Composite Vehicular Underframe with Integrated Ribs
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Solution Overview
Problem
Conventional vehicular underframe structures using steel materials for floor panels are heavy and have a high number of parts, which complicates weight reduction and fuel economy while providing improved impact strength.
Innovation Solution
A vehicular underframe structure is designed using composite materials for both the lower and upper panels, with integrated ribs forming an internal compartment, enhancing impact energy absorption and rigidity, and incorporating curved portions and rib configurations for improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel materials are used for floor panels with spot welding and adhesive assembly, then impact strength is improved, but weight increases and the number of parts increases
Solution Approach 1:
The patent applies composite materials (specifically SMC - Sheet Molding Compound) to replace traditional steel materials for manufacturing the lower panel and upper panel. This substitution maintains the required impact strength while significantly reducing the weight of the floor panel assembly, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent integrates multiple components into a unified structure by forming the lower panel and upper panel as single-piece composite components with integrated ribs and curved portions. This merging eliminates the need for separate reinforcement components and reduces the number of parts requiring assembly, thereby reducing weight while maintaining structural integrity and impact strength.
2Strength
If steel materials are used for floor panels with spot welding and adhesive assembly, then impact strength is improved, but the number of parts increases
Solution Approach 1:
The use of composite materials enables the integration of multiple functions into single components. The lower panel and upper panel are each formed as monolithic composite structures that incorporate ribs, curved portions, and reinforcement features, eliminating the need for separate metal stamping parts and reduction components that would be required with traditional steel construction.
Solution Approach 2:
The patent merges multiple structural elements into unified composite components. The lower panel integrates the base structure with ribs and curved portions, while the upper panel similarly integrates its structure with reinforcing ribs. This merging reduces the total number of parts from multiple separate metal components to just two main composite panels, simplifying the overall assembly.
3Strength
If rigid ribs are implemented in the floor panel structure, then impact energy absorption is improved, but structural complexity increases
Solution Approach 1:
The ribs are formed as integral features of the composite panels during the molding process, rather than being separate metal components requiring assembly. This integration maintains the rigid structural support needed for impact energy absorption while eliminating the complexity of assembling multiple rib components, as the ribs become inherent to the lower and upper panel structures.
Data Source
AI summary
A vehicular underframe structure may an include a lower panel including a composite material and having a central portion curved upwards along a longitudinal direction thereof; an upper panel including a composite material and combined on the lower panel wherein an undersurface thereof faces an upper surface of the lower panel with an internal compartment formed therebetween; and a rib portion provided in the internal compartment and having a lower rib integrally protruding upwards from the upper surface of the lower panel and an upper rib integrally protruding downwards from the undersurface of the upper panel.