Tab Matrix Interlock Structural Panels for Lightweight Chassis Loads
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Solution Overview
Problem
Current vehicle chassis frames are heavy and require numerous parts, leading to inefficiencies in manufacturing and increased weight, while lacking versatility in accommodating different loading conditions and material responses.
Innovation Solution
Multilayer structural panel assemblies with tab matrix interlocks, comprising two interconnected metallic panels joined by obliquely angled interlock tabs, allowing for efficient material utilization and customizable designs that reduce weight and part count, while enabling versatile manufacturing processes and additional functional uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional vehicle chassis frames are used, then structural support is provided, but weight increases and manufacturing complexity increases
Solution Approach 1:
The panel assembly is divided into multiple layers (first panel, second panel, third panel) with tab matrix interlocks distributed throughout the structure. This segmentation allows each layer to contribute to load-bearing while reducing the need for a heavy monolithic frame structure.
Solution Approach 2:
Multiple functional elements are merged into the tab matrix interlock system, which simultaneously provides structural connection, load transfer, and structural support functions. The interlocks integrate the first, second, and third panels into a unified load-bearing assembly, eliminating the need for separate fasteners and structural components.
2Reliability
If numerous parts are used in chassis construction, then structural integrity is maintained, but assembly time increases and manufacturing cost increases
Solution Approach 1:
The tab matrix interlocks are pre-formed on the panels during manufacturing, with tabs already positioned and configured in the desired pattern. This preliminary action eliminates the need for time-consuming assembly operations to create connections during final assembly, as the interlocking structure is prepared in advance.
Solution Approach 2:
The tab matrix interlocks provide self-aligning and self-securing functionality, where the geometric shape and arrangement of tabs automatically guide proper panel alignment and create rigid connections without requiring additional fasteners or complex assembly procedures. The structure serves its own fastening function.
3Adaptability or versatility
If traditional panel assemblies are used, then structural support is provided, but versatility in accommodating different loading conditions is limited
Solution Approach 1:
The tab matrix interlocks can be locally customized in terms of tab geometry, spacing, distribution pattern, and orientation to match specific loading conditions at different locations on the panel assembly. This allows the structure to be optimized for local stress patterns while maintaining overall design simplicity.
Solution Approach 2:
The tab matrix configuration can be dynamically adjusted or reconfigured for different applications and loading scenarios. The modular nature of the interlock system allows designers to modify tab patterns, densities, and geometries to adapt to varying structural requirements without changing the fundamental assembly architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides lightweight, high-stiffness structural support with reduced assembly time and cost, enabling efficient fluid drainage and thermal management, and adaptable for various applications, including battery protection and customer-facing storage.
Implementation Method 1
bending them at an oblique angle to project from the second panel
Implementation Method 2
two interconnected panels: a first (base) panel that is formed, in whole or in part, from a first (base panel) metallic material, and a second (cover) panel that is formed, in whole or in part, from a second (cover panel) metallic material
Data Source
AI summary
Presented are multilayer structural panel assemblies with tab matrix interlocks, methods for making/using such panel assemblies, and vehicles equipped with such panel assemblies. A structural panel assembly includes or, for some applications, consists essentially of two interconnected panels: a first (base) panel that is formed, in whole or in part, from a first metallic material, and a second (cover) panel that is formed, in whole or in part, from a second metallic material, which may be the same as or distinct from the first metallic material. An inward-facing (inboard) face of the first panel faces an inboard face of the second panel. The second panel is fabricating to include interlock tabs that are arranged in a predefined matrix pattern. The interlock tabs project at an oblique angle from the second panel's inboard face and rigidly mount to the first panel's inboard face to thereby join the two panels.