Integrated Rear Body Structure for Versatile PBV Configurations
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Solution Overview
Problem
The vehicle industry faces challenges with excessive mold investment and increased weight due to the need for diverse parts to accommodate various specifications in rear vehicle body assemblies, particularly in Purpose Built Vehicles (PBVs) like electric vehicles, which require different door and quarter glass configurations.
Innovation Solution
A rear structure for vehicle bodies incorporating an integrated extension member that connects to a master side outer assembly and rear quarter assembly, reducing mold investment and weight by sharing components across different vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If diverse parts are manufactured to accommodate various specifications in rear vehicle body assemblies, then adaptability to different vehicle types is improved, but mold investment cost and manufacturing cost increase
Solution Approach 1:
The integrated extension member is designed as a universal component that can be applied across different vehicle types (hailing type with quarter glass and delivery type without quarter glass). By creating a multi-functional part that serves multiple configuration needs, the patent eliminates the requirement for separate molds for each vehicle type, thereby reducing mold investment cost while maintaining adaptability to various specifications
Solution Approach 2:
The patent merges the extension member with the rear quarter assembly into a single integrated component. This consolidation allows one mold to produce a part that fulfills multiple structural requirements, reducing the number of molds needed from multiple (for separate parts) to one (for the integrated assembly), thus resolving the contradiction between versatility and manufacturing cost
2Adaptability or versatility
If diverse parts are manufactured to accommodate various specifications in rear vehicle body assemblies, then adaptability to different vehicle types is improved, but vehicle body weight increases
Solution Approach 1:
By integrating the extension member with the rear quarter assembly into a single unified structure, the patent eliminates the need for multiple separate parts that would require additional joining processes and fasteners. This consolidation reduces the total material usage and assembly hardware, thereby reducing vehicle body weight while maintaining the ability to adapt to different vehicle configurations
Solution Approach 2:
The integrated extension member serves multiple functions across different vehicle types, replacing the need for multiple specialized parts. This multi-functionality reduces the total material mass required in the rear vehicle body assembly while maintaining structural integrity and adaptability to various specifications
3Ease of manufacture
If multiple separate parts are used in rear vehicle body assembly, then ease of manufacturing individual parts is improved, but assembly complexity and manufacturing time increase
Solution Approach 1:
The patent combines the extension member and rear quarter assembly into a single integrated component that can be manufactured in one molding process. This eliminates the need for multiple separate manufacturing operations and subsequent assembly steps, thereby improving productivity by reducing both manufacturing time and assembly complexity while maintaining manufacturing feasibility
Data Source
AI summary
A rear structure of a vehicle body can be connected to a master side outer assembly of a predetermined shape. The rear structure can include an integrated extension member that can be provided with a rear side outer parting section connected to the master side outer assembly and connected to a rear quarter assembly.