Rear structure for a vehicle body

Abstract

The present disclosure relates to a rear structure (10) for a vehicle body, wherein the rear structure (10) comprises a base part (20) and a plate part (30) attached to the base part (20), wherein the base part (20) is made of a metal casting, and wherein the plate part (30) is attached to a base portion (21) of the base part (20), forming a beam section (40) in the rear structure (10), wherein the plate part (30) is attached to one or more base members (22) of the base portion (21) by one or more fasteners (1).

Description

Technical Field

[0001] This disclosure relates to a rear structure for a vehicle body and a method for manufacturing the rear structure. Background Technology

[0002] The vehicle body may include several different structures that can be attached to each other. One of these structures is the rear structure, which is typically located at the rear of the vehicle. The rear structure is often used, particularly for the vehicle's luggage compartment, where it supports the luggage compartment floor inside the compartment. Luggage or other loads can be placed on the luggage compartment floor inside the compartment and are thus supported by the rear structure. However, the rear structure may have additional components attached to it, such as shock absorbers or, typically, the rear suspension, battery, etc.

[0003] The rear structure typically includes a rear crossbeam, which is a beam segment that can benefit the overall stiffness and noise, vibration, and harshness (NVH) properties associated with the rear floor area of ​​a vehicle. By providing lateral stiffness to the structure (particularly the structure connecting the vehicle's subframe and suspension), this beam segment can eliminate vibration radiation that enters the rear structure during use. The crossbeam also provides stiffness to the flat areas of the floor that can also vibrate and generate noise at certain frequencies.

[0004] However, when the rear structure is advantageously cast from metal, especially as a single component in the form of a large casting, the casting process makes it difficult to include beam sections in the rear structure.

[0005] For example, for large-scale castings, a high-pressure die casting (HDPC) process can be used, in which molten metal (such as, but not limited to, aluminum) is pushed into a die, or in other words, into a mold. The die consists of molds that are pressed together and sealed just before the molten metal is pushed in. After the metal is pushed in, the die retracts, and the mold reopens, allowing the cast metal's rear structure to be removed from the open die.

[0006] This means that the design of the rear structure must be adapted to the mold tools and their direction of movement when the mold is opened and closed. In the case of the rear structure, the surface between the wheel covers can be produced, for example, by a vertically moving mold tool, and the exterior of the wheel covers can be made by a horizontally moving mold tool. The mold tools also need to have a certain draft angle so that aluminum does not get stuck in the mold tools when they release and open the mold.

[0007] A drawback of this method of manufacturing the rear structure for a vehicle body is that it is impossible to cast closed sections because the die tooling used for the closed mold needs to be damaged to allow the cast rear structure to be removed from the mold. This creates open sections in the direction of die tooling movement. In some areas, these open sections may be undesirable. One of these areas is the location of the crossbeams on the rear structure of the vehicle, as the open sections reduce the contribution of the open sections to the overall stiffness and NVH properties of the rear structure. Summary of the Invention

[0008] This problem is at least partially solved or mitigated by the subject matter of this disclosure.

[0009] According to a first aspect, a rear structure for a vehicle body is provided, wherein the rear structure includes a base and a plate member attached to the base, wherein the base is made of a metal casting, and wherein the plate member is attached to a base portion of the base to form a beam segment in the rear structure, wherein the plate member is attached to one or more base members of the base portion by one or more fasteners.

[0010] The rear structure can be, in particular, part of the luggage compartment or generally the vehicle’s cabin, or in other words, at least partially forms the luggage compartment or cabin of the vehicle, especially a support structure for the luggage compartment, so that luggage or other loads can be supported and thus transported at the rear of the vehicle.

[0011] The body can be, in particular, a car body, and more particularly, a passenger car body. In addition to the rear structure, the body may also include one or more other structures, such as a front structure and / or a mid-section structure, to which the rear structure may be attached to form the body.

