Die-Cast Lower Dash Assembly for Stiffness and Faster Vehicle Build
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Solution Overview
Problem
Existing methods for connecting components of a motor vehicle's lower dash require high labor and time expenditure, leading to increased logistics costs and reduced economic efficiency, while also failing to achieve the necessary stiffness and weight reduction.
Innovation Solution
The lower dash is designed as two one-piece parts made of die-cast light metal, with components such as the inner partial A-pillar, partial bulkhead, and side member front integrally molded, connected via a joining method, allowing for easier assembly and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple individual components (lower crossmember, bulkhead element, upper reinforcing member) are connected by welding, screwing, adhesive bonding or clinching, then the lower dash achieves structural integrity, but the production time and logistics expenses increase significantly
Solution Approach 1:
The patent combines multiple separate components (lower crossmember, bulkhead element, upper reinforcing member) into a single integrated lower dash component manufactured by die-casting. This merging eliminates the need for multiple joining operations (welding, screwing, adhesive bonding, or clinching) while maintaining the structural integrity that would otherwise require complex assembly of separate parts.
Solution Approach 2:
The lower dash is designed as a integrated single-piece component that segments out the assembly process from the manufacturing process. By creating one complete functional unit through die-casting, the patent separates the complexity of structural design from the simplicity of assembly installation, reducing production time while preserving structural requirements.
2Stability of the object's composition
If multiple individual components are assembled before installation in the vehicle body, then the lower dash achieves proper structural configuration, but the time expenditure for bringing elements together increases
Solution Approach 1:
The patent merges the lower crossmember, bulkhead element, and upper reinforcing member into a single integrated component manufactured by die-casting. This eliminates the time-consuming assembly process of bringing multiple elements together while preserving the structural configuration through the integrated design of the single component.
3Strength
If a steel construction is used to achieve the necessary stiffness for center pole crash energy absorption, then the required stiffness is achieved, but the weight increases significantly
Solution Approach 1:
The patent changes the material parameter from steel to light metal (aluminum alloy) while compensating for the lower inherent strength through optimized die-casting design and structural geometry. This parameter change reduces weight significantly while maintaining the stiffness required for center pole crash energy absorption through the integrated single-piece construction.
Solution Approach 2:
The patent employs light metal materials with optimized structural design to achieve composite-like performance, where the die-cast aluminum structure provides both weight reduction and the necessary stiffness characteristics traditionally associated with heavier steel constructions.
Data Source
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AI summary
Lower dash for a motor vehicle, the lower dash being configures to extend in y-direction transversely to the direction of travel for the motor vehicle and being configured to separate a passenger compartment and a front compartment of the motor vehicle, wherein the lower dash comprises, a partial bulkhead, an inner partial A-pillar arranged laterally with respect to the patrial bulkhead and a side member front including a connector to the sill and longitudinal rail, each on the left and right sides in the vehicle direction, wherein, the inner partial A-pillar, the partial bulkhead and the side member front arranged on the left side are designed as a one-piece part-lower dash made of die-cast light metal and the inner partial A-pillar, the partial bulkhead and side member front on the right side are designed as a one-piece part-lower dash made of die-cast light metal, wherein the part-lower dash arranged on the left-hand and right-hand sides being connected to one another via a joining.