One-piece energy absorbing casting

Abstract

An integrated energy absorption system for a vehicle includes a forward integral energy-absorbing casting and a rear integral energy-absorbing casting. The forward and rear castings are each a single, integrated casting that comprises the integrated energy absorption system. Ribbed sections, such as "I" and "C" sections, comprise the castings and are formed using a variety of different techniques and / or formations, such as cutouts, corrugated profiles, tapers, flares, and / or rib spacing. Additional sections, such as closed-section section castings, may also be integrated into the integrated energy absorption system.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] APPLICATION This application claims priority to U.S. Provisional Patent Application No. 63 / 062,728, filed August 7, 2020, the contents of which are expressly incorporated herein by reference in their entirety.

[0002] The subject matter of this disclosure relates generally to systems and methods for making one-piece energy-absorbing castings for use in vehicles. More particularly, the subject matter relates to vehicle body components that are cast as a one-piece, single piece and provide energy-absorbing crash protection from vehicle impacts. [Background technology]

[0003] Conventional crash impact energy absorption systems for vehicles include multiple multi-piece components. For example, a crash impact energy absorption system may have multiple connecting pieces at the front and rear ends of the vehicle configured into multiple sections designed to compress or crush in response to the impact force. These multiple sections may include metal stampings or extrusions that wrinkle in response to the impact force.

[0004] Conventional vehicle-mounted crash impact energy absorption systems cannot support the increased demand for efficient manufacturing and design scalability due to their multiple components and staged conventional designs. Furthermore, as the number of components comprising an impact energy absorption system increases, the complexity and costs associated with manufacturing, installing, and servicing these conventional impact energy absorption systems become excessive. Summary of the Invention [Means for solving the problem]

[0005] For summary purposes, certain aspects, advantages, and novel features have been described herein. It is to be understood that not all such advantages may be achieved in accordance with any one particular embodiment. Thus, the subject matter of the present disclosure may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages without achieving every advantage that may be taught or suggested herein.

[0006] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. However, the subject matter of this disclosure is not limited to any particular embodiment disclosed.

[0007] One embodiment is an integrated energy absorption system for a vehicle formed from a single-piece cast metal part. The system may include left and right wheel wells 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 the left wheel well and a second crumple zone adjacent the right wheel well.

[0008] Another embodiment is a method of manufacturing an integrated energy absorption system for a vehicle, the method may include casting a one-piece metal part having left and right wheel wells connected by a lateral support, the left and right wheel wells having crumple zones adjacent the left and front wheel wells. [Brief explanation of the drawings]

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the subject matter disclosed herein and, together with the description, serve to explain some of the principles associated with implementations of the present disclosure provided below.

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

[0011] [Figure 2] FIG. 1 is a side view of a front integral energy-absorbing casting and a rear integral energy-absorbing casting installed on a vehicle frame, according to some embodiments of the present disclosure.

[0012] [Figure 3] FIG. 1 illustrates a perspective view of a forward integral energy absorbing casting according to some embodiments of the present disclosure.

[0013] [Figure 4] FIG. 1 illustrates a perspective view of an aft integral energy absorbing casting according to some embodiments of the present disclosure.

[0014] [Figure 5] FIG. 10 is an exemplary top perspective view of a ribbed section of an aft integral energy absorbing casting showing notches, wave profiles, tapers, flares, and spacing according to some embodiments of the present disclosure.

[0015] [Figure 6] FIG. 10 is a perspective view of a partial cross section showing one embodiment of the internal structure of the aft ribbed section of the aft one-piece energy absorbing casting.

[0016] [Figure 7] 1 is an example of a ribbed "C" section casting according to some embodiments of the present disclosure.

[0017] [Figure 8] 10A-10C are exemplary cross-sectional views of ribbed sections further illustrating alternative embodiment corrugation designs of the aft integral energy absorbing casting according to some embodiments of the present disclosure.

