Modular Composite Passenger Compartment Module Block Assembly
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Solution Overview
Problem
The production cost of vehicles increases due to the use of carbon fiber reinforced plastic (CFRP) structures for cowl cross bars, limiting mass production and requiring a cost-effective substitute that can be processed by solution treatment.
Innovation Solution
A passenger compartment module block assembly using modularized blocks formed from composite materials, such as carbon fiber, which are integrally assembled to improve torsion and bending stiffness and provide installation locations for interior components, replacing the conventional cowl cross bar with a lighter and more efficient design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If carbon fiber reinforced plastic (CFRP) structures are used for cowl cross bars, then vehicle weight is reduced and fuel efficiency is improved, but production cost increases and mass production is limited
Solution Approach 1:
The cowl cross bar is divided into multiple modular blocks (center block, driver block, passenger block) that can be manufactured separately and assembled together. This segmentation enables mass production of individual blocks using cost-effective composite materials while maintaining the weight reduction benefits of CFRP structures.
Solution Approach 2:
The patent uses composite materials (specifically CFRP) for the modular blocks to achieve weight reduction. The composite material structure provides high strength-to-weight ratio, allowing the vehicle to benefit from reduced weight and improved fuel efficiency while the modular design addresses manufacturing cost concerns.
2Ease of manufacture
If conventional cowl cross bar structures are used, then production cost is lower, but torsion and bending stiffness of the vehicle is insufficient
Solution Approach 1:
The modular blocks are constructed using composite materials (CFRP) that provide superior strength-to-weight ratio compared to conventional materials. This enables the structure to achieve enhanced torsion and bending stiffness while maintaining cost-effectiveness through modular manufacturing.
Solution Approach 2:
The division into multiple modular blocks allows for optimized structural design of each component. The blocks can be individually engineered to provide specific structural support, collectively achieving high torsion and bending stiffness for the overall vehicle structure.
3Strength
If modularized blocks are integrally assembled, then torsion and bending stiffness are improved, but assembly complexity increases
Solution Approach 1:
The structure is segmented into modular blocks that are integrally assembled through connecting components. This segmentation allows each block to be manufactured and tested independently, then assembled together with standardized connectors, which actually simplifies the overall assembly process while maintaining high structural stiffness.
Data Source
AI summary
A passenger compartment module block assembly is provided. The passenger compartment module block assembly includes a center block which is made of composite material and disposed within a central portion of a crash pad and provided with assembly components formed on opposite sides of the center block, a driver block which is made of composite material and coupled to a first-side assembly component of the center block and disposed adjacent to a driver seat. A passenger block which is made of composite material and is coupled to a second-side assembly component of the center block and disposed adjacent to a passenger seat. The center block, the driver block and the passenger block are assembled integrally with each other and are disposed between a dash panel and a crush pad of a vehicle and to improve torsion and bending stiffness of the vehicle.