Vehicle Exoskeleton Panels for Crash Resistance Without Reinforcements
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Solution Overview
Problem
Conventional vehicle exterior panels lack sufficient strength, requiring additional components like anti-intrusion bars for crash protection, which increase manufacturing costs and complexity.
Innovation Solution
A monolithic metal sheet exterior panel is used, directly attached to the vehicle frame, providing structural support and crash resistance without additional support structures, such as anti-intrusion bars, and can be applied to various vehicle components like doors, roofs, and hoods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional exterior panels are used, then manufacturing cost and assembly complexity are reduced, but crash resistance and structural strength are insufficient
Solution Approach 1:
The patent merges the exterior panel and support structure into a single integrated component. The exterior panel includes integrated support features such as reinforcement ribs and mounting structures that eliminate the need for separate anti-intrusion bars and stamped reinforcements, thereby maintaining crash resistance while reducing assembly complexity
Solution Approach 2:
The exterior panel is designed to serve multiple functions simultaneously: it provides cosmetic coverage, structural support, crash resistance, and component mounting surfaces. This multi-functionality eliminates the need for separate dedicated support components, reducing both parts count and assembly complexity while maintaining strength
2Strength
If additional support structures are added to exterior panels, then crash resistance is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The support structures are integrated into the exterior panel as a single molded or formed component rather than separate parts. This eliminates multiple assembly steps for attaching anti-intrusion bars and reinforcements, reducing assembly time while maintaining crash resistance
Solution Approach 2:
The support features are pre-integrated into the exterior panel during panel manufacturing. The panel arrives at the assembly line with built-in reinforcement structures already in place, eliminating the need for additional assembly steps to install support components, thereby reducing assembly time
3Strength
If additional support structures are added to exterior panels, then crash resistance is improved, but manufacturing cost increases
Solution Approach 1:
The exterior panel and support structures are manufactured as a single integrated component, eliminating the need to manufacture, inventory, and assemble multiple separate parts. This consolidation reduces manufacturing cost despite maintaining crash resistance through integrated reinforcement features
Solution Approach 2:
The integrated exterior panel performs multiple functions (cosmetic coverage, structural support, crash protection) that would traditionally require separate components. This multi-functionality reduces total parts count and manufacturing cost while maintaining necessary strength through carefully designed integrated support features
Data Source
AI summary
A vehicle having an exoskeleton exterior panel that provides crash resistance is described. The exterior panel may be formed from a monolithic metal sheet and attached to an exterior portion of the vehicle frame, and the exterior panel does not comprise an additional support structure. At least one component may be directly attached to the exterior panel, and the exterior panel may bear the load of the at least one component. Methods of manufacturing the vehicle are also described.