Polymeric Vehicle Floor With Integral Climate Duct
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Solution Overview
Problem
The integration of vehicle components into the floor of a vehicle poses challenges in reducing assembly complexity and cost, while also maximizing passenger compartment space and minimizing packaging constraints.
Innovation Solution
The use of a polymeric material for the top and bottom panels of the vehicle floor, which includes an integral passenger-climate-control duct, allows for the integration of components such as the duct with the floor, reducing assembly complexity and cost, and providing additional space within the passenger cabin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vehicle components are integrated into the floor, then assembly complexity is reduced and manufacturing cost is decreased, but the structural complexity of the floor increases
Solution Approach 1:
The patent integrates the passenger-climate-control duct directly into the floor structure by forming it as an integral component during floor manufacturing. This merging of the duct and floor into a single unit reduces the number of separate parts and assembly steps, thereby reducing assembly complexity and manufacturing cost while accepting increased floor structural complexity.
2Volume of moving object
If vehicle components are integrated into the floor, then packaging constraints are minimized and passenger compartment space is maximized, but the manufacturing process complexity increases
Solution Approach 1:
The patent nests the passenger-climate-control duct within the floor cavity, effectively placing one component inside the structural envelope of another. This nesting arrangement maximizes the use of available space within the floor structure, thereby maximizing passenger compartment space while consolidating manufacturing into a single integrated process.
3Ease of manufacture
If polymeric material is used for the floor panels, then assembly simplicity is improved and cost is reduced, but the structural strength requirements become more challenging to meet
Solution Approach 1:
The patent employs polymeric material for the floor panels, utilizing composite material properties to achieve the necessary structural strength while maintaining assembly simplicity and cost reduction benefits. The polymeric material is engineered to provide adequate strength for floor applications while enabling the integrated component design.
Data Source
AI summary
A vehicle includes a floor including a top panel and a bottom panel defining a cavity therebetween. At least one of the top panel and the bottom panel includes a polymeric material. A passenger-climate-control duct is disposed in the cavity and is integral with the at least one of the top panel and the bottom panel.