[0012] The dimensions of the base of the rear structure can be substantially larger than the plate components and / or any other part of the rear structure. This is because the base is a metal casting component, particularly cast as a single part in a large-scale casting process as described herein. The base can be designed as a one-piece or integral structure. The base may include several components and sections as described herein, such as wheel arches. The base portion may be, in particular, the central and / or lower floor components of the rear structure. All parts and components of the base can be designed integrally with each other, meaning that all these components and sections are part of the one-piece or integral structure of the base. The rear structure can be made of a single material, particularly a metal, such as aluminum or an aluminum alloy. This aluminum casting can be made entirely of aluminum, or may include aluminum, for example, primarily aluminum, along with other materials, particularly metals.

[0013] Plate components can be formed or designed separately from the base portion. In particular, plate components can be manufactured using processes different from casting, such as stamping and / or bending. Plate components can be made, for example, from sheet metal. Plate components are components that typically have a plate-like shape. This means that a plate component has a significantly larger surface area on two opposite sides than on all other sides. In other words, in terms of a purely plate-like shape, the width and length of the plate component are significantly greater than its height. However, plate components can be curved. In other words, plate components are not limited to rectangular plates, but can also be plates with angular shapes or forms.

[0014] Advantageously, in order to form beam segments in the rear structure to benefit from the increased overall stiffness and improved NVH properties provided by such open segments, the plate members are provided and secured to a metal casting base using one or more fasteners, wherein the fasteners are attached to one or more base members of the base portion. Thus, although it is not possible to form closed segments in the rear structure to provide beam segments (especially crossbeams) during the casting process due to limited capacity, beam segments can still be provided in a simple yet effective manner. For this purpose, only the plate members need to be manufactured separately and attached to the base portion using one or more fasteners. Advantageously, the plate members with a plate-like shape add almost no weight and can geometrically complement the angled portions of the base, such that they together form beam segments.

[0015] In one example, at least one of the one or more base members can be formed as a rib. Advantageously, such base members can be configured to add very little weight and material to the rear structure, as their rigid design can securely secure the plate components to the base and further increase the stiffness of the base.

[0016] In one example, the rib may extend longitudinally, substantially parallel to the long base portion side of the base portion. The long base portion side may form a long beam section side extending along the length of the beam section. The length of the long base portion and / or beam section may extend perpendicular to the longitudinal direction of the vehicle body or vehicle, may extend parallel to the vehicle axle, and / or may extend between opposing wheel arches of the rear structure. Therefore, the beam section may alternatively be referred to as a crossbeam, particularly an axle crossbeam. The long base portion side of the base portion is the longest side or long side of that portion, and it may also be the longest side or long side of the beam section and plate member with which it forms. By making the rib extend substantially parallel to the long base portion side of the base portion, the plate member can advantageously be attached to the rib in a sufficiently rigid and reliable manner along the length of the plate member.

[0017] In one example, a rib can be arranged on another long base portion side of the base portion. This other long base portion side can be arranged transversely to the long base portion side and form another long beam segment side extending along the length of the beam segment. Thus, the beam segment can be formed, for example, by two or three sides of the base portion, specifically by at least the long base portion side and the other long base portion side. Alternatively, the beam segment can be formed by one or both sides of the plate member, providing a beam segment with four long sides. Advantageously, the rib can now be provided on one of those long base portion sides of the base portion, thereby increasing the rigidity of the connection and the beam segment without requiring additional components or complexity on the base.

[0018] In one example, at least one of the one or more base members may be formed as a recess. A recess can generally be considered as a shape or structure extending out of a given shape (in the case of a base portion) such that a recess is formed within that portion, particularly a recess having a structure or the like that is at least partially hollow.

[0019] In one example, the recess may extend protrudingly toward the plate member from the long base portion side of the base portion, the long base portion side extending along the length of the base portion. The recess is a large-volume variation of the rib form of the base member. Advantageously, the recess can be formed by the shape of the base portion, thus eliminating the need for additional material like a rib.

[0020] In one example, the long plate member side of the plate member can be positioned at the recess side of the recess extending from the long base portion, and one or more fasteners secure the long plate member side to the recess side. The long plate member side can be the longest side or the long side of either side of the plate member.

