Unitary Vehicle Floor Structure for Simpler Assembly and Better NVH
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Solution Overview
Problem
Existing vehicle floor systems face challenges in simplifying the assembly process, managing gap/height differences, and reducing noise, vibration, and harshness (NVH) due to the complexity of multiple cross members, longitudinal members, and brackets.
Innovation Solution
A unitary structural component is designed to form a one-piece structure with a front cross portion, rear cross portion, central extension portion, and edge extension portions, improving stiffness, strength, and crashworthiness, while allowing for good exterior styling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple cross members, longitudinal members, and brackets are individually joined to the floor, then the floor system can be assembled with standard components, but the number of assembled components and joint portions increases, leading to increased overall weight and complex assembly process
Solution Approach 1:
The patent merges multiple separate components (front cross member, rear cross member, central longitudinal member, and brackets) into a single integrated unitary structural component. This consolidation reduces the number of parts and joint portions, directly addressing the complexity issue while maintaining the structural functions of each original component through carefully designed integrated features
2Adaptability or versatility
If multiple cross members, longitudinal members, and brackets are individually joined to the floor, then standard components can be used, but the overall weight of the floor system increases
Solution Approach 1:
By consolidating multiple components into one unitary structure, the patent eliminates the weight of fasteners, welds, and redundant material at joint interfaces. The integrated design allows for optimized material distribution and removal of unnecessary structural elements that would be required to connect separate components, thereby reducing overall weight
3Ease of manufacture
If multiple cross members, longitudinal members, and brackets are individually joined to the floor using fasteners and welding, then the components can be manufactured separately, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The unitary structural component is manufactured as a single piece using stamping or forming processes, eliminating the need for separate manufacturing, assembly, and joining operations for multiple components. This single-step manufacturing approach maintains ease of production while dramatically improving assembly efficiency by reducing the number of installation steps and quality control checkpoints
4Ease of manufacture
If multiple cross members, longitudinal members, and brackets are assembled to the floor, then the floor structure can be built with modular components, but the cost of quality management for controlling gap and height differences becomes excessive
Solution Approach 1:
The integrated unitary structure eliminates all gaps and height differences between separate components since there are no joints or interfaces between parts. This monolithic design inherently solves the quality management issue by removing the sources of variation (fastener holes, weld seams, mounting surfaces) that would otherwise require expensive inspection and adjustment processes
Data Source
AI summary
Provided is a unitary structural component, including: a front cross portion; a rear cross portion spaced apart from the front cross portion; a central extension portion connecting the front cross portion and the rear cross portion; and a pair of edge extension portions connecting both ends of the front cross portion and both ends of the rear cross portion, respectively. The front cross portion, the rear cross portion, the central extension portion, and the pair of edge extension portions form a unitary one-piece structure.