Integrated Vehicle Floor Cross Structure for Stiffness and Assembly
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Solution Overview
Problem
Existing vehicle body structures face challenges in simplifying assembly processes, increasing weight, and complexity due to multiple components, which are difficult to manufacture with aluminum to reduce weight and improve stiffness, especially in electric vehicles.
Innovation Solution
A vehicle body structure design featuring a unified front and rear cross portion with recessed walls and reinforcements, connected by extension portions, and flanges, made of ultra-high strength steel, to enhance stiffness and reduce weight without using expensive materials like aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple associated components (crossmembers, longitudinal members, brackets) are individually joined to the floor, then the strength and stiffness of the floor are improved, but the number of assembled components and joint portions increases, making the assembly process complex and increasing overall weight
Solution Approach 1:
The patent combines multiple associated components (crossmembers, longitudinal members, brackets) into a single integrated floor structure. This unified design eliminates the need for individual joining operations, reducing the number of joint portions and simplifying the assembly process while maintaining the structural strength through optimized geometry and material distribution
2Weight of moving object
If aluminum material is used for associated components, then the weight of the vehicle body is reduced, but the manufacturing cost of the vehicle body increases due to the expensive material
Solution Approach 1:
The patent changes the material parameter from aluminum to ultra-high strength steel, compensating for the higher density of steel through optimized structural design. The integrated floor structure uses precise geometric parameters and material distribution to achieve weight reduction comparable to aluminum while utilizing the cost-effective steel material
Solution Approach 2:
The patent employs ultra-high strength steel as a composite solution that combines the advantages of high strength and cost-effectiveness. The material is strategically applied in the integrated floor structure to achieve optimal strength-to-weight ratio without incurring the high manufacturing costs associated with aluminum materials
3Strength
If multiple associated components are assembled using fasteners and welding, then the floor strength is improved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple components into a single integrated structure that can be installed as one unit. This eliminates numerous fastening and welding operations, dramatically improving assembly productivity while maintaining floor strength through the optimized monolithic design
Data Source
AI summary
An embodiment vehicle body includes a front cross portion having a substantially uniform cross-section throughout its entire length, a rear cross portion spaced apart from the front cross portion, the rear cross portion having a substantially uniform cross-section throughout its entire length, and a connection structure connecting the front cross portion and the rear cross portion.