“It expands modularly and is assembled like Lego blocks.” If there is a 'Flexible Body System', this becomes possible in cars.
Kia announced on the 17th that it will solidify its entry into the Platform Beyond Vehicle (PBV) market by leading with the mid-sized PBV 'The Kia PV5' (hereinafter PV5), which applies the next-generation body technology 'Flexible Body System'.
The Flexible Body System is a PBV-specialized technology that modularizes key components such as the body, moving parts (doors, tailgates, etc.), exterior, and interior, allowing for flexible development and production of various specifications through a new design and production method called 'a body assembled like Lego blocks'.
Kia has optimized the design flexibility and production efficiency for diverse vehicle development based on customer demands by being the first to apply the Flexible Body System to the PV5, while also ensuring structural stability and maintenance convenience of the body.
The PV5 is designed so that the front and first-row structures operate with the same common parts across all models, while the sections beyond the first row and the rear are modularized with parts such as rear overhang, tailgate, quarter glass, and roof, allowing for selective combinations. Through this, Kia has established a system that can expand the PV5's body lineup to a maximum of 16 types, developing a total of seven basic body types, including passenger (long), cargo compact (3-door/4-door), cargo long (3-door/4-door), and cargo high-roof (3-door/4-door). This design and development allow for the creation of various vehicle types reflecting customer preferences in response to the changing demands and market environment.
For example, the PV5 cargo long is produced by moving the 'rear overhang module' of the cargo compact backward and adding a 'long body module' between the D-pillar to extend the overall length, and it can easily switch to a passenger body with just a replacement of the 'quarter glass module' and 'tailgate module'.
Kia has applied 'assembled rear-side around garnish' and 'exoskeletal ring structure' to respond flexibly and quickly to new customer requirements while ensuring safety and maintenance convenience. The assembled rear-side around garnish is applied to the outer side of the side body behind the D-pillar and is made of plastic composite material that is easier to mold than general steel panels, allowing for production in various sizes and shapes according to the vehicle's overall length, height, and uses (passenger, cargo, etc.).
Kia designed the rear-side around garnish to consist of three pieces, allowing for easy replacement of only the damaged area in case of rear-end collisions or scratches, thus also ensuring customer maintenance convenience and reducing maintenance expenses. Additionally, by applying the 'exoskeletal ring structure', which thickens the outer body frame based on an assembled garnish structure, it enhanced the structural stability and NVH performance of the body.
In the case of the long body model, this structure has been designed as 'exoskeletal dual ring structure' with dual application on the rear overhang extension area (long body module) and the rear side (rear overhang module) to further strengthen body rigidity. Two types of molds are used to produce the steel panels that are differentiated by the presence or absence of the second-row sliding door and quarter glass, maximizing development and production efficiency.
Kia has also applied the Flexible Body System inside the PV5 to allow customers to utilize it in various ways according to their purposes.
The luggage side trim located in the trunk space operates with a total of seven types based on body specifications and customer needs, supporting customizable space arrangements that allow for the installation of various accessories such as Kia Add Gear and L-Track mounting.
Kia plans to gradually introduce various models of the PV5, starting mass production of the PV5 passenger five-seater (2-3-0) and cargo long model this month, and to expand its product portfolio by launching a large-sized PBV in 2027, establishing a foundation to meet diverse customer needs in the PBV market.
Lee Young-ho, executive director of MSV Body Design 1, which led the development of the Flexible Body System, said, “The concept of modular assembly with Lego blocks, unlike the existing method, was a challenging task at first, but ultimately created a turning point in developing new vehicles suitable for the PBV era,” adding, “We will continue to innovate technologies to effectively provide customized vehicles that can respond to various customer lifestyles and changes in business environments.”
Kia will hold the 'The Kia PV5 Tech Day' for the media at the I-Backs Studio in Gyeonggi Province on the 22nd, introducing core technologies and specialized product attributes of the PV5, including the Flexible Body System.
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