Foldable Underbody Panel with Integral Folding Connection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing underbody panels for motor vehicles are large and cumbersome, requiring significant storage and transport space due to their size, and current solutions fail to provide a gap-free underbody while minimizing storage and transport volume.

Innovation Solution

An integral underbody panel formed from lightweight sandwich material with a continuous folding connection that allows the panel to be folded in a transverse direction, reducing its size for transport and storage, and incorporating soft components and laser-cut slots to prevent damage and optimize packing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If large underbody panels are used to achieve a gap-free underbody, then aerodynamic performance is improved, but storage and transport space requirements increase

Engineering Contradiction:

Improvestorage and transport volumeVSAvoidgap-free underbody coverage

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The underbody panel is divided into multiple segments that can be folded relative to each other along folding connections. This segmentation allows the panel to be compacted for storage and transport while maintaining the capability to form a complete, gap-free underbody when installed on the vehicle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The underbody panel utilizes folding connections that enable transformation between a two-dimensional extended state (for installation) and a three-dimensional compact folded state (for storage). This dimensional transformation resolves the contradiction between large coverage area and small storage volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If underbody panels are made foldable to reduce transport space, then storage efficiency is improved, but structural complexity increases

Engineering Contradiction:

Improvetransport volumeVSAvoidpanel structure

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The folding connections are integrated directly into the underbody panel structure itself, merging the folding mechanism with the panel body. This eliminates the need for separate, complex folding mechanisms while still enabling compact folding for transport.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The underbody panel employs flexible folding connections that allow the rigid panel to bend and fold. This flexibility is built into the panel structure, enabling compact storage without requiring complex mechanical folding devices.

Inventive Principle:

Principle #30Flexible shells and thin films

3Volume of moving object

If folding connections are added to enable compact storage, then storage space is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvepacking sizeVSAvoidproduction process

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The folding connections are pre-formed during the manufacturing process using forming tools that create the folded structure in the panel before final assembly. This preliminary formation of folding connections simplifies the overall manufacturing process by integrating the folding capability into the base manufacturing step.

Inventive Principle:

Principle #10Preliminary action

4Productivity

If underbody panels are folded for transport, then transport efficiency is improved, but risk of deformation and damage increases

Engineering Contradiction:

Improvetransport efficiencyVSAvoiddeformation and damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The underbody panel incorporates cushioning elements at the folding connections and vulnerable areas before transport. These cushioning features protect the panel from deformation and damage during folding and transport, allowing efficient packing without increasing damage risk.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10246135B2Foldable underbody panel

Publication Date: 2019.04.02 DR ING H C F PORSCHE AG

AI summary

An underbody panel for a motor vehicle is composed of a lightweight sandwich material and is configured as a single part with at least one continuous folding connection (12) that is arranged between first and second portions of the underbody panel (14). The first and second portions can be folded together via the folding connection (12) and, in the folded state, are substantially parallel to each other to reduce a size of the underbody panel during transport and storage. Additionally, the underbody panel is gap-free when installed on a motor vehicle.