[0018] [Figure 9] 10 is an exemplary corrugation profile between ribs of a ribbed section casting according to some embodiments of the present disclosure.

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

[0020] [Figure 11] 1 is an exemplary ribbed "I" section casting according to certain alternative embodiments of the present disclosure.

[0021] [Figure 12] 1 is an exemplary ribbed "I" section casting showing progressive wall thickness, according to some embodiments of the present disclosure.

[0022] [Figure 13] 1 is an exemplary progressive collapse of a ribbed "I" section casting according to some embodiments of the present disclosure.

[0023] [Figure 14] 1 is an exemplary closed cross-section casting according to some embodiments of the present disclosure.

[0024] [Figure 15] 1 is an exemplary progressive collapse of a closed cross-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 illustrative. The relative placement of features and elements may be modified for purposes of clarity of illustration. Indeed, identical or similar reference numerals may indicate identical, similar, or equivalent structures, features, aspects, or elements according to one or more embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0026] In the following, numerous specific details are described to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations on the details. In some cases, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each element or feature should not be construed as limiting the novelty or importance of one feature over other features. overview

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

[0028] The disclosed technology relates to cast energy absorption systems for the front and rear of a vehicle that can be integrated with the frame or can 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, adhesive bonding, etc. The disclosed technology makes it possible to eliminate the need for these processes by integrating the energy absorption system with some or all of the backup structure through a single casting process. Thus, a single, integrated front, integrated energy absorption casting for the front end of the vehicle and a single, integrated rear, integrated energy absorption casting for the rear end of the vehicle may constitute an integrated energy absorption casting system for the entire vehicle.

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

[0030] As used herein, the term "metal" is meant to include any metal or metal alloy that can be die-cast and is useful for vehicle body parts. One 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 a further embodiment, the metal or metal alloy comprises aluminum, zinc, magnesium, copper, lead, or tin. In another embodiment, the metal or metal alloy comprises aluminum. Using the modified die-casting methods described herein, the resulting die-cast metal is not negatively affected, i.e., retains its desired porosity, 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, hardness, wear resistance, durability, and dimensional stability.

[0031] The casting process uses die-casting equipment, i.e., a die-casting machine. Such machines may be purpose-built or custom-built to produce one-piece, large-scale castings as described herein. As used herein, the term "one-piece" refers to a single piece, not formed by attaching separate pieces together. Thus, pouring metal into a casting mold creates a single, integral piece of metal, such as a front or rear end of a vehicle. This contrasts with forming separate front or rear end components and then attaching those several 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 approximately 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 time may take 60 to 120 seconds to complete, resulting in an output rate of 30 to 60 finished castings per hour.

[0032] Briefly, die casting is performed using die casting equipment, i.e., molds and hydraulic equipment. The hydraulic equipment utilized in metal die casting serves a variety of purposes and can be readily selected by one skilled in the art. In one embodiment, the hydraulic equipment is utilized for injection and ejection purposes and is operated using a water-immiscible hydraulic fluid.

[0033] Typically, prior to 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. Molten metal is then poured into the mold using the hydraulic equipment described above. After pouring, the molten metal is cast, typically taking a few seconds or as long as required depending on the metal being cast. After the casting period, the cast metal is ejected and collected using techniques known in the art. In one embodiment, the cast metal is ejected using hydraulic or robotic equipment.

[0034] Unlike extrusions and stampings, the disclosed cast energy-absorbing castings achieve energy absorption by causing the casting to undergo gradual deformation and fracture that begins on the outside and then propagates inward during an impact event. The gradual collapse ensures robust and repeatable crash performance. The disclosed techniques also incorporate and / or use various geometric designs and techniques to achieve gradual and repeatable deformation and fracture behavior in the cast parts.

