Monolithic Rear Floor Assembly With Rib Layout for Vehicle Rigidity
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Solution Overview
Problem
Traditional unibody vehicle construction using multiple steel stampings welded together is cumbersome, heavy, and time-consuming, lacking optimal structural rigidity and strength.
Innovation Solution
A monolithic rear floor assembly with strategically placed ribs and a die-cast construction, integrating a rear transverse beam and side members, provides enhanced structural integrity and rigidity by using aluminum casting with varying rib orientations and shapes to counteract applied forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple steel stampings are welded together to form unibody construction, then structural strength and rigidity are improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges multiple separate steel stampings into a single monolithic rear floor assembly that is integrally formed. This consolidation reduces the number of separate components that need to be welded together, thereby reducing manufacturing complexity and assembly time while maintaining the structural strength required for unibody construction.
Solution Approach 2:
The patent changes the manufacturing parameter from multiple separate stampings to a single integral formation process. This parameter change allows the rear floor assembly to be produced as one piece, eliminating the need for complex welding operations while preserving structural integrity through the integral design.
2Stability of the object's composition
If multiple steel stampings are welded together, then structural rigidity is improved, but assembly time increases
Solution Approach 1:
The patent combines multiple separate components into a single monolithic rear floor assembly that is integrally formed. This merging eliminates the time-consuming welding operations required to assemble multiple stampings, thereby reducing assembly time while maintaining structural rigidity through the integral construction.
Solution Approach 2:
The patent performs the structural formation action in advance by integrally forming the rear floor assembly as a single piece before installation. This preliminary action of integral formation eliminates the need for subsequent welding operations, thereby reducing assembly time while ensuring structural rigidity is built into the design.
3Strength
If traditional steel stamping construction is used, then structural strength is maintained, but weight increases
Solution Approach 1:
The patent changes the material parameter from traditional steel stampings to an integral formation process that can utilize lighter materials. The monolithic construction allows for optimized material distribution and reduced weight while maintaining structural strength through the integral design that eliminates the need for heavy welded connections.
Data Source
AI summary
A vehicle includes a monolithic rear floor assembly having a rear transverse beam and a first side member joined to the beam and extending forwardly therefrom in a longitudinal direction of the vehicle. The side member has a wheel-well section with a forward segment and a rear segment. The forward segment has a plurality of first ribs arranged in succession in the longitudinal direction and each with an upper U-shaped rib portion and a lower single rib portion extending downwardly from the U-shaped rib portion. The rear segment has a plurality of second ribs arranged in succession in the longitudinal direction and each with a lower, up-side-down U-shaped portion and an upper single rib portion extending upwardly from the up-side-down U-shaped rib portion.