[0021] In one example, the base portion may include two base members, to which the plate component may be attached, each of the base members located at one of two opposite longitudinal ends of the beam segment. Therefore, a strong and stable connection can be established using only or specifically the opposite longitudinal ends of the beam segment. Specifically, the connection between these ends may be unnecessary and can be omitted.

[0022] In one example, one or more base members may be positioned adjacent to one or more additional beam segments of the rear structure, the additional beam segments extending transversely to the length of the beam segment.

[0023] In one example, the beam segment may be located at the rear end of the rear structure, at the front end of the rear structure, or may extend between the rear end and the front end of the rear structure. The rear end of the rear structure may be the location where the bumper is attached to the rear structure. For this purpose, the rear structure may include a segment configured to attach the bumper thereto. Specifically, but not limited to, the segment may be configured to receive a crimped connecting beam, which may be connected to the bumper via one or more connecting devices (such as, but not limited to, screws). The front end of the rear structure may be located at the opposite end of the rear end; another variation is that the beam extends between the rear end and the front end.

[0024] In one example, the rear structure may include two or more beam segments, each formed by different plate components attached to different base portions. Each beam segment, plate component, and base portion may be constructed as described herein.

[0025] In one example, two or more beam segments can be located at different locations, namely: the rear end of the rear structure, the front end of the rear structure, and between the rear end and the front end of the rear structure. Therefore, increased stiffness and NVH properties can be provided at different locations within the rear structure.

[0026] In one example, one or more fasteners may be flow drill screws. Flow drill screws, or in other words, fasteners that only need to be approached from one side, and are capable of joining two different materials (e.g., steel for the plate component and aluminum for the base) when the plate component is made of a different material than the base. However, since it is a screw that penetrates both components, for safety purposes, the tip of the screw may be covered, and the total thickness of the two joining components may be set below certain limits.

[0027] In one example, the plate component could be made of a sheet of metal.

[0028] In one example, a plate component may include a substantially I-shaped or L-shaped profile. This profile refers to the cross-section of the plate component. An I-shaped profile may be a substantially flat profile. An L-shaped profile may be an angled profile comprising two substantially flat segments that are at an angle (generally perpendicular) to each other.

[0029] In one example, the base may further include a wheel arch portion for partially receiving a wheel therein. The wheel arch portion may be located at the opposite end of the rear structure, wherein beam segments extend between the opposite ends of the rear structure. The wheel arch portion typically includes a convex or raised shape that extends toward the base portion in its convex or raised shape. Furthermore, the wheel arch portion typically has at least a partially circular or round circumference or periphery. Thus, the vehicle's wheel can be received at least partially within the space formed by the convex or raised shape and within at least a partially circular or round periphery of the wheel arch portion. At least one wheel arch portion may include a shock absorber segment for receiving a shock absorber. A floor support structure may be supported between the wheel arch portions and / or on the base portion. The floor support structure may be configured to support a floor thereon.

[0030] According to a second aspect, a method for manufacturing a rear structure according to the first aspect is provided, wherein the method includes: The base of the rear structure is made of metal casting, the base including a base portion having one or more base members; Align the plate components with the base portion to form the beam section; and The plate component is attached to the base by drilling one or more fasteners through the plate component and one or more base components.

[0031] The resulting beam segment can be advantageously used for additional purposes, such as providing connectors on the plate component, for example, for attaching a luggage compartment component thereto. Therefore, the method can further include the step of providing one or more connectors on the plate component, for example, by attaching the connectors thereto.

[0032] According to another aspect, a vehicle body including the rear structure of the first aspect can be provided.

[0033] According to another aspect, a vehicle may be provided, which includes the rear structure of the first aspect or the body of the aforementioned aspect.

[0034] Note that the examples above can be combined with each other, regardless of the aspects involved. Specifically, the steps of the method can be combined with the structural features of the subsequent structure, and vice versa.

[0035] These and other aspects of this disclosure will become apparent from the examples described below and will be illustrated with reference to the examples described below. Attached Figure Description

[0036] Examples of this disclosure will now be described with reference to the following figures.