[0035] Generally, cast alloys (e.g., alloys used in the disclosed technology) tend to have lower ductility than wrought alloys, which are traditionally used in crash impact energy systems. The disclosed technology implements geometric features that limit fracture propagation and promote progressive deformation during energy absorption load cases. The designs of the disclosed technology are most effective at absorbing energy in alloys with a large amount of ductility, but are more flexible, particularly because they are made from cast materials with limited ductility. The casting geometry is specifically tailored to the ductility and strength levels of the material used in a given design (e.g., the designs of the disclosed technology described herein) to achieve the 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 with the disclosed techniques. Thus, the disclosed techniques may use structural (e.g., high vacuum) high-pressure die-cast aluminum and / or magnesium alloys.

[0037] Some examples of suitable alloys of the disclosed technology may include aluminum having a Mg and / or Si based system with low Fe content such as AlSi7, AlSi10Mn, AlSi10Mg, AlSi7Mg, AlSi9MgMnSr, AlMg5Si2Mn, aluminum having high Fe and low Si alloys such as AlMg4Fe2, and magnesium HPDC such as AZ91D or AE44.

[0038] More specifically, the cast aluminum alloys of the disclosed technology may contain 6-12% Si and may have compositions tailored to specifically limit microstructural features that promote brittle fracture modes, such as AlFeSi intermetallics with sharp aspect ratios, rounded (modified) silicon eutectic phases, and / or minimize other elements added to strengthen the alloy material.

[0039] The cast alloys (e.g., the alloys described herein) and their manufacturing processes may be used individually, in parts, or in combination to form an entire integrated energy absorption system for a vehicle. In one embodiment, the vehicle frame is made from only three major components: a front integrally cast energy absorption part, a rear integrally cast energy absorption part, and a center cab frame that attaches to the front and rear parts.

[0040] At least three design foundations may be used individually, partially, or in combination with one another to create a cast energy-absorbing structure. One design foundation is the use of ribbed "C"-section castings, where a particular impact-absorbing section includes "C"-shaped ribs that support the part but allow for a predetermined crush profile depending on the size and number of "C"-shaped sections placed 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 crush profile during an impact event. A third design may be a closed-section casting design, where each section may be tapered or contain a different number of internal structures to provide the desired structural support and have a closed-section section that also provides a desired crush profile during an impact event. These and other implementations are described more fully below with reference to the accompanying drawings. Exemplary integral energy absorbing casting system

[0041] FIG. 1 is a perspective view of a vehicle 100 having a center cab frame 105, a forward integral energy-absorbing casting 110, and a rear integral energy-absorbing casting 115. The front casting 110 includes a right side 120A and a left side 120B that form front right and left connection portions for attaching a front bumper or forward-facing grill panel to the vehicle. The right side 120A also includes a wheel well 130A that surrounds the right front wheel of the vehicle 100. The left side 120B includes a left wheel well 130B that surrounds 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 forward integral 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-cellular 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 edge and formed as a square, rectangle, or other geometric shape that converges into multiple adjacent cells to form the multi-cellular structure. As shown in more detail with reference to Figures 2 and 3, the crumple zones are designed to crumple or collapse when struck with a large force during an impact, thereby absorbing a portion of the impact energy. The left side 120B has multiple cast crumple zones 140B, which are also designed to crumple or collapse when impacted by a forward impact of the vehicle 100. The cast crumple zones 140B may be located adjacent to the left wheel well 130B.

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

[0044] FIG. 1 also shows details of the rear one-piece energy-absorbing casting 115, which includes a right side 150A and a left side 150B at the rearmost portion of the vehicle. The right side 150A and the left side 150B may include mounts for attaching a rear bumper or other rear body panel that covers the rearmost portion 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. A lateral support strut 165 and a rear lower carriage 170 connect the right side 150A and the left side 150B to form the one-piece cast rear one-piece energy-absorbing casting 115. The lateral support struts 165 can be used as connections or can include components or features that allow the aft integral energy absorbing casting 115 to be attached to the rear of the vehicle cabin frame. Other portions of the aft integral energy absorbing casting 115 may also include connections for connecting the aft integral energy absorbing casting 115 to the vehicle cabin frame.

