Integrated energy-absorbing casting

Abstract

This invention provides an integrated energy absorption system for a vehicle, comprising a front-integrated energy-absorbing casting and a rear-integrated energy-absorbing casting. [Solution] Each of the forward and backward castings is a single, integrated casting that constitutes an integrated energy absorption system. Ribbed sections, such as "I"-shaped sections and "C"-shaped sections, constitute the casting and are formed from various different techniques and / or formations such as notches, corrugated profiles, tapers, flares and / or rib spacing. Additional sections, such as closed section castings, may also be integrated into the integrated energy absorption system.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the priority of U.S. Provisional Patent Application No. 63 / 062,728, filed on August 7, 2020, the content of which is hereby expressly incorporated by reference in its entirety.

[0002] The subject matter of the present disclosure generally relates to systems and methods for fabricating an integrated energy - absorbing casting for use in a vehicle. More specifically, the subject matter relates to a vehicle body component that is cast as an integrated single part and provides energy - absorbing crash protection from vehicle impacts.

Background Art

[0003] Conventional crash impact energy - absorbing systems for vehicles include a plurality of multi - component elements. For example, a crash impact energy - absorbing system may have a plurality of connecting components at the front and rear ends of a vehicle configured in multiple stages designed to compress or crush in response to an impact force. These multiple stages may include metal stamping or extrusion components that can wrinkle in response to an impact force.

[0004] Conventional crash impact energy - absorbing systems attached to vehicles cannot support the increasing requirements for efficient manufacturing and design scalability due to their multiple components and step - by - step conventional designs. Further, as the number of components constituting the crash energy - absorbing system increases, the complexity and cost associated with the manufacture, installation, and inspection and repair of these conventional crash energy - absorbing systems become excessive.

Summary of the Invention

Means for Solving the Problems

[0005] [[ID=3For the purpose of summary, specific aspects, advantages, and novel features are described herein. It should be understood that not all of such advantages are achieved according to any one particular embodiment. Accordingly, the subject matter of this disclosure may be embodied or performed in a manner that achieves or optimizes one advantage or group of advantages without achieving all of the advantages that may be taught or suggested herein.

[0006] Details of one or more variations of the subject matter described herein are given in the accompanying drawings and the following description. Other features and advantages of the subject matter described herein will become apparent from the description and drawings, as well as the claims. However, the subject matter of this disclosure is not limited to any specific embodiment disclosed.

[0007] One embodiment is an integrated energy absorption system for a vehicle formed from a single cast metal component. The system may include a left wheel well and a right wheel well connected by a lateral support, a first connection to a cabin frame, a second connection to a body panel or bumper, and a first crumple zone adjacent to the left wheel well and a second crumple zone adjacent to the right wheel well.

[0008] Another embodiment is a method for manufacturing an integrated energy absorption system for a vehicle. This method may include casting an integrated metal component comprising a left wheel well and a right wheel well connected by a lateral support, wherein the left wheel well and the right wheel well have crumple zones adjacent to the left wheel well and the front wheel well, respectively. . [Brief explanation of the drawing]

[0009] The accompanying drawings incorporated herein and constituting part of this specification illustrate specific aspects of the subject matter disclosed herein and, together with the description, help to illustrate some of the principles associated with the implementations of this disclosure provided below.

[0010] [Figure 1] This is a perspective view of a front-integrated energy-absorbing casting and a rear-integrated energy-absorbing casting installed on a vehicle frame, according to some embodiments of the present disclosure.

[0011] [Figure 2] These are side views of a front-integrated energy-absorbing casting and a rear-integrated energy-absorbing casting installed on a vehicle frame, according to some embodiments of the present disclosure.

[0012] [Figure 3] This is a perspective view of a forward-integrated energy-absorbing casting according to some embodiments of the present disclosure.

[0013] [Figure 4] This is a perspective view of a rear-integrated energy-absorbing casting according to some embodiments of the present disclosure.

[0014] [Figure 5] This is an exemplary top perspective view of a ribbed section of a rear-integrated energy-absorbing casting, showing notches, corrugated profiles, tapers, flares, and spacing, according to some embodiments of the present disclosure.

[0015] [Figure 6] This is a partial cross-sectional perspective view showing one embodiment of the internal structure of the rear ribbed section of a rear-integrated energy-absorbing casting.

[0016] [Figure 7] This is an example of a ribbed "C"-shaped section casting according to some embodiments of the present disclosure.

[0017] [Figure 8] This is an exemplary cross-sectional view of a ribbed section further illustrating alternative embodiment waveform designs of a rear-integrated energy-absorbing casting according to some embodiments of the present disclosure.

[0018] [Figure 9] An exemplary wavy profile between ribs of a ribbed section casting according to some embodiments of the present disclosure.

[0019] [Figure 10] An example of a taper or flare of a ribbed section casting according to some alternative embodiments of the present disclosure.

[0020] [Figure 11] An exemplary ribbed "I" - shaped section casting according to some alternative embodiments of the present disclosure.

