DESC:FIELD
The present disclosure relates to the field of floor structures in vehicles.
BACKGROUND
A conventional floor structure in a vehicle is formed by joining multiple metal sheets together. Typically, the metal sheets are welded at the interface thereof to form the conventional floor structure. Due to this, overall weight of the conventional floor structure increases which adversely affects fuel efficiency of the vehicle. The presence of welding makes the conventional floor structure look unaesthetic. Further, all the cut-outs of sheet metal components are done separately which occupies more space leaving less room for fitment of other components of the vehicles, typically an engine. Also such floor structure acts as a barrier during servicing of a vehicle.
Therefore, there is felt a need of a floor structure that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the state of the art or to at least provide a useful alternative.
An object of the present disclosure is to provide a floor structure for a vehicle that has an improved structural integrity and higher strength.
Another object of the present disclosure is to provide a floor structure for a vehicle that requires less material and prevents wasting of raw material.
Still another object of the present disclosure is to provide a floor structure for a vehicle that has lesser weight as compared to that of conventional floor structures.
Yet another object of the present disclosure is to provide a floor structure for a vehicle that has reduced joineries.
Yet another object of the present disclosure is to provide a floor structure for a vehicle that is aesthetical.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a unibody floor structure for a vehicle. The floor structure is formed by drawing a sheet metal through at least one die. The floor structure is defined by a body. The floor structure comprises a plurality of openings and integral mountings. The integral mountings are configured for receiving seat fittings thereon. The openings are configured on the body for accessing the space below the floor structure.
In an embodiment, the plurality of openings includes a first opening configured on an operative top surface of the body. The first opening provides access to an engine disposed below the unibody floor structure. In another embodiment, the plurality of openings includes a second opening configured on opposite sides of the body. The second opening provides a passage to electrical wiring. In yet another embodiment, the plurality of openings includes a third opening for facilitating removal of gases accumulated in the space below the floor structure. In still another embodiment, the plurality of openings includes a fourth opening configured on an operative front side of the floor structure. The fourth opening facilitates routing of cables.
Further, the floor structure comprises multiple provisions for mounting various components related to the vehicle. In an embodiment, the floor structure comprises a first provision configured to facilitate mounting of a striker thereon. In another embodiment, the floor structure comprises a second provision configured on opposite sides of the body to facilitate mounting of a battery and an electronic control unit on either sides of the floor structure.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A unibody floor structure for a vehicle, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates an isometric view of a conventional floor structure in a vehicle;
Figure 2 illustrates an isometric view of a unibody floor structure for a vehicle, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates another isometric view of the unibody floor structure of figure 1; and
Fig. 4 illustrates an exploded view of the unibody floor structure of figure 1 with different components of the vehicle embedded therein.
LIST OF REFERENCE NUMERALS
50 – Conventional floor structure
52, 54, 56, 58, 60, 62, 64 – Components of the conventional floor structure
66, 68, 70 – Cutouts on the conventional floor structure
100 – Unibody floor structure of the present disclosure
102 – Body
105 – Integral mountings
110 – First opening
115 – Cover
120 – Cutout
125 – Second opening
130 – Third opening
135 – Fourth opening
140 – First provision
145 – Second provision
DETAILED DESCRIPTION
Figure 1 illustrates an isometric view of a conventional floor structure 50. The conventional floor structure 50 comprises a plurality of sheet metal components 52, 54, 56, 58, 60, and 62, and a door 64 for providing access to an engine disposed below the conventional floor structure 50. All the sheet metal components 52, 54, 56, 58, 60, and 62 are manufactured separately, and then joined at the interface thereof by means of welding. However, the presence of multiple joineries at interface of the components 52, 54, 56, 58, 60, 62, and 64 increases overall weight of the conventional floor structure 50. The increase in weight of the conventional floor structure 50 adversely affects the fuel efficiency of a vehicle. Further, use of welding makes the conventional floor structure 50 look inelegant and unaesthetic. Multiple cutouts 66, 68, 70 are provided on the conventional floor structure 50 externally during the manufacturing of sheet metal components or during the assembly of the sheet metal components or after the assembly of sheet metal components. Such multiple cutouts 66, 68, 70 are prone to error, unaesthetic and if done wrongly leads to the replacement of the whole conventional floor structure 50.
The present disclosure envisages a unibody floor structure (hereinafter also referred to as floor structure) that has higher structural rigidity and strength, reduced joineries, and has lesser weight as compared to the conventional floor structure 50.
The unibody floor structure of the present disclosure is now elaborated with reference to figure 2 through figure 4. Figure 2 illustrates an isometric view of a unibody floor structure 100 for a vehicle, in accordance with an embodiment of the present disclosure. Figure 3 illustrates another isometric view of the unibody floor structure 100. Figure 4 illustrates an exploded view of the unibody floor structure 100 with different components of a vehicle embedded therein.
The floor structure 100 is formed by drawing a sheet metal through at least one die (not shown in figures). More specifically, the floor structure 100 is made of a single metal sheet. In an embodiment, the manufacturing of the floor structure 100 is achieved in two draws. In an embodiment, the sheet metal is drawn through a plurality of dies. During manufacturing of the floor structure 100, possible defects like split of the sheet metal component, wrinkles on the sheet metal component, and excessive thinning of the sheet metal component were eliminated. The floor structure 100 is manufactured in a way such that all the essential features are integrated in the single metal sheet floor structure.