[0045] FIG. 2 shows a side perspective view of the forward integral energy-absorbing casting 110 and the rear integral energy-absorbing casting 115. The cast crumple zone 140B of the forward 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 cast metal and includes a multi-cellular structure made up of a plurality of individual cells configured to absorb a forward impact and crushing force and absorb the energy of such an impact. The forward crumple zone 205B also includes a multi-cellular structure and is configured to absorb an impact and to attach to the front bumper or body panel of the vehicle. This is shown in more detail with reference to FIG. 3.

[0046] 2 also shows a side view of the rear one-piece 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 mate with a rear bumper or body panel, as shown in more detail with reference to FIG.

[0047] Referring now to FIG. 3 , a perspective close-up view of the forward integral energy-absorbing casting 110 is shown. The forward casting 110 includes a right side 120A and a left side 120B that form front right and left connection portions for attaching a front bumper or forward-facing grill panel to a vehicle. The right side 120A also includes a wheel well 130A that surrounds the right front wheel of the vehicle 100. The left side 120B includes a left wheel well 130B that surrounds 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 forward integral energy-absorbing casting 110. The left side 120B includes a rear frame connection portion 325B, and the right side 120A includes a rear frame connection portion 325A. The rear frame connection portions 325A / B are used to attach the forward integral energy-absorbing casting 110 to the vehicle cabin frame.

[0048] As shown in more detail in FIG. 3 , crumple zone 140B includes lower crumple region 335B, center crumple region 338B, and 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 upon impact in a frontal impact. In addition, between crumple zone 140B and frame connection 325B is an additional multi-cell region 350 that collapses or shatters following a frontal impact but is configured to provide more impact force to protect the vehicle occupants. The ability to cast forward one-piece energy-absorbing casting 110 as a single piece allows it to be designed with specific multi-cell designs and other support features, thereby allowing the casting to be designed with specific crumple zones that provide various levels of crashworthiness. Thus, the forward-most zones may wrinkle most easily upon impact, 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] FIG. 4 is a side perspective view of rear one-piece energy-absorbing casting 115, which includes a right side 150A and a left side 150B at the rearmost portion of the vehicle. Right side 150A and left side 150B may include mounts for attaching a rear bumper or other rear body panel that covers the rearmost portion of vehicle 100. Right side 150A of casting 115 also includes a right wheel well 155A and a right rear crumple zone 160A. Left side 150B of casting 115 includes a left wheel well 155B and a left rear crumple zone 160B. A lateral support strut 165 and a rear lower carriage 170 connect right side 150A and left side 150B to form one-piece cast rear one-piece energy-absorbing casting 115.

[0050] Right side 150A connects to casting 115 through right crumple region 405A, which is configured to fracture and crumple upon impact from the rear. Crumple region 405A provides zonal stability but may be hollow with internal vertical supports or multi-cell structure that allows it to absorb energy from a rear impact. Similarly, left side 150B connects to casting 115 through left ribbed region 405B, which is configured to fracture and crumple upon impact from the rear. Left ribbed region 405B provides zonal stability but may be hollow with internal vertical supports or multi-cell structure that allows it to absorb energy from a rear impact.

[0051] Left rear crumple zone 160B shows an "X" shaped support structure 410 used to better support the left wheel well and allow rear impact forces to be absorbed as the impact travels toward the rear cabin section. Of course, 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 a close-up view of the left side surface 150B and the left ribbed region 405B. Figure 6 is an example cross-sectional view of the ribbed section 405B, further illustrating the corrugated platform of the aft one-piece energy-absorbing casting. As shown, the ribbed region 405B shows a set of ribs 510B with wave-like features 505B disposed between each rib. Also shown are notch 1e, wave profile 1d, taper 1a, taper 1c, flare 1a, flare 1c, and spacing 1b between each rib 510B.