[0037] Figure 1 A perspective view is shown at the base of the rear structure after it has been formed between the mold tools; Figure 2It shows Figure 1 A perspective partial view of the base of the rear structure; Figure 3 It shows Figure 2 Different perspective partial views on the base; Figure 4 It shows Figure 2 An enlarged view of the base; Figure 5 The rear structure is shown, which has Figure 2 The base and the plate components attached thereto; Figure 6 It shows Figure 1 A perspective partial view of the alternative base of the rear structure; Figure 7 The rear structure is shown, which has Figure 6 The base and the plate components attached thereto; Figure 8 It shows crossing Figure 5 A cross-sectional view of the rear structure; Figure 9 It shows crossing Figure 7 A cross-sectional view of the rear structure; Figure 10 It shows Figure 9 Front view of the rear structure; Figure 11 It shows Figure 8 A schematic cross-sectional view of the rear structure; and Figure 12 It shows Figure 9 A schematic cross-sectional view of the rear structure. Detailed Implementation

[0038] The accompanying drawings are merely schematic representations and are intended to illustrate this disclosure only. In principle, identical or equivalent elements have the same reference numerals.

[0039] Figure 1 As shown Figure 10 The diagram shows a perspective view of the base 20 of a rear structure 10 for a vehicle body. The rear structure 10 includes the base 20, which may include two wheel arch portions 25. The wheel arch portions 25 may be located at opposite ends 11, 12 of the base 20 or the rear structure 10. The wheel arch portions 25 are arranged to partially accommodate a wheel therein. The base 20 and / or its base portion 21 may extend lengthwise between the two wheel arch portions 25 (see [reference]). Figure 10 ).

[0040] In order to manufacture the base 20 of the rear structure 10 by casting it from metal, especially as a single component in the form of a large casting, the casting process makes it difficult to include beam sections in the rear structure 10. Specifically, Figure 1 The process of casting the base 20, which is part of the rear structure 10, using mold tools 100, 102, is shown, with the mold tools 100, 102 being retrieved from the mold in opposite directions 101, 103.

[0041] In order to still provide beam segments 40 on the base 20 and thereby form a rigid and robust rear structure 10, plate members 30 are attached to the base 20, such as Figure 11 and Figure 12 As can be seen in the image. In this example, beam segment 40 is formed at the rear end of the rear structure 10.

[0042] Specifically, such as Figure 8 and Figure 9 As shown, the plate component 30 can be attached to one or more base members 22 of the base portion 21 of the base portion 20 by one or more fasteners 1.

[0043] Figures 2 to 4 Different views of possible embodiments of the base 20 are shown. In this example, the base portion 21 includes base members 22a, 22b, as... Figure 2 and Figure 4 As shown, this is for attaching the plate member 30 thereto. In this example, one of the base members 22 is formed as a rib 22a. The rib 22a extends longitudinally, substantially parallel to the long base portion side 23 of the base portion 21. For example, as Figure 5 As shown, when the plate component 30 is attached to the base 20, the long base portion side 23 forms the long beam section side 43 of the beam section 40 extending along the length of the beam section 40.

[0044] In this example, rib 22a is arranged on another long base portion side 24 of the base portion 21. When the plate member 30 is attached to the base 20, the other long base portion side 24 is arranged transversely to the long base portion side 23 and forms another long beam section side 44 of the beam section 40 extending along the length of the beam section 40.

[0045] In addition, Figures 2 to 4 In the example, one of the base members 22 is formed as a recess 22b. The recess 22b extends protrudingly toward the plate member 30 from the long base portion side 23 of the base portion 21.

[0046] like Figure 5As shown in the base portion 20, when the plate member 30 is attached to the base portion 21, the long plate member side 31 of the plate member 30 can be arranged at the recess side 22c of the recess 22b extending from the long base portion side 23, and one or more fasteners 1 secure the long plate member side 31 to the recess side 22c. The long plate member side 31 can form another long beam section side 41 of the beam section 40.

[0047] Furthermore, in this example, there is another long plate component side 32, which is angled at the long plate component side 31 and arranged parallel to and / or opposite to the long base portion side 23. The other long plate component side 32 forms another long beam segment side 42 of the beam 40.

