Die-Cast Aluminum Bracket With Selective Chill Layer
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Solution Overview
Problem
Existing mounting structures for vehicles, such as those used in fuel cell vehicles, face challenges in balancing the need for strength against vibrations during normal operation with the requirement to fracture intentionally during collisions, where high loads are applied.
Innovation Solution
A die-cast aluminum bracket with a chill layer removed section on one surface and a larger chill layer on the opposing surface, designed to absorb vibrations while fracturing at the chill layer removed section during collisions, thereby achieving an intended break mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a chill layer is provided on the surface of the die-cast aluminum bracket, then strength against vibration during normal operation is improved, but the bracket becomes less likely to fracture during collision
Solution Approach 1:
The patent applies local quality by providing a chill layer only on specific surfaces (the second surface and portions of the first surface outside the chill layer removed section) while removing the chill layer from specific areas (the chill layer removed section). This creates localized differences in material properties: areas with the chill layer maintain high strength for vibration resistance, while areas without the chill layer have reduced strength to enable controlled fracture during collision. The selective presence or absence of the chill layer in different regions allows the bracket to simultaneously achieve both vibration resistance and controlled fracture characteristics.
2Reliability
If the bracket is designed to be strong to resist vibrations, then durability during normal operation is improved, but the bracket may not fracture at the intended location during collision
Solution Approach 1:
The patent creates localized weak points by removing the chill layer from specific regions (the chill layer removed section) while maintaining the chill layer in other regions. This local modification of material structure creates predetermined areas with lower strength that will preferentially fracture under high load during collision, while the remaining chill layer areas maintain sufficient strength for normal vibration resistance. The fracture is guided to occur in the chill layer removed section, achieving controlled break mode.
3Reliability
If the chill layer is removed from the entire surface, then the bracket can fracture easily during collision, but the bracket loses strength against vibrations during normal operation
Solution Approach 1:
The patent avoids complete chill layer removal by applying it selectively: the chill layer is removed only from the chill layer removed section (where controlled fracture is desired) while being maintained on the second surface and other portions of the first surface (where vibration resistance is needed). This partial removal strategy creates a spatial differentiation of material properties, allowing the bracket to exhibit both fracture susceptibility in specific areas and overall structural strength for vibration resistance.
Solution Approach 2:
The bracket effectively becomes a composite structure with two distinct material regions: areas with the chill layer (higher strength, finer grain structure) and areas without the chill layer (lower strength, coarser grain structure). This composite arrangement allows different regions to fulfill different functional requirements simultaneously - the chill layer regions provide vibration resistance while the non-chill layer regions provide controlled fracture capability during collision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively secures strength against vibrations and ensures controlled fracture during collisions, preventing suspension member crushing and enhancing collision energy absorption by selectively reducing tensile strength at the chill layer removed section.
Implementation Method 1
a second surface of the first attachment section has a chill layer, the second surface being on an opposite side of the first attachment section from the first surface
Implementation Method 2
the die-cast aluminum bracket is likely to be fractured from the chill layer removed section at the time when a large load is applied to the die-cast aluminum bracket during a collision of the vehicle
Data Source
AI summary
A die-cast aluminum bracket for a vehicle is provided between a mounted object and a vehicle structure. The die-cast aluminum bracket includes: a first attachment section configured to be coupled to the mounted object; and a second attachment section configured to be coupled to the vehicle structure, wherein a first surface, which faces the mounted object at the time when the mounted object is coupled, in the first attachment section has a chill layer removed section in which an internal layer of the bracket is exposed, and a second surface of the first attachment section has a chill layer, the second surface being on an opposite side of the first attachment section from the first surface.