[0021] [Figure 12] An exemplary ribbed "I" - shaped section casting showing a progressive wall thickness according to some embodiments of the present disclosure.

[0022] [Figure 13] An exemplary progressive crushing of a ribbed "I" - shaped section casting according to some embodiments of the present disclosure.

[0023] [Figure 14] An exemplary closed - section casting according to some embodiments of the present disclosure.

[0024] [Figure 15] An exemplary progressive crushing of a closed - section casting according to some embodiments of the present disclosure.

[0025] The figures may not be to scale, either absolutely or relatively, and are intended to be exemplary. The relative arrangement of features and elements may have been modified for the purpose of clarity of illustration. In practice, the same or similar reference numerals indicate the same or similar or equivalent structures, features, aspects, or elements according to one or more embodiments.

Best Mode for Carrying Out the Invention

[0026] Numerous specific details are described below to provide a complete description of various embodiments. Certain embodiments may be carried out without these specific details, or with some modifications in detail. In some cases, certain features are not described in much detail so as not to obscure other embodiments. The level of detail associated with each element or feature should not be interpreted as limiting the novelty or importance of one feature more than that of others. overview

[0027] Energy absorption systems are widely used in automotive crash structures. Examples of such systems include multi-cell extrusion and multi-component stamping, which primarily achieve energy absorption through the plastic deformation of metals, such as dynamic crushing, buckling, and bending.

[0028] The technology of this disclosure relates to cast energy absorption systems for the front and rear of a vehicle, which can be integrated with the frame or be part of a larger monolithic casting. Conventional energy absorption systems are connected to the vehicle structure (e.g., backup structure) by various manufacturing processes, including spot welding, seam welding, riveting, bolting, and adhesive bonding. The technology of this disclosure makes it possible to eliminate the need for these processes by integrating the energy absorption system with part or all of the backup structure in a single casting process. Thus, a single integrated forward monolithic energy absorption casting for the front end of the vehicle and a single integrated rear monolithic energy absorption casting for the rear end of the vehicle may constitute a single integrated energy absorption casting system for the entire vehicle.

[0029] To produce cast metal parts according to several embodiments, a casting mold is used to cast each energy-absorbing part or system. Typically, the mold cavity has two surfaces, namely a first surface and a second surface, which are pressed together to form the final casting mold. The casting mold contains a channel for molten metal alloy formed within the mold, which carries the molten metal alloy into each hollow section of the mold to produce the final cast form. During the casting procedure, the molten alloy is rapidly injected into the mold cavity, and then the mold cavity is cooled to produce a cast solid metal product from the molten alloy metal. In some embodiments, this process uses high-pressure die casting (HPDC), in which the molten alloy metal is supplied to a sealed mold under pressure.

[0030] As used herein, the term “metal” means any metal or metal alloy that can be die-cast and is useful for vehicle body parts. Those skilled in the art can select a metal or metal alloy based on the cast metal or cast metal alloy to be produced. In one embodiment, the metal is a metal alloy. In further embodiments, the metal or metal alloy includes aluminum, zinc, magnesium, copper, lead, or tin. In another embodiment, the metal or metal alloy includes aluminum. Using the modified die-casting method described herein, the resulting die-cast metal is not negatively affected, i.e., its desired porous ductility, strength, e.g., excellent strength-to-weight ratio, weight (either light or heavy, as determined by the type of metal being die-cast), corrosion resistance, mechanical properties, e.g., good thermal conductivity, high temperature resistance It maintains hardness, wear resistance, durability, and dimensional stability.

[0031] The casting process uses die-casting equipment, i.e., die-casting machines. Such machines may be made to suit the purpose or custom-made to manage large, one-piece castings as described herein. As used herein, the term “one-piece” means a single part and is not formed by joining separate parts together. Thus, when metal is poured into a casting mold, one one-piece part of metal is produced, such as the front or rear end of a vehicle. This is in contrast to forming separate front or rear end parts and then joining several of those metal pieces together with screws, bolts, tacks or welds. In one embodiment, the press die-casting machine may have a clamping force of 55,000 to 61,000 kilonewtons (5,600 to 6,200 tf). Using this system, molten alloy weighing 70, 80, 90, 100 kilograms or more may be poured into the casting mold at a speed of about 6 meters per second, although speeds of 5 to 10 meters per second are within the scope of embodiments of the present invention. Each cycle can take 60 to 120 seconds to complete, resulting in an output rate of 30 to 60 completed castings per hour.

[0032] Simply put, die casting is performed using die casting equipment, namely molds and hydraulic equipment. Hydraulic equipment used in metal die casting serves a variety of purposes and can be easily selected by those skilled in the art. In one embodiment, the hydraulic equipment is used for injection and discharge purposes and is operated using water-insoluble hydraulic fluid.