[0048] exist Figure 5 In this configuration, plate member 30 may be additionally or alternatively attached to rib 22a. However, rib 22a may alternatively not be used for attachment, but only as a reinforcing rib for recess 22b. Furthermore, in Figures 2 to 5 Rib 22a may be omitted in the embodiments.

[0049] exist Figure 6 and Figure 7 An alternative embodiment of the base 20 is shown. Here, the recess 22b is not provided. Instead, rib 22a is provided as the base member 22, and the plate member 30 is attached to the base member 22 via its other long plate member side 32 using two exemplary fasteners 1.

[0050] like Figure 5 and Figure 7 As shown in any of the diagrams, the base member 22 is positioned adjacent to, or directly formed with, or attached to, an additional beam segment 50 of the rear structure 10, which extends transversely to the length of the beam segment 40. This additional beam segment 50 may provide additional reinforcement or strengthening of the rear structure 10 along its transverse extension along the beam segment 40.

[0051] Figure 8 and Figure 9 A fastener 1 in the form of flow drill screws is shown, which attaches the plate component 30 to the base portion 21, particularly according to Figure 6 and Figure 7 Implementation examples Figure 9 The ribs in form 22a and their corresponding base members and according to Figures 2 to 5 Implementation examples Figure 8 The base component 22b is in the form of a recess 22b.

[0052] Figure 10The assembled rear structure 10 is shown, wherein plate member 30 is attached along the entire base portion 21 to form beam section 40, which extends between two additional beam sections 50 that extend transversely to beam section 40 and adjacent to wheel arch portion 25.

[0053] from Figure 10 As shown in the coordinate system, beam segment 40 extends longitudinally in the y-direction, while another beam segment 50 extends longitudinally in the x-direction perpendicular to it. The heights of beam segments 40, 50, and the typical rear structure 10 can be determined in the z-direction.

[0054] In this example, the base portion 21 extending between the additional beam segment 50 or the wheel arch portion 25 includes two base members 22, to which the plate member 30 is attached. Each base member 22 is located at one of two opposite longitudinal ends 45, 46 of the beam segment 40, as shown below. Figure 11 As shown.

[0055] Specifically, Figure 11 and Figure 12 A simplified illustration of beam segment 40 with its extension and another beam segment 50 is shown schematically. Figure 11 Corresponding to use Figures 2 to 5 In embodiments where the recess 22b is used to attach the plate member 30, the recess 22b creates a gap or space between the additional beam section 50 and the beam section 40. This is not the case in embodiments where the rib 22a is used to attach the plate member 30, where the plate member 30 is attached directly and / or adjacent to or near the additional beam section 50, resulting in an even more rigid and robust integral rear structure 10.

[0056] As used herein, the phrase “at least one” in relation to a list of one or more entities should be understood to mean at least one entity selected from any one or more entities in the entity list, but not necessarily at least one of each entity specifically listed in the entity list, and does not exclude any combination of entities in the entity list. This definition also allows for the optional presence of entities other than those specifically identified in the entity list referred to by the phrase “at least one,” whether related to or unrelated to those specifically identified entities. Thus, as a non-limiting example, “at least one of A and B” (or equivalently, “at least one of A or B”, or equivalently, “at least one of A and / or B”) could in one example mean at least one (optionally including more than one) A, without B (and optionally including entities other than B); in another example, at least one (optionally including more than one) B, without A (and optionally including entities other than A); and in yet another example, at least one (optionally including more than one) A and at least one (optionally including more than one) B (and optionally including other entities). In other words, the phrases “at least one,” “one or more,” and “and / or” are open-ended expressions that are both connected and separate in operation. For example, each of the expressions “at least one of A, B, and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and / or C” can mean a single A, a single B, a single C, A and B together, A and C together, B and C together, A, B, and C together, and optionally, any of the above combined with at least one other entity.

[0057] By studying the accompanying drawings, the disclosure, and the appended claims, those skilled in the art can understand and implement other variations of the disclosed examples in practice with respect to the claimed disclosure. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude multiple. The fact that certain measures are recited in mutually different dependent claims does not mean that a combination of these measures cannot be used advantageously. Any reference numerals in the claims should not be construed as limiting the scope of the claims.

