Vehicle Floor Cover Structure for Muffler Vibration Suppression

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Solution Overview

Problem

Existing vehicle muffler attachment structures increase the number of parts and attachment man-hours, leading to higher costs and potential reduction in supporting rigidity, which can cause vibration issues.

Innovation Solution

A vehicle lower structure design featuring a cover member with front and rear fixation portions, a bead portion, and a dimple shape to enhance rigidity and suppress vibration, while reducing the number of parts and attachment man-hours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If four attachment legs are used to attach the cover member to the sub-frame, then the supporting rigidity is improved, but the number of parts and attachment man-hours increase

Engineering Contradiction:

Improvesupporting rigidityVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple attachment functions into a single fixation bracket that can be attached to the sub-frame with fewer attachment portions. The fixation bracket integrates the support and attachment functions, eliminating the need for separate attachment legs while maintaining structural rigidity through its design that extends in the vehicle width direction.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fixation bracket serves multiple functions: it provides structural support, acts as an attachment interface, and maintains the cover member's position. This multi-functional component replaces the specialized attachment legs, reducing part count while achieving the same supporting rigidity through its extended structure in the vehicle width direction.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the number of attachment portions is reduced, then the number of parts and attachment man-hours are reduced, but the supporting rigidity decreases and vibration occurs

Engineering Contradiction:

Improveattachment man-hoursVSAvoidsupporting rigidity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The fixation bracket extends in the vehicle width direction (lateral dimension) rather than relying on multiple attachment points in the vertical dimension. This dimensional shift allows the structure to achieve rigidity through its lateral extension and integration with the sub-frame, compensating for the reduced number of attachment portions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If a fixation bracket is added to secure attachment portions, then the supporting rigidity is improved, but the number of parts and cost increase

Engineering Contradiction:

Improvesupporting rigidityVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the attachment portions and support structure into an integrated fixation bracket design. Rather than adding separate attachment portions to an existing structure, the bracket itself is configured with attachment portions built-in, eliminating the need for additional components while maintaining supporting rigidity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12428072B2Vehicle lower structure

Publication Date: 2025.09.30 HONDA MOTOR CO LTD

AI summary

A lower structure of a vehicle is configured to include a floor panel, an exhaust member arranged below the floor panel, and a cover member provided between the floor panel and the exhaust member and attached to the floor panel. The cover member includes front fixation portions provided on the front side and fixed to the floor panel and a bead portion arranged behind the front fixation portions and extending in a vehicle width direction.