Vehicular Frame Assembly Using Segmented Flange Panels
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Solution Overview
Problem
Existing structural frame assemblies in vehicles are costly and labor-intensive due to complex arrangements of parts, inefficient material usage, and unnecessary material costs, with limitations in shape formation and assembly complexity.
Innovation Solution
A structural frame assembly comprising interconnected flat flange members with spaced openings and web members between inner and outer panels, allowing for concentrated material use where needed, simplified assembly, and the creation of a lightweight, tubular-like frame structure using laser-cut plate material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous inner and outer sheets fully span the inner and outer sides of the frame, then the sheets provide continuous coverage and support, but this results in large material usage and unnecessary weight
Solution Approach 1:
The continuous sheets are segmented into discrete panels that are positioned only where structural support is needed. The frame structure is divided into multiple panels separated by spac ers, allowing material to be concentrated at critical load-bearing locations rather than providing continuous coverage throughout the entire frame volume.
Solution Approach 2:
Sheet material is applied locally only at positions where structural support is required, rather than continuously across the entire frame. The panel spacing and positioning are optimized to provide support precisely where needed, eliminating material waste in areas where minimal material is required for strength.
2Reliability
If beam elements are formed with flanges at top and bottom edges for sheet attachment, then the flanges provide support and attachment points, but this incurs further costs for material not necessary for strength
Solution Approach 1:
The unnecessary flange material is extracted or removed from the beam element design. Instead of forming flanges at top and bottom edges that extend beyond what is needed for structural strength, the beam elements are designed with precise material placement where flanges exist only where required for both strength and sheet attachment functions.
Solution Approach 2:
The structural support function and sheet attachment function are merged into a single optimized flange design. Rather than having separate flanges for support and separate attachment features, the flange geometry is integrated to simultaneously provide both structural reinforcement and attachment capability for the panels.
3Shape
If multiple beam elements are assembled with complex arrangements to form various contours and shapes, then the frame can achieve desired geometric configurations, but this requires a complex arrangement of parts which are individually joined together so as to be costly and labour intensive to assemble
Solution Approach 1:
The beam elements are pre-formed with integrated flanges and geometric features during manufacturing, so that when assembled, they automatically align and interconnect without requiring complex on-site adjustments. The preliminary shaping and feature integration reduces assembly complexity by eliminating the need for individual joining operations for each component.
Solution Approach 2:
The beam elements are designed with universal connection features that allow them to be assembled into various contours and shapes using the same basic component design. The flange geometry and connection interfaces are standardized to enable multiple configuration options without requiring different specialized parts for each shape variation.
Data Source
AI summary
A structural vehicular frame assembly includes an inner panel of interconnected flange members forming a first common plate of material and an outer panel of interconnected flange member forming a second common plate of material. Each of the flange members of the outer panel is joined to a respective one of the flange members of the inner panel in alignment therewith by one or more web members coupled between the inner panel and the outer panel such that the inner panel and the outer panel are spaced apart from one another and generally span alongside one another in a common direction of the frame assembly.