Modular Composite Floor Pan Structure for Stiffness Without Weight Gain
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Solution Overview
Problem
Automotive manufacturers need structural composites that are stiff enough to resist bending and strong enough to absorb energy without increasing part weight, while also being easily manufacturable at a low cost.
Innovation Solution
A modular composite structure comprising a first molded composite core structure bonded to a first fiber layer embedded in a polymer, with fiber reinforcement regions positioned to enhance stiffness and energy absorption, and a second molded composite core structure bonded to a fiber substrate, forming a segmented design such as a floor pan and utility tunnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional composite materials are used to increase stiffness and strength, then bending resistance is improved, but part weight increases
Solution Approach 1:
The floor pan is divided into multiple modular composite structures, each with optimized fiber reinforcement in specific regions. This segmentation allows stiffness to be concentrated where needed rather than uniformly distributed, reducing overall material usage and weight while maintaining bending resistance.
Solution Approach 2:
Fiber reinforcement is applied locally in specific regions of the molded composite core structures rather than uniformly throughout. The fiber layers are strategically positioned in areas requiring enhanced stiffness and energy absorption, reducing total fiber content and part weight while maintaining structural integrity.
2Strength
If fiber reinforcement is added to increase energy absorption, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The fiber reinforcement layers are integrated into the molded composite core structures during the molding process itself, combining the core formation and fiber reinforcement steps. This merging eliminates separate assembly operations, reducing manufacturing complexity while ensuring proper fiber placement for energy absorption.
Solution Approach 2:
The patent uses composite materials consisting of molded thermoplastic cores with embedded fiber layers. This composite approach provides enhanced energy absorption through the fiber reinforcement while maintaining manufacturability through conventional thermoplastic molding processes that can incorporate fibers directly during forming.
3Ease of manufacture
If modular segmented design is used to reduce weight, then ease of manufacture is improved, but structural integrity may worsen
Solution Approach 1:
The floor pan is segmented into multiple modular composite structures that can be manufactured separately using conventional molding methods, improving ease of manufacture and quality control. The modular sections are then joined through bonding of fiber layers and core structures to form an integrated assembly with maintained structural integrity.
Solution Approach 2:
The fiber layers and core structures are pre-formed and bonded together in modular sections before final assembly. This preliminary action allows each module to be optimized and pre-stressed, ensuring structural integrity is established before the modules are combined into the complete floor pan assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular composite structure provides increased stiffness, energy absorption, and reduced weight, while effectively attenuating vibration and sound, and is easily manufacturable using conventional molding methods.
Implementation Method 1
a first fiber layer embedded in a first polymer and a first fiber reinforcement region... a second fiber substrate, the first fiber substrate including fibers embedded in a second polymer... and a second fiber reinforcement region being bonded to and overlying a portion of the first fiber substrate
Implementation Method 2
a first fiber layer embedded in a first polymer... bonded to a first surface of the first molded composite core structure... a first fiber substrate being bonded to a first surface of the second molded composite core structure
Implementation Method 3
strong enough to absorb energy without increasing part weight... strong enough to resist bending and can absorb energy in a controlled manner
Data Source
AI summary
A modular composite structure containing multiple individual composite structures attached together. The individual composite structures form sections of a vehicle component. The composite structures are lightweight and made of materials that can function to absorb energy or attenuate vibration or noise. The composite structures contain a core material adhered to a fiber layer and a fiber reinforcement region for improving the strength and stiffness of the modular composite structure. The modular composite structure can include multiple floor pan segments that can be attached to a central composite structure that can be a utility tunnel or housing.