly operations, and significantly decreases production time while maintaining structural integrity through the continuous composite material structure.
3Adaptability or versatility
If traditional monocoque designs are created for rear engine cars, then specific vehicle configuration requirements are met, but adaptability to different vehicle configurations is lost
Solution Approach 1:
The shell is designed with modular segmentation principles, allowing different sections or versions of the shell to be used for different vehicle configurations. The standardized base design can be adapted to various engine placements (front, rear, mid-engine), drivetrain configurations (AWD, RWD, FWD), and seating arrangements by modifying only specific segments rather than the entire structure.
Data Source
AI summary
A vehicle load-bearing structure includes a cell made of composite materials and composed of a plurality of components joined to each other by at least one joining system to form a single structure; the cell is made up of a number n of components between 3 and 8, that is 3<n<8.