[0053] FIG. 7 is a side view of a forward integral energy-absorbing casting showing a ribbed "C" section that can be used as a rib configuration within embodiments of the present disclosure. As shown, the ribbed "C" section casting consists of an upper web, a vertical web, and a lower web that form the "C" section. Additionally, there are intermediate webs or supports that can increase energy absorption and scalloped ribs to promote progressive collapse. The scalloped features may also add mass efficiency to each rib within the casting. The illustrated "C" section in FIG. 7 has a casting design whose primary stretch direction is perpendicular to the collapse axis. However, the "C" section design may also be used when the primary stretch direction for the casting is parallel or nearly parallel to the vertical webs and the rib and intermediate web features are cast by slide.

[0054] The techniques described for the ribbed "I" section casting and the aft integral energy absorbing casting may also be used individually, in part, or in combination with the "C" section design of the forward integral energy absorbing casting.

[0055] 8 is an exemplary cross-sectional view of a ribbed section casting further illustrating the corrugated platform of the aft integral 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 a desired energy-absorbing profile for the section. Additionally, the number and size of C-sections located within the casting may be varied to increase or decrease the crush strength of the casting.

[0056] Figure 9 is an exemplary corrugated profile located between the ribs of a ribbed section casting. In some embodiments, corrugated profiles can be added to the middle web and / or the top and bottom webs to initiate fracture between the ribs.

[0057] Figure 10 shows an example of a taper or flare on a ribbed section casting. The middle web or the upper and lower webs may be tapered to promote progressive collapse. The taper or flare technique may be used to compensate for undesirable offsets and tapers that a design might otherwise have due to packaging and process constraints.

[0058] FIG. 11 of the present disclosure illustrates an embodiment of a ribbed "I" 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 through the casting. FIG. 12 illustrates an example of a ribbed "I" section casting, showing progressive wall thickness along the lateral dimension of the cast part, with each "I" section within the casting being thicker. FIG. 13 illustrates an actual example of a trial progressive collapse of a ribbed "I" section casting, showing that the casting fractured as expected along the lateral length of the part. A key feature of the "I" section design is the spacing ribs, which maximize fracture volume and increase energy absorption. For mass efficiency, scalloped features are added to each rib. The ribs provide localized reinforcement that limits deformation and fracture propagation in directions that destabilize the collapse. FIG. 13 illustrates the progressive fracture behavior of the "I" section design.

[0059] Additionally, the following supplemental design techniques may be used independently, partially, or in combination to promote progressive crush and mass efficiency of any of the described structures of the exemplary integrally energy-absorbing cast systems described herein. These techniques are employed to accommodate specific crash performance requirements and casting process constraints. The techniques include: 1. progressively increasing wall thickness; 2. rib spacing; 3. axial tapered or flared profile; 4. corrugated profile between webs; and 5. notches between ribs on the upper and lower webs.

[0060] Additionally, the cast wall thickness may be gradually increased in the direction of collapse. The increasing gradual wall thickness may be applied independently, partially, or in combination to the middle web, upper and lower webs, and / or ribs. Rib spacing may also be varied to ensure fractures occur between the ribs and minimize fracture propagation perpendicular to the ribs. The preferred rib 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 is an exemplary progressive collapse of a closed section casting. A closed section casting design such as that shown in Figure 14 may include a square or rectangular section tapered to accommodate the draft required by the casting process. Alternatively, fins may be added to the design to compensate for the reduction in section due to the taper. The open square section itself lends itself to axial collapse, and the fins promote stability and energy absorption.

