Cast Hollow Rear Vehicle Structure for Strength Without Weight Gain
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Solution Overview
Problem
Conventional methods for improving vehicle rear structure strength often result in increased weight, complexity, and costs due to thicker components and multiple assembly steps.
Innovation Solution
A vehicle rear structure with a hollow, integrally cast rear structural member comprising a main body portion, tower portion, and suspension member portion, connected by a connection member, forming a first truss structure, and further enhanced by a roof rail forming a second truss structure, all with closed cross-sections, reducing the need for separate members and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plate thickness of component members is increased to improve strength, then strength is improved, but vehicle weight increases
Solution Approach 1:
The patent combines multiple separate structural members (rear suspension tower, rear pillar, and surrounding structures) into a single integrally cast rear structural member. This merging eliminates the need for individual plate thickness increases while maintaining overall structural strength through the integrated design and closed cross-section configuration.
Solution Approach 2:
The patent employs a closed cross-section hollow structural configuration that provides high strength-to-weight ratio. The integrally cast structure with closed sections creates a composite-like effect that distributes loads efficiently throughout the structure, achieving strength without requiring thicker individual plates.
2Strength
If structural complexity is increased to improve strength, then strength is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges multiple separate structural components into one integrally cast rear structural member. This consolidation simplifies the manufacturing process by eliminating the need for assembling multiple complex parts, reducing manufacturing steps, and lowering production costs while maintaining structural integrity.
Solution Approach 2:
While the overall structure is integrated, the patent incorporates closed cross-sections at critical locations (main body portion and suspension member portion) to strategically enhance strength where needed. This segmented approach to reinforcement within an integrated structure optimizes strength without requiring complex overall design.
3Adaptability or versatility
If multiple separate members are assembled through welding, then structural flexibility is improved, but manufacturing time and costs increase
Solution Approach 1:
The patent integrates multiple structural functions into a single cast component, eliminating welding operations and assembly steps. This significantly improves manufacturing efficiency and productivity while reducing labor hours and manufacturing costs.
Solution Approach 2:
The patent maintains structural adaptability by incorporating closed cross-sections at specific locations within the integrated structure. These closed sections provide enhanced strength and stiffness where required, allowing the structure to adapt to different load requirements without requiring multiple separate members.
Data Source
AI summary
The vehicle rear structure includes a rear structural member connected to a rear end of a rocker and a rear pillar and extending rearward, and a connection member connected to the rear pillar and the rear structural member, wherein the rear structural member is an integrally cast hollow member and is composed of a body portion, a tower portion, and a suspension member portion. The body portion has a closed cross-section and is connected to the rear pillar and the rear member. The suspension member portion has a space, the suspension portion has a closed cross-section, is arranged below the main body portion, and has a front end connected to the rocker and the rear pillar.