Motor Vehicle Floor Cross Member with Split Half-Shells
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Solution Overview
Problem
In vehicles with a long wheelbase, the rear floor structure lacks structural reinforcement, compromising accessibility and comfort for row 3 seats and the positioning of a common tank, which affects ergonomics and passenger comfort.
Innovation Solution
A motor vehicle floor structure featuring two side members, a floor, and a cross member with a concave upper and lower half-shell configuration that reduces vertical bulk, incorporating Omega-shaped sections and adjustable thickness for enhanced resistance and comfort, with fixing elements for seats and tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional cross member is used to reinforce the floor structure, then structural strength is improved, but vertical footprint increases compromising accessibility and comfort for row 3 seats
Solution Approach 1:
The cross member is divided into two separate half-shells (upper and lower) that are positioned on opposite sides of the floor. This segmentation allows each half-shell to be optimized independently for structural strength while minimizing the overall vertical footprint, thereby improving accessibility and comfort for row 3 seats.
Solution Approach 2:
Instead of increasing vertical height to improve structural strength, the invention transitions to a different dimensional arrangement by placing half-shells on opposite sides of the floor plane. This lateral distribution of structural elements provides reinforcement without compromising the vertical clearance needed for passenger comfort.
2Ease of operation
If the cross member height is reduced to improve accessibility, then vertical footprint is minimized, but structural reinforcement is compromised
Solution Approach 1:
By segmenting the cross member into two half-shells positioned on opposite sides of the floor, the invention maintains structural reinforcement through distributed lateral support while minimizing vertical height, thus improving accessibility without compromising strength.
Solution Approach 2:
The cross member utilizes composite construction with half-shells made from materials having different properties (e.g., upper half-shell from a first material and lower half-shell from a second material). This allows optimization of each component for its specific function while maintaining overall structural integrity with reduced vertical footprint.
3Ease of manufacture
If uniform thickness is used throughout the cross member, then manufacturing is simplified, but structural optimization for different zones is lost
Solution Approach 1:
The cross member features non-uniform thickness distribution where the first half-shell has a first thickness and the second half-shell has a second thickness. This local quality variation allows each zone to be optimized for its specific structural requirements while maintaining manufacturability through standardized forming processes.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a motor vehicle floor structure comprising two side members extending in a longitudinal direction of the structure, a floor (7) extending between the two side members, and a cross member (10) which extends in a transverse direction of the structure and connects the side members and is attached to the floor structure, characterised in that the cross member (10) comprises a concave upper portion (12) forming a first half-shell, a concave lower portion (14) forming a second half-shell, the lower (14) and upper (12) portions being arranged on either side of the floor (7) so as to face each other, the floor (7) closing off their cavity.