[0033] Generally, before casting, a water-soluble mold release agent is applied to the mold using techniques known in the art. In one embodiment, the release agent is sprayed onto the mold. Then, the molten metal is poured into the mold using the aforementioned hydraulic equipment. After pouring, the molten metal is cast, typically taking a few seconds or the time required depending on the metal being cast. After the casting period, the cast metal is discharged and collected using techniques known in the art. In one embodiment, the cast metal is discharged using hydraulic or robotic equipment.

[0034] Unlike extrusion and stamping, the cast energy-absorbing castings of this disclosure achieve energy absorption by inducing gradual deformation and crushing in the casting, which begins initially from the outside and then propagates inward during the impact event. Gradual crushing ensures robust and repeatable impact performance. The technology of this disclosure also incorporates and / or uses a variety of geometric designs and techniques to achieve gradual and repeatable deformation and crushing behavior in the cast parts.

[0035] Generally, cast alloys (e.g., alloys used in the art of this disclosure) tend to have lower ductility than forged alloys, which are conventionally used in impact energy systems. The art of this disclosure implements geometric features that limit fracture propagation and promote gradual deformation in an energy-absorbing load case. The design of the art of this disclosure is most effective for absorbing energy in alloys with high ductility, but is particularly more flexible because it is made from cast materials with limited ductility. The shape of the casting is specifically tailored to the levels of ductility and strength of the material used in a given design (e.g., the design of the art of this disclosure described herein) in order to achieve a desired energy absorption rate.

[0036] Any alloy and manufacturing process that exhibits significant deformation before fracture (e.g., ductile fracture) may be suitable for use in the art of this disclosure. Accordingly, the art of this disclosure may use structural (e.g., high vacuum) high-pressure die-cast aluminum and / or magnesium alloys.

[0037] Some examples of suitable alloys of the art of this disclosure may include aluminum having a Mg and / or Si base with a low Fe content, such as AlSi7, AlSi10Mn, AlSi10Mg, AlSi7Mg, AlSi9MgMnSr, and AlMg5Si2Mn; aluminum having a high Fe and low Si alloy, such as AlMg4Fe2; and magnesium HPDC, such as AZ91D or AE44.

[0038] More specifically, the cast aluminum alloys of the art of this disclosure may contain 6–12% Si and may have a composition adjusted to particularly limit microstructural features that promote brittle fracture modes. The composition may minimize AlFeSi intermetallic compounds with sharp aspect ratios, rounded (modified) silicon eutectic phases, and / or other elements added for strengthening the alloy material.

[0039] Cast alloys (e.g., the alloys described herein) and their manufacturing processes may be used individually, in part, or in combination with the entire integrated energy absorption system of a vehicle. In one embodiment, the vehicle frame is made from only three main components: a front integrated cast energy absorption component, a rear integrated cast energy absorption component, and a central cab frame to which the front and rear components are attached.

[0040] To fabricate a cast energy-absorbing structure, at least three design foundations may be used individually, partially, or in combination with each other. One design foundation is the use of ribbed "C"-shaped section castings, where a particular impact-absorbing section includes "C"-shaped ribs that support the part but allow for a predetermined fracture profile depending on the size and number of "C"-shaped sections arranged within each casting. In another design, each cast part uses an "I"-shaped central rib within the cast part to provide structural support and a desired fracture profile during an impact event. A third design may be a closed section casting design, where each part has a closed section that may be tapered to provide a desired structural support or may include a different number of internal structures and also provide a desired fracture profile during an impact event. These and other implementations are described more fully below with reference to the attached drawings. Exemplary integrated energy absorption casting system

[0041] Figure 1 is a perspective view of a vehicle 100 having a central cab frame 105, a front integrated energy-absorbing casting 110, and a rear integrated energy-absorbing casting 115. The front casting 110 includes a right side 120A and a left side 120B that form a front right and front left connection for mounting a front bumper or forward-facing grille panel to the vehicle. The right side 120A also includes a wheel well 130A surrounding the right front wheel of the vehicle 100. The left side 120B includes a left wheel well 130B surrounding the left front wheel of the vehicle 100. A lateral support 135 connects the right side 120A to the left side 120B to form the front integrated energy-absorbing casting 110.

[0042] The right side 120A has multiple cast crumple zones 140A formed by a series of repeating cells to create a multi-cell structure formed in the casting 100. The multiple cast crumple zones 140A may be located adjacent to the right wheel well 130A. Each cell may be defined by a center and an end and formed as a square, rectangle, or other geometric shape that converges into multiple adjacent cells to form a multi-cell structure. As shown in more detail with reference to Figures 2 and 3, the crumple zones are designed to crumple or collapse when struck by a large force during an impact to absorb some of the impact energy. The left side 120B has multiple cast crumple zones 140B, which are also designed to collapse or crumple when impacted by a forward impact of the vehicle 100. The cast crumple zones 140B are located adjacent to the left wheel well It may be placed adjacent to Ru130B.

