Structure assembly with concave cavity

Abstract

The present disclosure provides a structural assembly with a cavity. A structural assembly for a vehicle includes a cast body. The cast body has a main wall, a non-circular cavity formed in the main wall, and at least one mounting feature. The cavity is at least partially defined by a bottom wall and an arcuate wall. The bottom wall has a first end and an opposite second end. The arcuate wall extends in a first direction from the first end of the bottom wall to the main wall. The arcuate wall also extends from a first side of the cavity to an opposite second side of the cavity. The mounting feature extends from the bottom wall in a second direction opposite the first direction and is configured to couple to a vehicle component.

Description

Technical Field

[0001] The present disclosure relates to a structural assembly having a concave cavity. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] The vehicle structure may be manufactured by a casting process (comprising filling a mold with a molten or semi-solid material and then hardening the material into a shape defined by the mold). The vehicle structure manufactured by the casting process may include features that allow the structure to interact with (e.g., be secured to) other components or parts of the vehicle.

[0004] The present disclosure addresses the mechanical properties of structural castings that may include features that interact with other components or parts of a vehicle. Summary of the Invention

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form, the present disclosure provides a structural assembly for a vehicle including a cast body. The cast body includes a main wall, a non-circular first cavity formed in the main wall, and at least one mounting feature. The first cavity is at least partially defined by a bottom wall and a curved wall. The bottom wall has a first end and an opposite second end. The curved wall extends from the first end of the bottom wall to the main wall in a first direction. The curved wall also extends from a first side of the first cavity to an opposite second side of the first cavity. The mounting feature extends from the bottom wall in a second direction opposite the first direction. The feature is further configured to couple to a vehicle component.

[0007] In a variation of the structural assembly of the above paragraph, which may be implemented individually or in any combination: the mounting feature includes a plurality of mounting features extending from the bottom wall in the second direction; the mounting feature is a boss, the boss including a hole extending at least partially therethrough; the boss includes a length having a variable thickness; the boss has a proximal end and a distal end, the proximal end having a thickness greater than the distal end; the first cavity has a Kammtail virtual foil profile; the bottom wall is planar; the cast body further includes a non-circular second cavity, the second cavity having a Kammtail virtual foil profile; the first cavity extends in a third direction and the second cavity extends in a fourth direction, the third direction being different from the fourth direction; the first cavity extends perpendicular to the mounting feature; and the cast body is a front end structure of the vehicle, the front end structure including a left upper rail and a right upper rail.

[0008] In another form, the present disclosure provides a structural assembly for a vehicle including a cast body. The cast body includes a main wall, a non-circular first cavity formed in the main wall, and a plurality of bosses. The first cavity is at least partially defined by a bottom wall and an arcuate wall. The bottom wall has a first end and an opposite second end, the second end being straight. The arcuate wall extends from the first end of the bottom wall to the main wall in a first direction. The arcuate wall also extends from a first side of the first cavity to an opposite second side of the first cavity. Each of the plurality of bosses extends from the bottom wall in a second direction and includes a hole extending at least partially therethrough. The second direction is opposite to the first direction. Each of the plurality of bosses is configured to be coupled to a vehicle component.

[0009] In a variation of the structural assembly of the previous paragraph that may be implemented individually or in any combination: each boss has a proximal end and a distal end, the proximal end being thicker than the distal end; the first cavity having a Cam's tail virtual airfoil profile; the casting body further includes a non-circular second cavity having a Cam's tail virtual airfoil profile; the first cavity extends in a third direction and the second cavity extends in a fourth direction, the third direction being different from the fourth direction; the casting body is a front end structure of the vehicle, the front end structure including a left upper longitudinal beam and a right upper longitudinal beam; and the main wall is inclined.

[0010] In yet another aspect, the present disclosure provides a structural assembly for a vehicle including a cast body. The cast body includes a main wall, a plurality of non-circular cavities formed in the main wall, and a plurality of bosses. Each cavity is at least partially defined by a bottom wall and an arcuate wall. The bottom wall has a first end and an opposite second end, the second end being straight. The arcuate wall extends from the first end of the bottom wall to the main wall in a first direction. The arcuate wall also extends from a first side of the first cavity to a second side opposite the first cavity. Each of the plurality of bosses extends from the bottom wall in a second direction opposite the first direction. Each boss is configured to couple to a vehicle component and includes a proximal end and a distal end. The proximal end has a greater thickness than the distal end. A first non-circular cavity of the plurality of non-circular cavities extends in a third direction, and a second non-circular cavity of the plurality of non-circular cavities extends in a fourth direction. The third direction is different from the fourth direction.

