Single-Blank Floor Panel Reinforcement for Crash Energy Absorption
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Solution Overview
Problem
Current floor panel reinforcement structures in vehicles face challenges in achieving high crash management efficiency while minimizing weight, production complexity, and costs, while also ensuring safety and environmental sustainability.
Innovation Solution
A floor panel reinforcement member composed of a single metal blank, featuring a front longitudinal portion, a front transverse portion, and a front transition portion, which are designed to absorb crash energy, prevent intrusion, and enhance vehicle rigidity, while being manufactured using a simplified process that reduces assembly points and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate parts are used to form the floor panel reinforcement member, then the structural complexity and assembly steps increase, but the manufacturing precision and structural integrity can be improved
Solution Approach 1:
The patent merges multiple separate reinforcement parts (longitudinal members, transverse members, and transition portions) into a single integrated floor panel reinforcement member formed from one metal blank. This eliminates the need for multiple assembly steps and welding operations while maintaining the structural integrity and crash management efficiency of the original multi-part design.
2Reliability
If heavier materials and more parts are used, then the crash management efficiency is improved, but the vehicle weight increases leading to higher fuel consumption and CO2 emissions
Solution Approach 1:
The patent optimizes the physical parameters of the reinforcement member including the thickness distribution, material properties, and geometric dimensions of the single metal blank to achieve high crash management efficiency. The design incorporates varying thickness zones and optimized cross-sectional shapes that provide superior strength-to-weight ratio compared to conventional multi-part structures.
Solution Approach 2:
The patent employs advanced high-strength steel materials with optimized mechanical properties to create a single blank reinforcement member that delivers enhanced crash performance while reducing overall weight. The material selection and processing parameters are tailored to achieve the desired balance between strength, ductility, and weight.
3Strength
If conventional multi-part reinforcement structures are used, then the structural strength is adequate, but the production costs and environmental footprint increase
Solution Approach 1:
The patent combines multiple reinforcement components into a single integrated part formed from one metal blank, eliminating the need for separate manufacturing and assembly operations. This reduces production complexity, lowers manufacturing costs, and decreases the environmental footprint by reducing the number of production steps and material waste.
Data Source
AI summary
Floor panel reinforcement member (1) for an automotive vehicle (100) attached to a floor panel (3) and including at least a front longitudinal portion (11) extending substantially longitudinally from a dash panel (4) to a transition portion (31) and forming with the floor panel (3) a front longitudinal hollow volume (10), a front transverse portion (21) extending in a substantially transverse direction between right and left side sills (61, 62) of the vehicle, forming with the floor panel (3) a front transverse hollow volume (20) and connected to the front longitudinal portion (11) in the transition portion (31), wherein the floor panel reinforcement member (1) is manufactured by forming a single metal blank (7).