Cast Vehicle Structural Assembly With Non-Circular Energy Pockets
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Solution Overview
Problem
Existing vehicle structures manufactured through casting processes lack efficient integration features for securing components, leading to non-uniform energy absorption and increased weight.
Innovation Solution
A structural assembly with non-circular shaped pockets and mounting features, such as bosses with variable thickness and Kammtail virtual foil profiles, integrated into a cast body to enhance energy absorption and reduce weight, utilizing a cast-allowable alloy material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional casting processes are used to manufacture vehicle structures, then manufacturing simplicity is maintained, but energy absorption uniformity deteriorates and weight increases
Solution Approach 1:
The patent applies local quality by creating pockets with varying depths and configurations at specific locations within the vehicle structure. These pockets are strategically positioned to optimize energy absorption in high-stress areas while maintaining lighter weight in lower-stress regions, thereby achieving uniform energy absorption without increasing overall weight.
Solution Approach 2:
The patent employs asymmetry by incorporating non-uniform pocket designs with different depths, shapes, and orientations throughout the structure. This asymmetric configuration allows the structure to absorb energy more uniformly across different impact directions and locations, improving energy absorption characteristics without requiring symmetric reinforcement that would increase weight.
2Strength
If traditional casting processes are used to manufacture vehicle structures, then manufacturing simplicity is maintained, but structural integrity deteriorates
Solution Approach 1:
The patent merges the pocket features directly into the cast body as an integrated component rather than separate elements. This combining of the pocket structure with the main body allows for improved structural integrity through optimized material distribution while maintaining manufacturing simplicity, as the entire structure can be formed in a single casting operation without requiring additional assembly steps.
3Adaptability or versatility
If mounting features are integrated into the cast body, then component securing capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates mounting features such as bosses, flanges, and attachment points directly into the cast body during the molding process. This merging of mounting features with the structural body allows for improved component securing capability while avoiding the complexity of separate mounting component fabrication and assembly, as the features are formed as part of the single integrated casting.
Data Source
AI summary
A structural assembly for a vehicle includes a cast body having a main wall, a non-circular shaped pocket formed in the main wall, and at least one mounting feature. The pocket is defined at least partially by a base wall and an arcuate wall. The base wall has a first end and a second opposing end. The arcuate wall extends in a first direction from the first end of the base wall to the main wall. The arcuate wall also extends from a first side of the pocket to a second opposing side of the pocket. The mounting feature extends in a second direction from the base wall that is opposite the first direction and is configured to be coupled to a vehicle component.