[0043] It should be understood that the casting 110 is formed by casting a single metal alloy component into a single, integrated structure. This is in contrast to conventional automotive crumple zones, which consist of various parts that are all assembled together to form the vehicle frame. The casting form allows for a much easier and more flexible vehicle manufacturing process due to lower component costs, and also enables the ability to produce more complex shapes of crumple zones, as each part or section of the casting 110 can be designed to have maximum performance without relying on the need for additional mounting brackets, bolts, welds, and other features that may have different performance when individually installed in the vehicle.

[0044] Figure 1 also shows details of a rear-integrated energy-absorbing casting 115, including a right side 150A and a left side 150B at the rear of the vehicle. The right side 150A and left side 150B may include fixtures for mounting a rear bumper or other rear body panel that covers the rear of the vehicle 100. The right side 150A of the casting 115 also includes a right wheel well 155A and a right rear crumple zone 160A adjacent to the right wheel well. The left side 150B of the casting 115 includes a left wheel well 155B and a left rear crumple zone 160B adjacent to the left wheel well. The lateral support struts 165 and the rear lower carriage 170 connect the right side 150A and the left side 150B to each other to form the integrated rear-integrated energy-absorbing casting 115. The lateral support strut 165 can be used as a connector that allows the rear integrated energy absorbing casting 115 to be attached to the rear of the vehicle cabin frame, or it may include components or features. Other parts of the rear integrated energy absorbing casting 115 may also include connectors for connecting the rear integrated energy absorbing casting 115 to the vehicle cabin frame.

[0045] Figure 2 shows side perspective views of the front integrated energy-absorbing casting 110 and the rear integrated energy-absorbing casting 115. The cast crumple zone 140B of the front casting 110 is shown as part of the lower region of the wheel well 130B. The crumple zone 140B is formed as part of the casting metal and includes a multi-cell structure consisting of a plurality of individual cells configured to absorb forward impacts and fractures and absorb the energy of such impacts. The front crumple zone 205B also includes a multi-cell structure that absorbs impacts and is configured to be mounted to the front bumper or body panel of the vehicle. This is shown in more detail with reference to Figure 3.

[0046] Figure 2 also shows a side view of the rear integrated energy-absorbing casting 115, which includes a multi-cell structure, and the cast left rear crumple zone 160B. Rearward from the left rear crumple zone 160B is the left rear end crumple zone 210B, which is configured to fit with the rear bumper or body panel. This is shown in more detail with reference to Figure 4.

[0047] Referring here to Figure 3, a perspective enlargement view of the front integrated energy-absorbing casting 110 is shown. The front casting 110 includes a right side 120A and a left side 120B, which form a front right and front left connection for mounting a front bumper or forward-facing grille panel to the vehicle. The right side 120A also includes a wheel well 130A surrounding the right front wheel of the vehicle 100. The left side 120B includes a left wheel well 130B surrounding the left front wheel of the vehicle 100. A lateral support 135 connects the right side 120A to the left side 120B to form the front integrated energy-absorbing casting 110. The left side 120B includes a rear frame connection 325B, and the right side 120A includes a rear frame connection 325A. The rear frame connection 325A / B is used to mount the front integrated energy-absorbing casting 110 to the vehicle cabin frame.

[0048] As shown in more detail in Figure 3, the crumple zone 140B includes a lower crumple region 335B, a central crumple region 338B, and an upper crumple region 340. Each of these regions is designed with a set of vertical supports that allow the entire crumple zone 140B to collapse rearward when impacted by a forward impact. In addition, between the crumple zone 140B and the frame connection 325B, there is an additional multi-cell region 350, which is configured to collapse or shatter following a forward impact but to impart more impact force to protect the vehicle occupants. The ability to cast the forward integrated energy absorption casting 110 as a single piece allows it to be designed with specific multi-cell designs and other support mechanisms, thereby allowing the casting to be designed with specific crumple zones that provide varying levels of impact resistance. Thus, the foremost zones are most likely to follow an impact and wrinkle, while zones closer to the cabin may be designed with additional supports to prevent the impact from penetrating into the vehicle's cabin area.

[0049] Figure 4 is a side perspective view of a rear-integrated energy-absorbing casting 115, including a right side 150A and a left side 150B, at the rear of the vehicle. The right side 150A and the left side 150B may include fixtures for mounting a rear bumper or other rear body panel that covers the rear of the vehicle 100. The right side 150A of the casting 115 also includes a right wheel well 155A and a right rear crumple zone 160A. The left side 150B of the casting 115 includes a left wheel well 155B and a left rear crumple zone 160B. The lateral support struts 165 and the rear lower carriage 170 connect the right side 150A and the left side 150B to each other to form the integrated rear-integrated energy-absorbing casting 115.

[0050] The right side 150A connects to the casting 115 via a right crumple region 405A configured to fracture and wrinkle when subjected to a rearward impact. The crumple region 405A may be hollow with an internal vertical support or multi-cell structure that provides regional stability but allows for energy absorption from a rearward impact. Similarly, the left side 150B connects to the casting 115 via a left ribbed region 405B configured to fracture and wrinkle when subjected to a rearward impact. The left ribbed region 405B may be hollow with an internal vertical support or multi-cell structure that provides regional stability but allows for energy absorption from a rearward impact.