The floor structure 100 is defined a body 102. The floor structure 100 comprises integral mountings 105 and a plurality of openings. The integral mountings 105 are configured on the body 102 for receiving seat fittings thereon. In an embodiment, the mountings 105 are formed integral with the body 102 during manufacturing. In another embodiment, the mountings 105 are fitted onto the body 102.
The floor structure 100 comprises a plurality of openings provided on the body 102. The openings provide access to a space below the floor structure. The openings are provided on the body 102 during manufacturing process itself to minimize the errors and to reduce overall maintenance and replacement cost.
The plurality of openings include, but not limited to, a first opening 110, a second opening 125, a third opening 130, a fourth opening 135.
In an embodiment, the first opening 110 is configured on an operative top surface of the body 102 to provide access to an engine disposed below the floor structure during servicing of the vehicle. The first opening 110 is provided with a cover 115. In an embodiment, the cover 115 is hingeably connected to the body 102. A cutout 120 is provided on the cover 115 for facilitating insertion of a dip stick.
In another embodiment, the second opening 125 is configured on opposite sides of the body 102. The second opening 125 provides a passage to electrical wiring.
In yet another embodiment, the third opening 130 is configured on the operative top surface of the body 102. The third opening 130 facilitates removal of gases accumulated in the space below the floor structure 100. In an embodiment, the third opening 135 is configured proximal to the first opening 110.
In yet another embodiment, the fourth opening 135 is configured on an operative front side of the body 102 to facilitate routing of cables.
The floor structure 100 further comprises a plurality of provisions configured on the body 102 to facilitate mounting of various components of the vehicle on the floor structure 100.
In an embodiment, a first provision 140 is configured on the body 102 to facilitate mounting of a striker thereon. More specifically, the first provision 140 is a slot configured proximal back end of the operative top surface of the body 102. The slot has holes configured on the base thereof to facilitate attachment of the striker in the slot. In another embodiment, a second provision 145 is configured on the body 102 to facilitate mounting of a battery and an electronic control unit thereon. The second provision 145 is configured on opposite sides of the body 102, and the battery and an electronic control unit can be mounted on either side of the body 102.
Typically, the conventional floor structure 50 is formed by joining seven pieces together, whereas the floor structure 100 is formed by a single metal sheet. This reduces the requirement of multiple fixtures and dies on a manufacturing line, which results in optimum utilization of the work area.
The floor structure 100 is made of SPRC-35 grade cold rolled steel which has better yield strength as compared the conventional SPCEN grade material. This improves the structural rigidity and overall strength of the floor structure 100.
The floor structure 100 is manufactured using minimum joineries which results in reduction of overall weight of the floor structure 100. In an exemplary embodiment, the weight of the floor structure 100 is about 20% lesser as compared to a conventional floor structure having same size and functionality. The reduction in weight is due to elimination of interface welding. Further, the manufacturing cost of the floor structure 100 is also lesser as compared to that of the conventional floor structure due to elimination of interface joineries. Furthermore, the floor structure 100 is aesthetical in nature and looks elegant due to absence of interface joineries. The floor structure 100 waterproof as interface joineries are eliminated. The raw material requirement and power consumption for manufacturing of the floor structure 100 are also reduced as compared to that of the conventional floor structure.
Further, the floor structure 100 occupies less space and provides more space and access to the components disposed below the floor structure 100, thereby providing better serviceability. The floor structure 100 has better noise, vibration and harshness (NVH) performance. The floor structure 100 also improves the quality of floor in a vehicle.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a unibody floor structure for a vehicle that:
• has an improved structural integrity and higher strength;
• requires less material, and prevents wasting of raw material;
• has lesser weight as compared to that of conventional floor structures;
• has reduced joineries; and
• is aesthetical.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation

,CLAIMS:WE CLAIM:
1. A unibody floor structure (100) for a vehicle, said floor structure (100) formed by drawing a sheet metal through at least one die, said floor structure (100) defining a body (102), said floor structure (100) comprising a plurality of openings configured on said body (102) for accessing a space below said floor structure (100).
2. The unibody floor structure (100) as claimed in claim 1, which comprises integral mountings (105) configured on said body (102) for receiving seat fittings thereon.
3. The unibody floor structure (100) as claimed in claim 1, wherein said plurality of openings includes a first opening (110) configured on an operative top surface of said body (102) to provide access to an engine disposed below said floor structure (100).
4. The unibody floor structure (100) as claimed in claim 1, wherein said plurality of openings includes a second opening (125) configured on opposite sides of said body (102) for providing a passage to electrical wiring.
5. The unibody floor structure (100) as claimed in claim 1, wherein said plurality of openings includes a third opening (130) for facilitating removal of gases accumulated in said space below said floor structure (100).
6. The unibody floor structure (100) as claimed in claim 1, wherein said plurality of openings includes a fourth opening (135) configured on an operative front side of said body (102) to facilitate routing of cables.
7. The unibody floor structure (100) as claimed in claim 1, wherein said floor structure (100) comprises a first provision (140) configured to facilitate mounting of a striker thereon.
8. The unibody floor structure (100) as claimed in claim 1, wherein said floor structure (100) comprises a second provision (145) configured on opposite sides of said body (102) to facilitate mounting of a battery and an electronic control unit on either sides of said floor structure (100).
9. The unibody floor structure (100) as claimed in claim 3, wherein said first opening (110) is provided with a cover (115) having a cutout (120) for inserting a dip stick.