Embossed Rear Floor Panel Structure for EV NVH Rigidity
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Solution Overview
Problem
Conventional rear floor panels in electric vehicles require a grid arrangement of longitudinal and transverse members for NVH performance, leading to increased complexity, weight, cost, and complexity in sealer lines, as well as reduced torsional rigidity due to the increased number of parts and welds.
Innovation Solution
A rear floor panel design where transverse members are maintained, and longitudinal members are omitted, utilizing embossed and engraved forming portions alternately formed in the width direction to enhance static and dynamic rigidity, allowing for optimal NVH performance without separate longitudinal members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a grid arrangement of longitudinal and transverse members is used to secure floor rigidity for NVH performance, then the rigidity of the floor is improved, but the number of parts, welds, and complexity of sealer lines increases
Solution Approach 1:
The patent removes longitudinal members from the floor panel structure, extracting only the essential transverse members while achieving rigidity through geometric forming portions. This reduces the number of parts and welds while maintaining NVH performance.
Solution Approach 2:
The patent transitions from a two-dimensional grid arrangement to a three-dimensional structure by creating embossed and engraved forming portions that extend vertically from the panel surface. This dimensional change provides rigidity without requiring additional longitudinal members.
2Strength
If a grid arrangement of longitudinal and transverse members is used to secure floor rigidity, then the rigidity of the floor is improved, but weight and cost increase
Solution Approach 1:
By removing longitudinal members from the structure, the patent directly reduces the weight of the floor panel while maintaining rigidity through the geometric forming portions that provide structural support without additional material.
Solution Approach 2:
The patent changes the geometric parameters of the transverse members by creating embossed and engraved forming portions with specific dimensions and orientations. These parameter changes optimize the structural efficiency, providing maximum rigidity with minimum material usage.
3Strength
If longitudinal members are included in the grid arrangement, then floor rigidity is improved, but the complexity of sealer lines increases
Solution Approach 1:
By extracting longitudinal members from the structure, the patent eliminates the need for complex sealer line routing that would be required to seal joints between longitudinal and transverse members, simplifying the sealing system.
4Strength
If a grid arrangement with multiple members is used, then local rigidity is improved, but torsional rigidity of the vehicle body decreases
Solution Approach 1:
The patent uses three-dimensional embossed and engraved forming portions that create a more integrated structural system. These geometric features extend through the thickness of the panel and interact to provide both local and global rigidity, including torsional resistance, without the need for a grid of longitudinal members.
Solution Approach 2:
The patent merges the functions of longitudinal and transverse members into a unified structure where the geometric forming portions of transverse members provide both local support and global torsional rigidity, eliminating the need for separate longitudinal members.
Data Source
AI summary
An embodiment floor panel includes an embossed forming portion extending in a length direction of the floor panel and an engraved forming portion extending in the length direction of the floor panel, wherein the embossed forming portion and the engraved forming portion are alternately disposed in a width direction of the floor panel.