[0058] List of reference numerals 10 Rear Structure 11, 12 Opposite ends of the rear structure 20 base 21. Base section 22 Base components 22a Rib 22b Depression 22c Concave side 23. Long base portion side 24 Another long base portion side 30 plate components 31. Side of long plate component 32. Another long plate component side 40 beam section 41. Another long beam section side 42. Another long beam section side 43 Long beam section side 44. Another long beam section side Opposite longitudinal ends of beam segments 45 and 46 50 Other beam sections

Claims

1. A rear structure (10) for a vehicle body, wherein, The rear structure (10) includes a base (20) and a plate member (30) attached to the base (20), wherein the base (20) is made of metal casting, and wherein the plate member (30) is attached to a base portion (21) of the base (20) to form a beam segment (40) in the rear structure (10), wherein the plate member (30) is attached to one or more base members (22) of the base portion (21) by one or more fasteners (1).

2. The rear structure (10) according to claim 1, wherein, At least one of the one or more base members (22) is formed as a rib (22a).

3. The rear structure (10) according to claim 2, wherein, The rib (22a) extends longitudinally substantially parallel to the long base portion side (23) of the base portion (21), which forms the long beam section side (43) of the beam section (40) extending along the length of the beam section (40).

4. The rear structure (10) according to claim 3, wherein, The rib (22a) is arranged on another long base portion side (24) of the base portion (21), which is arranged transversely to the long base portion side (23) and forms another long beam segment side (44) of the beam segment (40) extending along the length of the beam segment (40).

5. The rear structure (10) according to any one of the preceding claims, wherein, At least one of the one or more base members (22) is formed as a recess (22b).

6. The rear structure (10) according to claim 5, wherein, The recess (22b) extends protrudingly from the long base portion side (23) of the base portion (21) toward the plate member (30), the long base portion side (23) extending along the length of the base portion (21).

7. The rear structure (10) according to claim 6, wherein, The long plate component side (31) of the plate component (30) is arranged at the recess side (22c) of the recess (22b) extending from the long base portion side (23), and the one or more fasteners (1) secure the long plate component side (31) to the recess side (22c).

8. The rear structure (10) according to any one of the preceding claims, wherein, The base portion (21) includes two base members (22), to which the plate member (30) is attached, each of the base members (22) being located at one of two opposite longitudinal ends (45, 46) of the beam segment (40).

9. The rear structure (10) according to any one of the preceding claims, wherein, The one or more base members (22) are positioned adjacent to one or more additional beam segments (50) of the rear structure (10), the one or more additional beam segments (50) extending in length transverse to the length of the beam segment (40).

10. The rear structure (10) according to any one of the preceding claims, wherein, The beam section (40) is located at the rear end of the rear structure (10), at the front end of the rear structure (10), or extends between the rear end and the front end of the rear structure (10).

11. The rear structure (10) according to any one of the preceding claims, wherein, The rear structure (10) includes two or more beam segments (40), each beam segment being formed by different plate components (30) attached to different base portions (21) of the base (20).

12. The rear structure (10) according to any one of the preceding claims, wherein, The one or more fasteners (1) are flow drill screws.

13. The rear structure (10) according to any one of the preceding claims, wherein, The plate component (30) is made of a metal sheet.

14. The rear structure (10) according to any one of the preceding claims, wherein, The base (20) also includes a wheel cover (25) for partially accommodating a wheel therein, the wheel cover (25) being located at opposite ends (11, 12) of the rear structure (10), wherein the beam section (40) extends between the opposite ends (11, 12) of the rear structure (10).

15. A method for manufacturing a rear structure (10) according to any one of the preceding claims, wherein, The method includes: - The base (20) of the rear structure (10) is cast from metal, the base (20) including the base portion (21) having the one or more base members (22). - Align the plate component (30) with the base portion (21) to form the beam segment (40); and - The plate component (30) is attached to the base (20) by drilling the one or more fasteners (1) through the plate component (30) and the one or more base components (22).

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