[0051] The left rear crumple zone 160B shows an "X" shaped support structure 410 used to provide good support for the left wheel well and allow rearward impact forces to be absorbed as the impact travels toward the rear cabin section. Naturally, the particular shape of the support structure can be modified to different compressible or crushable configurations without departing from the spirit of this disclosure.

[0052] Figure 5 shows an enlarged view of the left side surface 150B and the left ribbed region 405B. Figure 6 is an exemplary cross-sectional view of the ribbed section 405B, further illustrating the corrugated platform of the rear-integrated energy-absorbing casting. As shown, the ribbed region 405B shows a set of ribs 510B, including a corrugated mechanism 505B positioned between each rib. Notches 1e, corrugated profiles 1d, tapers 1a, tapers 1c, flares 1a, flares 1c, and spacings 1b between each rib 510B are also shown.

[0053] Figure 7 is a side view of a forward-integrated energy-absorbing casting showing a ribbed "C"-shaped section that can be used as a rib configuration in embodiments of the present disclosure. As shown, the ribbed "C"-shaped section casting consists of an upper web, a vertical web, and a lower web that form the "C"-shaped section. Furthermore, there is an intermediate web or support that can increase energy absorption and scalloped ribs to promote progressive crushing. The scallop mechanism can also add mass efficiency to each rib within the casting. The "C"-shaped section illustrated in Figure 7 has a casting design in which its primary stretching direction is perpendicular to the crushing axis. However, the "C"-shaped section design may also be used when the primary stretching direction for casting is parallel or substantially parallel to the vertical web and the rib and intermediate web mechanism is cast by sliding.

[0054] The techniques described for ribbed "I"-shaped section castings and rear-integrated energy-absorbing castings may also be used individually, partially, or in combination with "C"-shaped section designs for front-integrated energy-absorbing castings.

[0055] Figure 8 is an exemplary cross-sectional view of a ribbed section casting further illustrating the corrugated platform of a rear-integrated energy-absorbing casting. The corrugated profile may be provided in the upper and lower sections, or in the upper section only, or in the lower section only, to provide the desired energy-absorbing profile of the section. In addition, the number and size of the C sections placed within the casting may be varied to increase or decrease the crushing strength of the casting.

[0056] Figure 9 shows an exemplary corrugated profile placed between the ribs of a ribbed section casting. In some embodiments, corrugated profiles can be added to the intermediate web and / or upper and lower webs to initiate fracturing between the ribs.

[0057] Figure 10 shows an example of tapering or flaring in a ribbed section casting. The intermediate web or upper tapered and lower web may be tapered to facilitate gradual collapse. Tapering or flaring techniques may be used to compensate for undesirable offsets and tapers, or otherwise, may be dictated by the design due to packaging and process constraints.

[0058] Figure 11 of this disclosure shows an embodiment of a ribbed "I"-shaped section casting. As shown, there is an upper web, a lower web, and an intermediate web, which form a set of "I"-shaped scalloped ribs throughout the casting. Figure 12 is an example of a ribbed "I"-shaped section casting, showing progressive wall thickness, with each "I"-shaped section in the casting having a greater thickness along the lateral dimension of the cast part. Figure 13 shows a real example of experimental progressive crushing of a ribbed "I"-shaped section casting, showing that the casting fractured as expected along the lateral length of the part. A key mechanism of the "I"-shaped section design is the spaced ribs, which maximize the amount of crushing and increase energy absorption. For mass efficiency, a scallop mechanism is added to each rib. The ribs provide local reinforcement that limits deformation and crushing propagation in directions that would destabilize the crushing. Figure 13 shows the progressive crushing behavior of the "I"-shaped section design.

[0059] In addition, the following supplemental design techniques may be used independently, partially, or in combination to enhance the progressive crushing and mass efficiency of any of the described structures of the exemplary integrated energy absorption casting systems described herein. These techniques are employed to address specific impact performance requirements and constraints of the casting process. These techniques include: 1. progressively increasing wall thickness; 2. rib spacing; 3. axial tapered or flared profiles; 4. corrugated profiles between webs; and 5. notches between ribs in the upper and lower webs.

[0060] In addition, the cast wall thickness may be progressively increased in the crushing direction. The progressively increasing wall thickness can be applied independently, partially, or in combination to the intermediate web, upper web, lower web, and / or ribs. Furthermore, the rib spacing may be varied to ensure that fracturing occurs between the ribs and to minimize vertical fracturing propagation in the ribs. Preferred ribs The spacing is influenced by various factors, including web thickness and process constraints.