[0062] The rear of the closed section casting is integrated into the larger casting. Square or rectangular sections may be made using slides parallel or nearly parallel to the crush direction. Exemplary Implementation

[0063] It should be understood that many variations and modifications may be made to the above-described embodiments, and that the elements thereof are among other acceptable examples. All such modifications and variations are intended to be within the scope of the present disclosure. The above description details particular embodiments. However, it will be understood that no matter how detailed the above content is, the systems and methods can be implemented in many ways. Also, as noted above, the use of a particular term when describing a particular feature or aspect of the systems and methods should not be interpreted as meaning that the term has been redefined herein to be limited to including any particular characteristic of the feature or aspect of the systems and methods with which the term is associated.

[0064] The systems, methods, and devices described herein each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of the disclosure, some non-limiting features will now be briefly described. The following paragraphs describe various exemplary implementations of the devices, systems, and methods described herein.

[0065] Example 1: A vehicle integrated energy absorption system comprising a front integrated energy absorption casting and a rear integrated energy absorption casting.

[0066] Example 2: The integral energy absorption system of Example 1, wherein the forward integral energy absorption casting is located at the front of the vehicle.

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

[0068] Example 4: The integral energy absorption system of Example 1, wherein the forward integral energy absorption casting comprises a ribbed "C" section.

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

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

[0071] Example 7: The integrated energy absorption system of Example 4, wherein the ribbed "C" section further comprises a plurality of scalloped ribs for promoting gradual collapse.

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

[0073] Example 9: The integral energy absorption system of Example 1, wherein the aft integral energy absorption casting comprises a ribbed section.

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

[0075] Example 11: The integral energy absorption system of Example 9, wherein the ribbed section of the aft integral energy absorption casting comprises a corrugated platform.

[0076] Example 12: The integral energy absorption system of Example 9, wherein the ribbed section of the aft integral energy absorption casting includes notches to promote gradual collapse.

[0077] Example 13: The integral energy absorption system of Example 9, wherein the ribbed section of the aft integral energy absorption casting comprises a corrugated profile.

[0078] Example 14: The integrated energy absorption system of Example 13, wherein the corrugated profile is on the upper and lower webs of the ribbed section.

[0079] Example 15: The integrated energy absorption system of Example 13, wherein the corrugated profile is between the ribs of the ribbed section.

[0080] Example 16: The integrated energy absorption system of Example 13, wherein the corrugated profile is on the intermediate web of the ribbed section.

[0081] Example 17: The integral energy absorption system of Example 13, wherein the ribbed section of the aft integral energy absorption casting comprises a taper.

[0082] Example 18: The integral energy absorption system of Example 13, wherein the ribbed section of the aft integral energy absorption casting comprises a flare.

[0083] Example 19: The integral energy absorption system of Example 13, wherein the ribbed section of the aft integral energy absorption casting comprises spacing between each rib.

[0084] Example 20: The integrated energy absorption system of Example 1, wherein the integrated energy absorption system further comprises a closed cross-section section casting.

[0085] As mentioned above, implementations of the above-described examples may include hardware and / or methods or processes. Additional Implementation Considerations

[0086] When a feature or element is referred to herein as being "on" another feature or element, it may be directly on the other feature or element, or intervening features and / or elements may also be present. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there may not be intervening features or elements. When a feature or element is referred to as being "connected," "attached," or "coupled" to another feature or element, it will also be understood that it may be directly connected, attached, or coupled to the other feature or element, or intervening features or elements may be present. In contrast, when a feature or element is referred to as being "directly connected," "directly attached," or "directly coupled" to another feature or element, there may not be intervening features or elements.

[0087] Although described or illustrated with respect to one embodiment, the features and elements so described or illustrated may apply to other embodiments. Those skilled in the art will also understand that a reference to a structure or feature being located "adjacent" another feature may have portions that overlap or underlie the adjacent feature.

[0088] The terminology used herein is for the purpose of describing particular embodiments and implementations only and is not intended to be limiting. For example, as used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that the term "comprising," as used herein, specifies the presence of stated features, steps, operations, processes, functions, elements, and / or components, but does not exclude the presence or addition of one or more other features, steps, operations, processes, functions, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as " / ."

