Single-Shell Chassis Module With Open Section and Joint Receptacles

The patent merges multiple individual chassis components into a single integrated chassis module produced from one sheet metal blank. The module base is formed as a monolithic structure containing multiple recesses for different chassis joints, eliminating the need to manufacture and assemble separate components. This combining approach maintains structural integrity while significantly reducing manufacturing complexity and production effort.

The single sheet metal blank is segmented into functional zones during the forming process, with specific recesses created for different joint receptacles. The forming process divides the blank into regions that will become the module base with integrated joint housings, achieving multiple functional components from one segmented blank without requiring post-assembly operations.

The patent uses the sheet metal blank itself to form the structural shell of the chassis module. The forming process creates a shell structure with integrated stiffening elements and recesses that provide rigidity without requiring additional filling materials or complex closed-profile constructions. The thin film nature of the sheet metal allows for complex geometries to be formed through shaping rather than assembly.

The forming process introduces curved surfaces and geometric features into the sheet metal blank, including arched stiffening elements and contoured joint receptacles. These curved geometries enhance structural rigidity by distributing stresses more effectively compared to flat surfaces, while being achieved through forming operations rather than additional manufacturing steps.

The single sheet metal blank serves multiple functions simultaneously: it forms the module base, contains all joint receptacles, provides stiffening elements, and creates mounting surfaces. This multi-functional approach allows one forming process to produce what previously required multiple separate manufacturing operations, significantly improving productivity while maintaining the flexibility to adapt the design for different chassis configurations.

The forming process performs preliminary shaping of all structural features, joint receptacles, and stiffening elements during the initial blank formation. This preliminary action eliminates the need for subsequent machining, welding, or assembly operations, as all features are pre-formed in the correct positions and geometries during the single forming operation.