[0061] Figure 14 shows an embodiment of a closed section casting, and Figure 15 shows an exemplary gradual collapse of a closed section casting. A closed section casting design, such as that shown in Figure 14, may feature a tapered square or rectangular section to accommodate the draft angle required by the casting process. Alternatively, fins may be added to the design to compensate for the tapering of the section. The open square section contributes to axial collapse on its own, while the fins promote stability and energy absorption.

[0062] The rear of the closed section casting is integrated with a larger casting. The square or rectangular section may be fabricated using slides parallel or substantially parallel to the crushing direction. Example Implementation

[0063] Many variations and modifications are possible to the embodiments described above, and it should be understood that such elements are found in other acceptable examples. All such modifications and variations are intended to be within the scope of this disclosure. The above description details specific embodiments. However, it should be understood that, no matter how detailed the above description may be, the systems and methods can be implemented in many ways. Also, as stated above, the use of specific terms when describing particular features or aspects of the systems and methods should not be construed as meaning that the terms are redefined herein to include any particular characteristics of the features or aspects of the systems and methods to which the terms relate.

[0064] Each of the systems, methods, and apparatus described herein has several embodiments, and not just one of them exclusively embodies its desired attributes. Some non-limiting features are briefly described here without limiting the scope of this disclosure. The following paragraphs describe various exemplary implementations of the apparatus, systems, and methods described herein.

[0065] Example 1: An integrated energy absorption system for a vehicle, comprising a front-integrated energy-absorbing casting and a rear-integrated energy-absorbing casting.

[0066] Example 2: The integrated energy absorption system described in Example 1, wherein the forward integrated energy absorption casting is positioned at the front of the vehicle.

[0067] Example 3: The integrated energy absorption system described in Example 1, wherein the forward integrated energy absorption casting is located at the rear of the vehicle.

[0068] Example 4: The integrated energy absorption system according to Example 1, wherein the forward integrated energy absorption casting comprises a ribbed "C"-shaped section.

[0069] Example 5: The integrated energy absorption system according to Example 4, wherein the ribbed "C"-shaped section comprises an upper web, a lower web, and a vertical web that form the "C"-shaped section.

[0070] Example 6: The integrated energy absorption system described in Example 4, wherein the ribbed "C"-shaped section further comprises an intermediate web for increased energy absorption.

[0071] Example 7: The integrated energy absorption system according to Example 4, wherein the ribbed "C"-shaped section further comprises multiple scalloped ribs to promote gradual collapse.

[0072] Example 8: An integrated energy absorption system as described in Example 7, wherein the scallops of the scalloped ribs add mass efficiency to each rib.

[0073] Example 9: The integrated energy absorption system according to Example 1, wherein the rear integrated energy absorption casting comprises a ribbed section.

[0074] Example 10: The integrated energy absorption system according to Example 9, wherein the ribbed section is either a ribbed "I"-shaped section or a ribbed "C"-shaped section.

[0075] Example 11: The integrated energy absorption system described in Example 9, wherein the ribbed section of the rear integrated energy absorption casting comprises a corrugated platform.

[0076] Example 12: The integrated energy absorption system according to Example 9, wherein the ribbed section of the rear integrated energy absorption casting has notches to facilitate progressive crushing.

[0077] Example 13: The integrated energy absorption system described in Example 9, wherein the ribbed section of the rear integrated energy absorption casting has a corrugated profile.

[0078] Example 14: An integrated energy absorption system as described in Example 13, wherein the waveform profile is located on the upper and lower webs of the ribbed section.

[0079] Example 15: An integrated energy absorption system as described in Example 13, wherein the waveform profile is located between the ribs of the ribbed section.

[0080] Example 16: An integrated energy absorption system as described in Example 13, wherein the waveform profile is located on the intermediate web of the ribbed section.

[0081] Example 17: An integrated energy absorption system of Example 13, wherein the ribbed section of the rear integrated energy absorption casting has a taper.

[0082] Example 18: The integrated energy absorption system according to Example 13, wherein the ribbed section of the rear integrated energy absorption casting is flared.

[0083] Example 19: The integrated energy absorption system according to Example 13, wherein the ribbed section of the rear integrated energy absorption casting has spacing between each rib.

[0084] Example 20: The integrated energy absorption system according to Example 1, further comprising a closed section casting.

[0085] As described above, the implementation of the example above may include hardware and / or methods or processes. Additional implementation considerations

[0086] Where a feature or element is referred to in this specification as being "on top of" another feature or element, it may also be directly on top of the other feature or element, or there may be intervening features and / or elements. In contrast, where a feature or element is referred to as being "directly on top of" another feature or element, there may not be any intervening features or elements. Where a feature or element is referred to as being "connected," "attached," or "joined" to another feature or element, it may also be directly connected, attached, or joined to the other feature or element, or there may be intervening features and / or elements. It will also be understood that the intervening feature or element may exist. In contrast, when a feature or element is referred to as being "directly connected," "directly attached," or "directly coupled" to another feature or element, the intervening feature or element may not exist.