[0089] In the above description and in the claims, phrases such as "at least one" or "one or more" may appear followed by a list of conjunctive elements or features. The term "and / or" may also appear with a list of two or more elements or features. Unless implicitly or explicitly contradicted by the context of use, such phrases are intended to refer to any of the listed elements or features individually, or any of the listed elements or features in combination with any of the other listed 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 each intended to mean "A alone, B alone, or A and B together." A similar interpretation is intended for lists containing more than two 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. Use of the term "based on" above and in the claims is intended to mean "based at least in part on," allowing for unrecited features or elements.

[0090] Spatially relative terms, such as "forward," "backward," "below," "lower," "bottom," "upper," and "top," may be used herein for ease of description to describe the relationship of one element or feature to another, as shown in the figures. It will be understood that spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as being "below" or "directly below" other elements or features would be oriented "above" the other elements or features due to the inverted state. Thus, the term "below" can encompass both an orientation of above and below, depending on the reference point or orientation. The device may be oriented in other directions (rotated 90 degrees or at 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] Although the terms "first" and "second" may be used herein to describe various (including steps or processes) features / elements, these features / elements should not be limited by these terms as an indication of the order of the features / elements or whether one is primary over the other, unless the context dictates otherwise. These terms may be used to distinguish one feature / element from another. Thus, a first feature / element described could be referred to as a second feature / element, and similarly, a second feature / element described below could be referred to as a first feature / element without departing from the teachings provided herein.

[0092] As used in this specification and claims, including when used in the examples, unless expressly specified otherwise, all numbers may be read as if preceded by the word "about" or "approximately," even if the term does not explicitly appear. The phrase "about" or "approximately" may be used when describing a size and / or location to indicate that the stated value and / or location is within a reasonably expected range of value and / or location. For example, a numerical value may have a value of + / -0.1% of the stated value (or range of values), + / -1% of the stated value (or range of values), + / -2% of the stated value (or range of values), + / -5% of the stated value (or range of values), + / -10% of the stated value (or range of values), etc. Any numerical value set forth herein should also be understood to include about or approximately the value unless the context indicates otherwise.

[0093] For example, if the value "10" is disclosed, "about 10" is also disclosed. Any numerical range recited herein is intended to include all subranges subsumed therein. As would be appreciated by one of ordinary skill in the art, when a value is disclosed, it is understood that "less than or equal to" that value, "greater than or equal to" that value, and possible ranges therebetween are also disclosed. For example, if a value "X" is disclosed, "less than or equal to X" and "greater than or equal to X" (e.g., 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 that this data may represent endpoints or starting points, and ranges for any combination of the data points. For example, if a specific data point "10" and a specific data point "15" may be disclosed, it is understood that greater than, greater than, less than, less than, and equal to 10 and 15, as well as between 10 and 15, may be considered disclosed. It is also understood that each unit between two specific units may also be disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0094] While various exemplary embodiments have been disclosed, any of several modifications may be made to the various 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 or alternative embodiments, and in other embodiments, one or more method steps may be skipped entirely. Optional or desirable features of the various apparatus and system embodiments may be included in some embodiments and not in other embodiments. Therefore, the foregoing description has been provided primarily for illustrative purposes and should not be construed as limiting the scope of the claims and any particular embodiment or the specific details or features disclosed.

[0095] The examples and illustrations contained herein illustrate, by way of illustration and not limitation, specific embodiments in which the subject matter of the present disclosure may be practiced. As noted above, other embodiments may be utilized and derived, such that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Such embodiments of the subject matter of the present disclosure may be referred to herein, individually or collectively, by the term "invention," merely for convenience when more than one is actually disclosed, and without any intention to intentionally limit the scope of the present application to any single invention or inventive concept. Thus, while specific embodiments are illustrated and described herein, any configurations intended, practical, or calculated to achieve the disclosed purposes, whether expressly stated or implied, may be substituted for the specific embodiments shown. The present disclosure is intended to cover any and all applications or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reviewing the above description.