[0011] In a variation of the structural assembly of the previous paragraph, each non-circular cavity of the plurality of non-circular cavities has a Kam's tail virtual airfoil profile.

[0012] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order that the present disclosure may be better understood, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0014] Figure 1 is a perspective view of a portion of a vehicle body including a structural assembly having a casting according to the principles of the present disclosure;

[0015] Figure 2 yes Figure 1 A perspective view of a casting of a structural assembly;

[0016] Figure 3 yes Figure 1 A top view of the casting of the structural assembly;

[0017] Figure 4A yes Figure 1 a bottom perspective view of a casting of a structural assembly;

[0018] Figure 4B is Figure 4A A perspective view of a portion of the structural assembly indicated as 4B in FIG.

[0019] Figure 5 yes Figure 1 a perspective view of a portion of a casting of a structural assembly;

[0020] Figure 6 yes Figure 5 a cross-sectional view of the casting of the structural assembly taken along line 6-6;

[0021] Figure 7 yes Figure 1 another cross-sectional view of the casting of the structural assembly through one of the recessed cavities;

[0022] Figure 8 is a schematic diagram illustrating melt flow through a die according to the principles of the present disclosure; and

[0023] Figure 9 is a flow chart illustrating a method of forming a structural assembly according to the principles of the present disclosure.

[0024] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0025] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0026] refer to Figure 1 , a vehicle 12 including a structural assembly 10 is provided. In the example shown, the vehicle 12 is of unibody construction. In some forms, the vehicle 12 may be a body-on-frame split architecture. In some forms, the vehicle 12 may be an electric vehicle. In other forms, the vehicle 12 may have an internal combustion engine (ICE). Still further, in other forms, the vehicle 12 may be a hybrid electric vehicle (HEV). The structural assembly 10 according to the present disclosure includes a casting or cast body 14 and a pair of strut caps (not shown) secured to the casting 14.

[0027] As used herein, a "casting" 14 is a product manufactured by a casting process (i.e., by filling a molten or semi-solid material into a mold and then hardening the material into a shape defined by the mold). The casting 14 includes a plurality of structural components that are joined together in a casting process. The plurality of structural components form a structural load path and extend in multiple directions in 3D space. That is, the casting process provides the casting 14 with a deformation and energy absorption pattern throughout the 3D space, which is easier to absorb energy than forming each component separately and joining them together later. By forming the casting 14 using a casting process, the casting 14 increases the uniformity of the energy absorption characteristics of the entire structural component and reduces the overall weight of the portion of the hybrid structural assembly 10. The casting process reduces the machining of the structural components when forming the casting 14, thereby reducing manufacturing time.

[0028] The casting 14 is formed from a castable alloy material (i.e., a material that can be used in a casting process). As described above, the material used in the casting process is heated to a liquid phase or a semi-solid phase and then introduced into a mold to form the casting 14. The castable alloy material can be, for example, one of an aluminum alloy, fiber-reinforced aluminum, fiber-reinforced magnesium, etc. The castable alloy material can have a lower weight, ductility, and / or toughness than other materials used in vehicle components. In other words, the ductility of the castable alloy material may be less and may have lower toughness than other materials that cannot be used in the casting process. The lower weight of the castable alloy reduces the overall weight of the vehicle 12.

[0029] refer to Figure 2 、 Figure 3 、 Figure 4A The casting 14 can be the front end of the vehicle 12 and can be secured to a subframe (not shown) of the vehicle 12 such that the subframe is supported by the casting 14. In the example shown, the casting 14 includes a front fascia cross member 30, a pair of opposing beams or inner longitudinal beams 32a, 32b, a pair of opposing upper longitudinal beams 34a, 34b, a pair of opposing skirt panels 36a, 36b, mounting features 41, and a plurality of recesses 43a, 43b (collectively, recesses 43). A bumper (not shown) extends in a transverse direction Y relative to the longitudinal direction X of the vehicle 12 and is secured to the front ends of the pair of beams 32a, 32b. The front fascia cross member 30 extends in the transverse direction Y at the rear end 39a of the casting 14 and is connected to the intermediate inner longitudinal beams 32a, 32b and the subframe (not shown). Each beam 32a, 32b extends from a lower portion of a corresponding hinge pillar to the bumper. Each beam 32a, 32b is also curved and extends around the front wheels (not shown) of the vehicle 12 and forms a portion of the respective front wheel well. Upper longitudinal beams 34a, 34b are positioned above the beams 32a, 32b and extend from the upper portion of the respective hinge pillar to the front end of the respective beam 32a, 32b. In other words, each upper longitudinal beam 34a, 34b includes a first end 42a located at the upper portion of the respective hinge pillar and a second end 42b located at the front end of the respective beam 32a, 32b.