[0087] While the description or illustration relates to one embodiment, the features and elements described or illustrated in this manner may also apply to other embodiments. References to structures or features positioned "adjacent" to another feature may also be understood by those skilled in the art, as they may have portions that overlap or lie beneath the adjacent feature.

[0088] The terms used herein are for the purpose of describing only specific embodiments and implementations, and are not intended to be limiting. For example, as used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural form unless the context clearly indicates otherwise. It will be further understood that the term “equipped with,” as used herein, identifies the presence of a described feature, step, action, process, function, element, and / or component, but does not exclude the presence or addition of one or more other features, steps, actions, processes, functions, elements, components, and / or groups thereof. As used herein, the term “and / or” includes any combination of one or more of the associated enumerated items, and may be abbreviated as “ / .”

[0089] In the above description and claims, phrases such as “at least one” or “one or more” may appear, followed by a conjunctive list of elements or features. The term “and / or” may also appear in a list of two or more elements or features. Unless implicitly or explicitly contradicted by the context in which it is used, such phrases are intended to mean any of the enumerated elements or features individually, or any of the enumerated elements or features in combination with any of the other enumerated elements or features. For example, the phrases “at least one of A and B,” “one or more of A and B,” and “A and / or B” are intended to mean “A alone, B alone, or A and B together,” respectively. The same interpretation is intended for lists containing three or more items. For example, the phrases “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, and / or C” are intended to mean “A alone, B alone, C alone, A and B, A and C, B and C, or A, B and C,” respectively. The use of the term “based on” in the foregoing and in the claims is intended to mean “at least partially based,” so as to allow for features or elements that are not enumerated.

[0090] Spatially relative terms such as “forward,” “backward,” “downward,” “below,” “underside,” “upward,” and “top” may be used herein to facilitate descriptions of the relationship between one element or feature and another, as shown in the figures. It will be understood that spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation shown in the figures. For example, if the device in the figure is inverted, an element described as being “below” or “directly below” another element or feature will be oriented “above” the other element or feature due to the inverted state. Thus, the term “downward” may encompass both upward and downward orientations, depending on the reference point or orientation. The device may be oriented in other directions (rotated by 90 degrees or other orientations), and the spatially relative descriptors used herein will be interpreted accordingly. Similarly, terms such as “upward,” “downward,” “vertically,” and “horizontally” may be used herein for descriptive purposes only, unless otherwise specified.

[0091] The terms “first” and “second” are used herein to refer to various (steps or pros) While these terms may be used to describe features / elements (including Seth), these features / elements should not be limited by these terms as an indication of the order of features / elements or whether one is more important than the other, unless the context indicates otherwise. These terms may be used to distinguish one feature / element from another. Thus, the first feature / element described may be called the second feature / element, and similarly, the second feature / element described below may be called the first feature / element without departing from the teachings provided herein.

[0092] Where used herein and in the claims, including where used in examples, unless otherwise expressly specified, all numbers may be read as if they begin with the word “about” or “approximately.” The phrase “about” or “approximately” may be used when describing a magnitude and / or location to indicate that the stated value and / or location is within a reasonable expected range of the value and / or location. For example, a number may have values ​​such as + / -0.1% of the stated value (or range of value), + / -1% of the stated value (or range of value), + / -2% of the stated value (or range of value), + / -5% of the stated value (or range of value), + / -10% of the stated value (or range of value), etc. Any numbers shown herein should also be understood to include an approximate or approximate value unless the context indicates otherwise.

[0093] For example, if the value "10" is disclosed, then "about 10" is also disclosed. Any numerical range enumerated herein is intended to include all subranges contained therein. It is also understood, as will be well understood by those skilled in the art, that when a value is disclosed, then the possible ranges "less than or equal to" that value, "greater than or equal to" that value, and the range between the values ​​are also disclosed. For example, if the value "X" is disclosed, then "less than or equal to X" and "greater than or equal to X" (for example, where X is a number) are also disclosed. It is also understood that throughout this application, data may be provided in several different formats, and this data may represent an endpoint or a start point, and a range of any combination of data points. For example, if a particular data point "10" and a particular data point "15" may be disclosed, then it is understood that greater than 10 and 15, greater than or equal to, less than, less than or equal to, and equal to, as well as between 10 and 15, may be considered disclosed. It is also understood that each unit between two particular units may also be disclosed. For example, if 10 and 15 may be disclosed, then 11, 12, 13, and 14 may also be disclosed.

[0094] While various exemplary embodiments are disclosed, any of several modifications may be made to these embodiments without departing from the teachings herein. For example, the order in which various described method steps are performed may be changed or rearranged in different embodiments or alternative embodiments, and in other embodiments, one or more method steps may be skipped entirely. Any or desirable features of the embodiments of various devices and systems may be included in some embodiments and not in others. Therefore, the above description is provided primarily for illustrative purposes and should not be construed as limiting the scope of the claims and any particular embodiments or any particular details or features disclosed.

