Rear Floor Extension Support for Frontal Impact

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In motor vehicle bodies with a rear floor extension, frontal impacts cause significant deformation and potential damage due to the rigidity of the rear floor extension and central tunnel, particularly when carrying heavy loads.

Innovation Solution

The rear floor extension support is designed to undergo vertical deformation during a frontal impact, featuring stamped vertical deformation initiation zones with openings and horizontal ribs, allowing it to absorb impact and reduce structural deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the rear floor extension is made rigid to support heavy loads, then load-bearing capacity is improved, but deformation and damage during frontal impact increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoidimpact deformation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The support structure is divided into a rigid upper portion (supporting the floor extension) and a deformable lower portion (absorbing impact). This segmentation allows different parts to have different mechanical properties - the upper part maintains rigidity for load support while the lower part provides deformability for impact absorption.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure utilizes parameter changes in material behavior under different stress conditions. Under normal loading, the support maintains high stiffness for load bearing. Under impact conditions, the support transitions to a deformable state through controlled plastic deformation in its lower portion, changing its mechanical parameters dynamically.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the rear floor extension support is made rigid to prevent deformation, then structural stability is improved, but impact energy absorption decreases

Engineering Contradiction:

Improvestructural stabilityVSAvoidimpact energy absorption

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The support structure incorporates a pre-designed deformable portion that acts as a cushion before impact occurs. This portion is specifically engineered to deform under impact loads, absorbing energy in advance and preventing the transmission of full impact force to the rigid upper support and floor extension.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The invention converts the harmful impact energy into beneficial structural deformation. The controlled deformation of the lower support portion during impact serves as a energy dissipation mechanism, transforming the harmful kinetic energy of the impact into plastic work within the support structure itself, thereby protecting the overall vehicle structure.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Volume of moving object

If the rear floor extension is designed to be cantilevered for space efficiency, then vehicle interior space is improved, but vulnerability to impact damage increases

Engineering Contradiction:

Improveinterior spaceVSAvoidimpact resistance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The deformable support portion acts as an intermediary element between the rigid floor extension and the vehicle body structure. This intermediary component absorbs and dissipates impact energy, mediating the force transmission and protecting the cantilevered floor extension from damage while maintaining the space-efficient design.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support structure transitions from a static rigid design to a dynamic system that adapts its mechanical properties based on loading conditions. During normal operation, it provides stable support for the cantilevered floor. During impact, it dynamically changes its stiffness characteristics through controlled deformation, reducing the floor extension's vulnerability while preserving interior space.

Inventive Principle:

Principle #15Dynamics

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

This design absorbs impact by deforming vertically, reducing the need for repairs to the rear floor extension and the vehicle structure, while being simple and cost-effective to implement.

Implementation Method 1

the rear floor extension support is configured to undergo vertical deformation in the event of a frontal impact on the vehicle

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentEP3787959B1Motor vehicle structure with rear floor extension support for frontal impact

Publication Date: 2022.03.30 PSA AUTOMOBILES SA

Figure 1~3
Figure 4~5

AI summary

The invention concerns a motor vehicle body structure (2) comprising a passenger compartment floor (4) with a central tunnel (6); a rear loading floor (8), which is raised relative to the passenger compartment floor; a rear floor extension (10) that extends towards the front from said floor (8) and above the passenger compartment floor (4); a rear floor extension support (12), arranged between said extension (10) and the central tunnel (6). The rear floor extension (10) support (12) is configured to undergo vertical deformation in the event of a frontal impact on the vehicle.