[0030] In the example shown, each skirt panel 36a, 36b is curved and extends from the corresponding upper longitudinal rail 34a, 34b to the corresponding rail 32a, 32b. In this manner, each skirt panel 36a, 36b is positioned between the corresponding upper longitudinal rail 34a, 34b and the corresponding rail 32a, 32b. Each skirt panel 36a, 36b also extends from the rear end 39a of the casting 14 to the front end 39b of the casting 14 and includes an opening 48 formed therein. In other words, the opening 48 extends through each skirt panel 36a, 36b, allowing one or more components (not shown) of the vehicle suspension system (not shown) to extend through (or pass through) the opening 48. In the example shown, the opening 48 formed in the skirt panels 36a, 36b is closer to the corresponding upper longitudinal rail 34a, 34b than the corresponding rail 32a, 32b. In the example shown, each skirt panel 36a, 36b includes a mounting feature or flange 52 that allows a strut cap (not shown) to be mounted to the casting 14. In the example shown, the mounting feature 52 extends upward from the skirt panels 36a, 36b and extends at least partially around the opening 48 in the skirt panels 36a, 36b.

[0031] Each strut cap (not shown) is secured to a mounting feature 52 of a corresponding skirt panel 36 a, 36 b of the casting 14 and houses at least a portion of the vehicle suspension system. An example of such a strut cap is disclosed in U.S. patent application Ser. No. 18 / 599,541, filed on the same date as the present application and entitled “VEHICLE STRUCTURAL ASSEMBLY HAVING STRUT CAPS,” which is commonly owned with the present application and is incorporated herein by reference in its entirety.

[0032] refer to Figure 4A 、 Figure 4B and Figure 6 , a plurality of mounting features 41 extend from the casting 14 and are attached to a portion of the vehicle 12. For example, one or more mounting features 41 may be located in the area of ​​the front fascia cross member 30 and may secure a subframe (not shown) to the casting 14. In another example, one or more mounting features 41 may be located in the area of ​​the skirts 36a, 36b, the upper longitudinal rails 34a, 34b, and / or the beams 32a, 32b and may secure different parts or components of the vehicle 12 to the casting 14. The mounting features 41 may have different lengths and / or thicknesses. As shown in FIG. Figure 6As shown, each mounting feature 41 includes a proximal end 41a and a distal end 41b extending from the casting 14. In some forms, the mounting feature 41 has a variable thickness from the proximal end 41a to the distal end 41b. In one example, the thickness of the proximal end 41a is greater than the thickness of the distal end 41b. In other words, the mounting feature 41 tapers from the proximal end 41a to the distal end 41b. In some forms, the mounting feature 41 has a constant thickness from the proximal end 41a to the distal end 41b. In the example shown, each mounting feature 41 is a boss that includes a hole 58 extending at least partially therethrough and is configured to receive a fastener (e.g., a bolt, screw, and / or rivet). In some forms, the hole 58 can be threaded.

[0033] refer to Figure 2 and Figure 3 , a cavity 43 is formed in the front fascia cross member 30 of the casting 14. In some forms, the cavity 43 may be formed at other areas of the casting 14, such as, for example, at the skirt panels 36a, 36b. In the example shown, the cavity 43 is formed in the wall 60 of the front fascia cross member 30 and may extend in different directions. For example, one or more of the cavities 43a may have a length that extends along the longitudinal direction X of the vehicle 12, and / or one or more of the cavities 43b may have a length that extends at a certain angle relative to the longitudinal direction X and the transverse direction Y of the vehicle. Figure 3 As shown, the cavity 43b extends in a direction that is angled (e.g., an acute angle) relative to the longitudinal direction X and the transverse direction Y. In the example shown, the wall 60 is angled or inclined. In some forms, the wall 60 is planar or flat.

