Variable Width Vehicle Body Structure with Common Floor Panel

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The complexity and cost of manufacturing different vehicle sizes with unique components lead to inefficient packaging and increased weight, as existing methods fail to maximize interior roominess while minimizing exterior width and tooling costs.

Innovation Solution

A method and structure that allows for varying vehicle widths using a common floor panel and side sill configuration, where the lateral position of the joint between the floor panel and side sill is maintained across different vehicles, enabling the reuse of components and adjusting the side sill structure to accommodate unique widths through varying shelf sizes and positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If unique components and configurations are constructed for each vehicle width, then vehicle performance attributes and aesthetics are optimized, but manufacturing complexity and tooling costs increase

Engineering Contradiction:

Improvevehicle width variationVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The floor panel is designed as a universal component that can be used across multiple vehicle widths by combining it with different side sill structures. The common floor panel serves multiple functions by pairing with various side sill configurations to create different vehicle widths, thereby reducing the need for completely unique components for each vehicle type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The vehicle body structure is segmented into modular components: a common floor panel and separate side sill structures. This segmentation allows the side sills to be varied independently to accommodate different vehicle widths while maintaining the same floor panel, reducing manufacturing complexity by standardizing the most complex component.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If unique components are constructed for each vehicle width, then vehicle aesthetics and performance are optimized, but tooling costs and manufacturing costs increase

Engineering Contradiction:

Improvevehicle width variationVSAvoidtooling costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The side sill structures are designed with variable parameters (different shelf sizes, riser heights, and lateral positions) that can be adjusted to accommodate different vehicle widths while using the same basic component architecture. This allows cost-effective manufacturing through parameter variation rather than complete redesign.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If inefficient packaging of structures is used, then manufacturing is simplified, but lateral roominess of the passenger compartment is reduced

Engineering Contradiction:

Improvestructural packagingVSAvoidinterior roominess

Core Design Contradiction:

Device complexityVSVolume of moving object

Solution Approach 1:

The side sill structures incorporate local quality variations with different shelf sizes and configurations at specific locations to optimize the passenger compartment volume. By strategically positioning shelves and risers at critical locations, the design maximizes interior roominess in the passenger compartment while maintaining structural efficiency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The side sill structures utilize vertical dimensionality through multiple risers and shelves to create storage and structural volume. By extending structures vertically with multiple levels (first riser, second riser, shelves), the design maximizes the use of three-dimensional space within the vehicle body, increasing interior roominess without proportionally increasing exterior width.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Strength

If unnecessarily added mass is used, then structural strength is improved, but vehicle weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The side sill structures are designed with optimized parameters including varying shelf sizes, riser heights, and wall thicknesses that provide sufficient structural strength while minimizing material usage. By carefully selecting and varying these parameters across different vehicle widths, the design achieves necessary strength without unnecessary mass addition.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The vehicle body structures utilize composite material construction combining different materials with appropriate strength-to-weight ratios. This allows optimization of structural strength in critical areas while using lighter materials in less demanding areas, reducing overall vehicle weight without compromising necessary structural integrity.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9505439B2Variable width platform vehicle body structure and method

Publication Date: 2016.11.29 FORD GLOBAL TECH LLC

AI summary

A method of varying vehicle width on a single platform includes providing a plurality of vehicles, where each vehicle includes a side sill extending longitudinally along a lower portion of a vehicle body. The side sill defines a door opening interface on each opposing side of the vehicle body. Each of the plurality of vehicles also includes a floor panel extending laterally across a width of each vehicle. The floor panel is joined at a lateral edge to the side sill. The method also includes maintaining a common lateral position of the joint between the floor panel and the side sill across each of the plurality of vehicles. The method further includes positioning the door opening interface at first lateral position corresponding to a first one of the plurality of vehicles and at a second lateral position corresponding to a second one of the plurality of vehicles.