Exoskeleton Exterior Panel Structure for Crash-Resistant Vehicle Assembly

Solution Overview

Problem

Conventional vehicle exterior panels lack sufficient strength, requiring additional components like anti-intrusion bars for crash protection, which increase manufacturing costs and complexity.

Innovation Solution

A vehicle design featuring a monolithic metal sheet exterior panel attached directly to the vehicle frame, providing structural support and crash resistance without additional support structures, such as anti-intrusion bars, allowing components like hinges and motors to be directly attached to the panel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional exterior panels with additional support structures are used, then crash resistance is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvecrash resistanceVSAvoidpanel assembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the exterior panel and support structures into a single integrated component. The exterior panel itself is designed with built-in structural features that provide crash resistance without requiring separate support structures, thereby reducing assembly complexity while maintaining strength

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exterior panel is designed to serve multiple functions simultaneously: it provides the vehicle's exterior appearance, structural support, and crash resistance. This multi-functional design eliminates the need for dedicated support structures, reducing both complexity and manufacturing cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If conventional exterior panels with additional support structures are used, then crash resistance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecrash resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines the exterior panel and support structures into a single integrated component. The exterior panel itself is designed with built-in structural features that provide crash resistance without requiring separate support structures, thereby reducing assembly complexity while maintaining strength

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates unnecessary support structures from the panel assembly. By removing redundant components and retaining only the essential structural features integrated into the exterior panel, manufacturing cost is reduced while crash resistance is maintained

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If conventional exterior panels with additional support structures are used, then crash resistance is improved, but assembly requirements and installation time increase

Engineering Contradiction:

Improvecrash resistanceVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent combines the exterior panel and support structures into a single integrated component. The exterior panel itself is designed with built-in structural features that provide crash resistance without requiring separate support structures, thereby reducing assembly complexity while maintaining strength

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240166032A1Vehicle with exoskeleton

Publication Date: 2024.05.23 TESLA INC

AI summary

A vehicle having an exoskeleton exterior panel that provides crash resistance is described. The exterior panel may be formed from a monolithic metal sheet and attached to an exterior portion of the vehicle frame, and the exterior panel does not comprise an additional support structure. At least one component may be directly attached to the exterior panel, and the exterior panel may bear the load of the at least one component. Methods of manufacturing the vehicle are also described.