[0096] The subject matter of the present disclosure is provided herein with 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 the embodiments without limiting or departing from the generally intended scope. These and various other applications and combinations of the embodiments provided herein are within the scope of the subject matter of the present disclosure, as defined by the complete set of disclosed elements and features and their equivalents.

Claims

1. a left wheel well and a right wheel well connected by a lateral support; at least one connection to a vehicle cabin frame; a second connection to a body panel or bumper; a first crumple zone adjacent the left wheel well and a second crumple zone adjacent the right wheel well; An integrated energy absorption system for a vehicle formed from a single piece cast metal part, wherein the first crumple zone and the second crumple zone comprise a corrugated profile.

2. The integrated energy absorption system of claim 1 , wherein the integrated energy absorption system is located at the front of the vehicle.

3. The integrated energy absorption system of claim 2 , wherein the at least one connection to the vehicle cabin frame is aft of the integrally cast metal component.

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

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

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

7. The integrated energy absorption system of claim 6 , wherein the at least one connection to the vehicle cabin frame is forward of the integrally cast metal component.

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

9. An integrated energy absorption system as described in claim 2 or 6, wherein the integrated energy absorption system is positioned at at least one of the front and rear of the vehicle, and the first crumple zone and the second crumple zone have a microcellular structure formed from a plurality of individual cells.

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

11. The integrated energy absorption system of claim 10 , wherein the ribbed “C” section comprises an upper web, a lower web, and a vertical web that form the “C” section.

12. The integrated energy absorption system of claim 11 , wherein the ribbed “C” section further comprises an intermediate web for increased energy absorption.

13. The integrated energy absorption system of claim 10 , wherein the ribbed “C” section further comprises a plurality of scalloped ribs for promoting gradual collapse.

14. The integrated energy absorption system of claim 1 , wherein the corrugated profile is on an upper web and a lower web of a ribbed section.

15. The integrated energy absorption system of claim 1 , wherein the corrugated profile is between ribs of a ribbed section.

16. The integrated energy absorption system of claim 1 , wherein the corrugated profile is on an intermediate web of a ribbed section.

17. The integrated energy absorption system of claim 1 , wherein the integrally cast metal component comprises aluminum metal.

18. The integrated energy absorption system of claim 17 , wherein the one-piece cast metal component comprises an aluminum and magnesium alloy or an aluminum and silicon alloy.

19. A left wheel well and a right wheel well connected by a lateral support; at least one connection to a vehicle cabin frame; a second connection to a body panel or bumper; a first crumple zone adjacent the left wheel well and a second crumple zone adjacent the right wheel well; 1. An integrated energy absorption system for a vehicle formed from a single-piece cast metal part, wherein the first crumple zone and the second crumple zone comprise a ribbed "I" section having an upper web, a lower web, and an intermediate web that extend in a crush direction and form an "I" shaped section, the ribbed "I" section comprising a plurality of "I" shaped scalloped ribs in the crush direction.

20. An integrated energy absorption system as described in claim 19, wherein the integrated energy absorption system is positioned at the front of the vehicle.

21. An integrated energy absorption system as described in claim 20, wherein the at least one connection to the vehicle cabin frame is rearward of the one-piece cast metal part.

22. An integrated energy absorption system as described in claim 20, wherein the second connection portion is attached to a front bumper.

23. An integrated energy absorption system as described in claim 19, wherein the integrated energy absorption system further comprises a rear lower carriage positioned at the rear of the vehicle and connecting a left wheel well and a right wheel well.

24. An integrated energy absorption system as described in claim 1, wherein the integrated energy absorption system further comprises a rear lower carriage positioned at the rear of the vehicle and connecting a left wheel well and a right wheel well.

25. An integrated energy absorption system as described in claim 19, wherein the ribbed "I" shaped section has a wall thickness that gradually increases in the direction of the crushing.

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