Motor Vehicle Floor Element with Variable Thickness Reinforcement
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Solution Overview
Problem
Current motor vehicle floor elements face challenges in achieving high strength at low weight while providing satisfactory acoustic comfort and minimizing pollutant emissions.
Innovation Solution
A motor vehicle floor element with a reinforcing structure that varies in thickness, incorporating an acoustic fleece or sound-insulating foam as the insulating material, and a honeycomb reinforcement structure made from lightweight materials like polypropylene or polyamide, combined with a thin wood top layer for optimal strength-to-weight ratio and noise insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the floor element uses a uniform thick reinforcing structure throughout, then strength is improved, but weight increases
Solution Approach 1:
The reinforcing structure is designed with variable thickness: thicker in areas where the floor element rests on the vehicle body structure for maximum strength, and thinner in areas that do not contact the body structure to reduce weight. This local differentiation optimizes the strength-to-weight ratio by concentrating material only where structurally necessary.
2Object-affected harmful factors
If the floor element uses thicker insulating material throughout, then acoustic insulation is improved, but weight increases
Solution Approach 1:
The insulating material thickness is varied according to acoustic requirements in different zones. Thicker insulation is applied in areas requiring superior noise protection, while thinner insulation suffices in areas with lower acoustic demands, thereby optimizing noise reduction while minimizing added weight.
3Weight of moving object
If the floor element uses lighter materials, then weight is reduced, but strength may be compromised
Solution Approach 1:
The floor element employs a composite construction combining lightweight materials (such as aluminum or plastic) with strategically placed reinforcing structures. This composite approach maintains overall lightness while providing localized strength enhancement where required, achieving an optimal balance between weight reduction and structural integrity.
4Reliability
If the reinforcing structure is made thicker in contact areas, then connection stability is improved, but manufacturing complexity increases
Solution Approach 1:
The reinforcing structure is segmented into distinct zones with different thicknesses: thicker sections in contact areas for stable connection to the vehicle body, and thinner sections in non-contact areas. This segmentation can be efficiently manufactured using modular components or progressive forming techniques, balancing connection reliability with manufacturing feasibility.
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 solution provides enhanced acoustic insulation, improved strength, and reduced weight, while maintaining low material costs and manufacturing complexity, ensuring efficient power transmission and stable connection to the vehicle body.
Implementation Method 1
the insulating material can be, for example, an acoustic fleece, a sound-insulating foam or an insulating mat. Good noise insulation is particularly desirable in the field of electromobility.
Implementation Method 2
the insulating material can be connected to the adjoining layer of the floor element, for example by an adhesive connection, before the floor element is installed in the motor vehicle.
Data Source
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AI summary
A floor element (2) for a motor vehicle, comprising a top layer (10) terminating the floor element upwards, a middle layer made of a carrier material (12) which has a reinforcing structure (14), and a lower layer, is characterized by the fact that the lower layer has an insulating material (20).