Undulating Structural Panel Assembly for Battery Floor Support
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Solution Overview
Problem
Existing structural panel assemblies in vehicles require additional supports to reinforce the floor panel, especially in battery-powered vehicles where the panel must enclose and support batteries.
Innovation Solution
A method for manufacturing a structural panel assembly that includes forming a third material with an undulating shape, positioning it between two materials, and using a sensor and processor to control a welder to weld the materials to the undulating third material, thereby reducing the need for additional supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional supports are added to reinforce the floor panel, then the strength and support capability are improved, but the device complexity and weight increase
Solution Approach 1:
The intermediate panel is formed with an undulating shape featuring peaks and valleys instead of a flat configuration. This curvature creates structural rigidity and load distribution capabilities that eliminate the need for additional support members, thereby maintaining strength while reducing structural complexity
Solution Approach 2:
The geometry of the intermediate panel is changed from a flat configuration to an undulating configuration with specific peak and valley formations. This parameter change in shape provides inherent structural support, eliminating the need for additional supports and reducing overall device complexity
2Strength
If the floor panel is made thicker to increase strength, then the strength is improved, but the weight increases
Solution Approach 1:
The undulating shape with peaks and valleys provides structural strength through geometric configuration rather than increased material thickness. This allows the panel to maintain or improve strength while using less material, thereby reducing weight
Solution Approach 2:
The structural panel assembly combines multiple materials (first material, second material, and third material for the intermediate panel) in a composite structure. The undulating intermediate panel creates a composite construction that achieves superior strength-to-weight ratio compared to solid thick panels
3Reliability
If more support structures are added to protect batteries, then the protection capability is improved, but the device complexity increases
Solution Approach 1:
The undulating intermediate panel with peaks and valleys serves as both a structural component and a protective barrier for batteries. The curved geometry provides impact resistance and protection without requiring additional protective structures, maintaining reliability while minimizing complexity
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 structural panel assembly achieves enhanced support and impact resistance without the need for additional supports, effectively distributing loads and protecting batteries and occupants.
Implementation Method 1
weld the first material and the second material to the third material
Data Source
AI summary
A method for manufacturing a structural panel assembly includes providing at least a first material, a second material and a third material positioned between the first material and the second material. The method includes forming the third material to have an undulating shape, and observing, by a sensor, the undulating shape of the third material. The method includes controlling, by a processor, a movement of a welder relative to the first material or the second material based on the observing to weld the first material and the second material to the third material.