[0034] refer to Figures 5 to 7 , each cavity 43 has a non-circular shape and is recessed in the -Z direction from the wall 60 of the front instrument panel cross member 30. The size of each cavity 43 is designed to receive one or more cooling molds during the casting process, as will be described in more detail below. In the example shown, the cavity 43 has a generally Cam's tail virtual airfoil profile and is defined by a bottom wall 62, an arcuate wall 64 and opposing side walls 66a, 66b. The bottom wall 62 is planar or flat and includes a first end 62a and a second end 62b opposite the first end 62a. The first end 62a is arcuate. In some forms, the second end 62b is straight. In other forms, the second end 62b is angled. One or more mounting features 41 are recessed in the -Z direction ( Figure 6 ) such that the proximal end 41a of the mounting feature 41 is positioned proximate to the bottom wall 62. The mounting features 41 extending from the bottom wall 62 also extend in a direction perpendicular to the length of the cavity 43. It should be understood that the aperture 58 in each mounting feature 41 does not extend through the bottom wall 62.

[0035] Arc-shaped wall 64 extends from bottom wall 62 to wall 60 in the +Z direction. In other words, arc-shaped wall 64 extends from bottom wall 62 in a direction opposite to the direction in which one or more mounting features 41 extend from bottom wall 62. Arc-shaped wall 64 extends from sidewall 66a of cavity 43 to sidewall 66b of cavity 43 opposite sidewall 66a. In other words, first end 64a of arc-shaped wall 64 is located at sidewall 66a of cavity 43, and second end 64b of arc-shaped wall 64 is located at sidewall 66b of cavity 43. Sidewall 66a extends from first end 64a of arc-shaped wall 64 to second end 62b of bottom wall 62, and sidewall 66b extends from second end 64b of arc-shaped wall 64 to second end 62b of bottom wall 62. In some embodiments, sidewalls 66a and 66b are straight. In other embodiments, sidewalls 66a and 66b are curved outward (i.e., convex) from the center of cavity 43. The portion of the side wall 66a located near the arcuate wall 64 extends further in the +Z direction than the portion of the side wall 66a located near the second end 62b of the bottom wall 62. Similarly, the portion of the side wall 66b located near the arcuate wall 64 extends further in the +Z direction than the portion of the side wall 66b located near the second end 62b of the bottom wall 62.

[0036] refer to Figure 8 and Figure 9 , provides a method for manufacturing a part or structural casting for a vehicle 12. At 204, a molten material (e.g., molten aluminum) is conveyed or directed through the cavity of molds 94a, 94b. Molds 94a, 94b include mounting features 96 and cooling features 97 adjacent to mounting features 96. Cooling features 97 are also shaped to reduce directional changes in the molten material flowing through the cavity. For example, cooling features 97 can have a non-circular shape. In one example, the non-circular shape is a Cam's tail virtual airfoil profile including a curved leading edge and a straight trailing edge. The molten material flowing through the cavity flows substantially parallel to the longitudinal axis of cooling features 97. The Cam's tail virtual airfoil profile of cooling features 97 reduces turbulence in the wake of cooling features 97. At 208, one or more cooling molds 98 are inserted into the space of mold 94a. In this way, the molten material received in mounting features 86 can be cooled, which reduces the local temperature and any shrinkage porosity. In the example shown, the cooling mold 98 is circular and has a cooling fluid (e.g., water) flowing therethrough. In some forms, the cooling mold 98 can have different shapes, such as oval, rectangular, square, or any other suitable shape that can be received in the space of the mold 94a.

[0037] The casting 14 of the present disclosure provides a cavity 43 including a Cam's tail virtual airfoil profile, which reduces local hot spots and reduces air entrapment during the manufacture of the structural casting. Although the present disclosure discloses a casting 14 of a front end structure of a vehicle 12 having the cavity 43, it should be understood that the cavity 43 may be included in other portions of the vehicle 12 formed by the casting process, such as, for example, hinge pillar reinforcements, center rails, and drop rails.

[0038] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics when describing the scope of the present disclosure should be understood as modified by the word "about" or "approximately." Such modification is desirable for various reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0039] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical "or", and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0040] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the essence of the disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

[0041] According to the present invention, a structural assembly for a vehicle is provided, the structural assembly having: a cast body, the cast body including a main wall; a non-circular first cavity, the non-circular first cavity being formed in the main wall; and a plurality of bosses, the non-circular first cavity being at least partially defined by a bottom wall and an arcuate wall, the bottom wall having a first end and an opposite second end, the second end being straight, the arcuate wall extending from the first end of the bottom wall in a first direction to the main wall, the arcuate wall also extending from a first side of the non-circular first cavity to an opposite second side of the non-circular first cavity, wherein each of the plurality of bosses extends from the bottom wall in a second direction opposite to the first direction and includes a hole extending at least partially therethrough, the second direction being opposite to the first direction, and each of the plurality of bosses being configured to be coupled to a vehicle component.