[0095] The examples and illustrations contained herein illustrate, not limiting, specific embodiments in which the subject matter of this disclosure may be carried out. As stated above, other embodiments may be utilized and derived in such a way that structural and logical substitutions and modifications may be made without departing from the scope of this disclosure. Where two or more such embodiments of the subject matter of this disclosure are actually disclosed, they are referred to individually or collectively by the term “invention” herein, solely for convenience and without the intention of voluntarily limiting the scope of this application to any single invention or inventive concept. This may be referred to in the following. Therefore, although specific embodiments are illustrated and described herein, any configuration calculated to achieve the intended, practical, or disclosed purpose, whether explicitly stated or implied, may substitute for any particular embodiment shown. This disclosure is intended to cover all possible applications or variations of the various embodiments. Combinations of the embodiments described above, and other embodiments not specifically described herein, will be apparent to those skilled in the art by considering the above description.

[0096] The subject matter of this disclosure is provided herein by reference to one or more features or embodiments. Those skilled in the art will recognize and understand that, despite the detailed nature of the exemplary embodiments provided herein, changes and modifications may be applied to such embodiments without limiting or departing from the generally intended scope. These and various other applications and combinations of the embodiments provided herein fall within the scope of the subject matter of this disclosure as defined by the complete set of disclosed elements and features and their equivalents.

Claims

1. The left wheel well and the right wheel well are connected by a lateral support, At least one connection point to the vehicle cabin frame, A second connection point to the vehicle body panel or bumper, An integrated energy absorption system for a vehicle, formed from a single cast metal component, comprising a first crumple zone adjacent to the left wheel well and a second crumple zone adjacent to the right wheel well.

2. The integrated energy absorption system according to claim 1, wherein the integrated energy absorption system is positioned in front of the vehicle.

3. The integrated energy absorption system according to claim 2, wherein the at least one connection portion to the vehicle cabin frame is located behind the integrated cast metal component.

4. The integrated energy absorption system according to claim 2, wherein the second connection portion is attached to the front bumper.

5. The integrated energy absorption system according to claim 2, wherein the first crumple zone and the second crumple zone have a microcell structure formed from a plurality of individual cells.

6. The integrated energy absorption system according to claim 1, wherein the integrated energy absorption system is located at the rear of the vehicle.

7. The integrated energy absorption system according to claim 6, wherein the at least one connection portion to the vehicle cabin frame is located in front of the integrated cast metal component.

8. The integrated energy absorption system according to claim 6, wherein the second connection portion is attached to the rear vehicle body panel or bumper.

9. The integrated energy absorption system according to claim 2 or 6, wherein the first crumple zone and the second crumple zone have a microcell structure formed from a plurality of individual cells.

10. The integrated energy absorption system according to claim 1, wherein the first crumple zone or the second crumple zone comprises a ribbed "C"-shaped section.

11. The integrated energy absorption system according to claim 10, wherein the ribbed "C"-shaped section comprises an upper web, a lower web, and a vertical web that form the "C"-shaped section.

12. The integrated energy absorption system according to claim 11, wherein the ribbed "C"-shaped section further comprises an intermediate web for increasing energy absorption.

13. The integrated energy absorption system according to claim 10, wherein the ribbed "C"-shaped section further comprises a plurality of scalloped ribs for promoting gradual collapse.

14. The integrated energy absorption system according to claim 1, wherein the first crumple zone and the second crumple zone each comprise a ribbed "I"-shaped section.

15. The integrated energy absorption system according to claim 1, wherein the integrated energy absorption system is located at the rear of the vehicle, and the first crumple zone and the second crumple zone have waveform profiles.

16. The integrated energy absorption system according to claim 15, wherein the waveform profile is located on the upper and lower webs of the ribbed section.

17. The integrated energy absorption system according to claim 15, wherein the waveform profile is located between the ribs of the ribbed section.

18. The integrated energy absorption system according to claim 15, wherein the waveform profile is located on the intermediate web of the ribbed section.

19. The integrated energy absorption system according to claim 1, wherein the casting comprises aluminum metal.

20. The integrated energy absorption system according to claim 19, wherein the casting comprises an aluminum and magnesium alloy, or an aluminum and silicon alloy.

21. A method for manufacturing an integrated energy absorption system for a vehicle, comprising casting a single metal component comprising a left wheel well and a right wheel well connected by a lateral support, wherein the left wheel well and the right wheel well have crumple zones adjacent to the left wheel well and the front wheel well.

22. The method according to claim 21, wherein casting the integrated metal part includes placing molten metal under pressure into a mold for casting the integrated metal part.

23. The method according to claim 22, wherein placing the molten metal in the molding die includes placing the molten metal in a die-casting machine having a clamping force of 55,000 to 61,000 kilonewtons (5,600 to 6,200 tf).

24. The method according to claim 22, wherein placing the molten metal into the molding die includes placing the molten metal into a die-casting machine at a speed of approximately 6 meters per second.

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