Integrated Resin Floor Panel for Golf Car Assembly
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Solution Overview
Problem
The existing assembly process for golf car floor and front panels is complex, leading to increased costs and assembly steps due to the need for separate components and welding, which also compromises the sealing properties at the connecting portion.
Innovation Solution
Integrating the foot panel and front panel as a single unitary resin member, reducing assembly steps and eliminating the need for welding, while enhancing sealing properties and maintaining cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the floor portion and front portion are formed as individual parts and assembled separately, then the manufacturing flexibility is improved, but the number of assembly steps increases and the sealing property of the connecting portion deteriorates
Solution Approach 1:
The patent merges the floor portion and front portion into a single integrated resin member. This eliminates the connecting portion between separate parts, thereby improving sealing properties and reducing the number of assembly steps while maintaining manufacturing flexibility through resin molding processes
2Device complexity
If the floor portion and front portion are integrated by welding steel plates, then the number of assembly steps is decreased and the sealing property is enhanced, but the cost increases due to the welding step
Solution Approach 1:
The patent replaces the mechanical welding process with a resin molding process. The floor portion and front portion are formed as an integrated resin member through molding, eliminating the need for welding operations and associated costs while maintaining structural integrity and sealing properties
3Device complexity
If the floor portion and front portion are integrally press-formed, then the assembly process is simplified, but a large mold is required which increases the cost
Solution Approach 1:
The patent changes the material parameter from metal press-forming to resin molding. This allows for integral formation of the floor and front portions without requiring extremely large and expensive molds, as resin molding can achieve complex shapes with more cost-effective tooling while simplifying the assembly process
Data Source
AI summary
A small-sized vehicle has a structure that enables reductions in the number of assembly steps and that improves the sealing property of a connecting portion without causing a cost increase. The small-sized vehicle includes a floor panel having a foot panel portion on which an occupant places his/her feet and a front panel portion arranged to extend upwardly between a suspension system and the legs of the occupant, the foot panel portion and the front panel portion being integrally formed of resin, and the floor panel made of resin is arranged and fixed on a vehicle body frame.