[0042] According to one embodiment, each boss has a proximal end and a distal end, and wherein the thickness of the proximal end is greater than the thickness of the distal end.

[0043] According to one embodiment, the non-circular first cavity has a Kam's tail virtual airfoil profile.

[0044] According to one embodiment, the casting body further comprises a non-circular second cavity, and wherein the non-circular second cavity has a Cam's tail virtual airfoil profile.

[0045] According to one embodiment, the non-circular first cavity extends in a third direction, and the non-circular second cavity extends in a fourth direction, the third direction being different from the fourth direction.

[0046] According to one embodiment, the cast body is a front end structure of the vehicle, and wherein the front end structure includes a left upper longitudinal beam and a right upper longitudinal beam.

[0047] According to one embodiment, said main wall is inclined.

[0048] According to the present invention, a structural assembly for a vehicle is provided, the structural assembly having: a casting body, the casting body including a main wall; a plurality of non-circular cavities, the plurality of non-circular cavities formed in the main wall; and a plurality of bosses, each cavity being at least partially defined by a bottom wall and an arcuate wall, the bottom wall having a first end and an opposite second end, the second end being straight, the arcuate wall extending from the first end of the bottom wall to the main wall in a first direction, the arcuate wall also extending from a first side of a non-circular first cavity of the plurality of non-circular cavities to an opposite second side of the first non-circular cavity, wherein each of the plurality of bosses extends from the bottom wall in a second direction opposite to the first direction, each boss being configured to be coupled to a vehicle component and including a proximal end and a distal end, the proximal end having a thickness greater than a thickness of the distal end, wherein a first non-circular cavity of the plurality of non-circular cavities extends in a third direction, and a second non-circular cavity of the plurality of non-circular cavities extends in a fourth direction, the third direction being different from the fourth direction.

[0049] According to one embodiment, each non-circular cavity of the plurality of non-circular cavities has a Kamm's tail virtual airfoil profile.

Claims

1. A structural assembly for a vehicle, comprising: a casting body comprising a main wall; a non-circular first concave cavity formed in the main wall; and at least one mounting feature, the non-circular first concave cavity being at least partially defined by a bottom wall and a curved wall, the bottom wall having a first end and an opposite second end, the curved wall extending from the first end of the bottom wall to the main wall in a first direction, the curved wall also extending from a first side of the non-circular first concave cavity to an opposite second side of the non-circular first concave cavity, wherein the at least one mounting feature extends from the bottom wall in a second direction opposite the first direction, the at least one mounting feature being configured to couple to a vehicle component. 2 . The structural assembly of claim 1 , wherein the at least one mounting feature comprises a plurality of mounting features extending from the bottom wall in the second direction. 3 . The structural assembly of claim 1 , wherein the at least one mounting feature is a boss, and wherein the boss includes a hole extending at least partially therethrough.

4. The structural assembly of claim 3, wherein the boss comprises a length having a variable thickness.

5. The structural assembly of claim 3, wherein each boss has a proximal end and a distal end, and wherein the thickness of the proximal end is greater than the thickness of the distal end.

6. The structural assembly of claim 1, wherein the non-circular first cavity has a Cam's tail virtual airfoil profile.

7. The structural assembly of claim 1, wherein the bottom wall is planar.

8. The structural assembly of claim 1, wherein the cast body further comprises a non-circular second cavity, and wherein the non-circular second cavity has a Cam's tail virtual airfoil profile. 9 . The structural assembly of claim 8 , wherein the non-circular first cavity extends in a third direction and the non-circular second cavity extends in a fourth direction, the third direction being different from the fourth direction.

10. The structural assembly of claim 1, wherein the non-circular first cavity extends perpendicular to the at least one mounting feature.

11. The structural assembly of claim 1, wherein the cast body is a front end structure of the vehicle, and wherein the front end structure includes a left upper longitudinal member and a right upper longitudinal member.

12. The structural assembly of claim 1, wherein the main wall is inclined.

13. The structural assembly of claim 11, wherein the second opposite end is straight.

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