Over-Molded Vehicle Under-Shield Structure for NVH and Stiffness
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Solution Overview
Problem
Conventional under-shield structures in vehicles, while aiming to reduce weight and enhance aerodynamics, often compromise on noise, vibration, and harshness (NVH) characteristics due to lack of stiffness, affecting the overall performance and range of electric vehicles.
Innovation Solution
An under-shield structure comprising a support beam and a panel over-molded onto the beam, which is configured to attach to the vehicle's underside, providing increased stiffness and aerodynamic efficiency, and optionally featuring aerodynamic surfaces and reinforcement structures to enhance durability and reduce NVH issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials are used for the under-shield, then the overall vehicle weight is reduced, but the stiffness and NVH characteristics deteriorate
Solution Approach 1:
The under-shield structure combines a lightweight panel (such as composite plastic or carpet) with a support beam structure, creating a composite construction that achieves both weight reduction and adequate stiffness. The panel provides lightweight coverage while the support beam framework supplies the necessary structural rigidity and NVH performance.
Solution Approach 2:
The under-shield is divided into separate functional components: a lightweight panel for weight reduction and a support beam structure for stiffness provision. This segmentation allows each component to optimize its specific function while working together to resolve the contradiction between lightness and strength.
2Strength
If the under-shield structure is made more complex with additional reinforcement, then the NVH characteristics improve, but the manufacturing complexity increases
Solution Approach 1:
The support beam structure is integrated with the panel through attachment mechanisms (such as adhesives, fasteners, or over-molding), combining the lightweight panel and structural beams into a unified under-shield assembly. This merging approach achieves improved NVH characteristics without requiring separate complex reinforcement additions, thereby controlling manufacturing complexity.
3Reliability
If the under-shield structure is made more complex with additional reinforcement, then the stiffness and durability improve, but the manufacturing time and complexity increase
Solution Approach 1:
The support beams are pre-positioned or pre-attached to the panel during the manufacturing process, or the panel is designed with integrated attachment features that facilitate quick assembly. This preliminary preparation reduces the time and complexity required during final assembly, maintaining high productivity while achieving the desired durability through the reinforced structure.
Data Source
AI summary
The present disclosure relates to a vehicle, an under-shield structure and a method for manufacturing the under-shield structure. The under-shield structure comprises at least one support beam and a panel over-molded on the at least one support beam. The panel further comprises a base plate and at least one reinforcement structure protruding vertically from the base plate. Thereby reducing the fluttering, noise, vibration, and harshness at high vehicle speed and increasing the overall stiffness of the under-shield structure.