Cast Front Side Frame With H-Section for Frontal Impact Bending Resistance
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Solution Overview
Problem
Conventional automobile front side frames, whether hollow or formed from cast aluminum alloys, struggle to effectively absorb impact loads during frontal collisions, leading to potential bending and inadequate occupant protection.
Innovation Solution
A vehicle frame with a cross-sectional H-shape, featuring horizontal and vertical plate portions and bulging ribs, is integrally molded to enhance rigidity and resist bending, while maintaining a reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the front side frame is formed by a cast member as in Patent Literature 1, then the number of components is reduced, but it is difficult to obtain a hollow structure from a front end to a rear end of the front side frame due to a mold structure, making it likely to be bent by impact load from the front
Solution Approach 1:
The patent introduces a bulging portion that protrudes in the thickness direction of the horizontal plate portion, adding a dimensional feature to the cast structure. This bulging portion creates an internal cavity that acts as a hollow rib, significantly improving bending resistance without requiring complex multi-component assembly or advanced mold structures
2Strength
If the front side frame has the hollow structure as in the conventional general automobile, then the structure is less likely to be bent by the impact load from the front, but the number of components increases
Solution Approach 1:
The patent merges the reinforcing rib function and the hollow structure function into a single integrated feature - the bulging portion. This bulging portion simultaneously provides the hollow cavity for bending resistance and serves as the rib structure, eliminating the need for separate components and simplifying the overall structure
Data Source
Figure 1
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AI summary
A front side frame (60) that is integrally molded by casting has: a horizontal plate portion (63); a first vertical plate portion (64) that continues from one end portion in a width direction of the horizontal plate portion (63) and extends to both sides in a thickness direction of the horizontal plate portion (63); and a second vertical plate portion (65) that continues from another end portion in the width direction of the horizontal plate portion (63) and extends to both of the sides in the thickness direction of the horizontal plate portion (63). The horizontal plate portion (63) has a bulging portion (63a).