Die-Cast Rear Floor Structure for Multi-Path Crash Load Transfer
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Solution Overview
Problem
Conventional vehicle rear floor structures suffer from single force transmission paths, leading to increased stress and bending during rear collisions, and have manufacturing defects due to spot welding, resulting in insufficient structural strength and poor impact buffering.
Innovation Solution
A lower vehicle body rear structure featuring a die-cast rear floor, rear floor longitudinal beams, a shelf, and a spare tire cabin, with an annular reinforcing structure and herringbone-shaped force transmission passages, enhancing structural compactness and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional rear floor structure with multiple sheet metal parts welded together is used, then the manufacturing process is simple, but the overall rigidity is insufficient and the risk of bending during collision is high
Solution Approach 1:
The patent merges multiple separate sheet metal parts (rear floor panel, longitudinal beams, cross beams) into a single integrated die-casting rear floor assembly. This consolidation eliminates welding joints and creates a unified structure with superior overall rigidity and collision resistance, directly resolving the contradiction between strength and structural complexity.
2Strength
If spot welding is used to assemble multiple sheet metal parts, then the manufacturing process is straightforward, but local structural connection defects occur and structural strength is insufficient
Solution Approach 1:
The patent replaces the mechanical welding process with a die-casting manufacturing process. Instead of assembling multiple parts through spot welding (which creates local connection defects), the entire rear floor structure is formed as a single piece through die-casting, eliminating welding joints and achieving uniform structural strength throughout the assembly.
3Force
If a single force transmission path through the rear floor longitudinal beam is used, then the structure is simple, but the beam suffers excessive stress and bending during rear collision
Solution Approach 1:
The patent segments the force transmission function by creating multiple independent force transmission paths within the integrated rear floor structure. The die-casted structure includes longitudinal beams, cross beams, and connecting portions that distribute collision forces across multiple pathways, preventing excessive stress concentration in any single beam and improving overall collision resistance.
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 proposed structure improves the bearing performance of the shelf and spare tire cabin, provides a stable foundation for the spare tire cabin, and enhances the overall structural rigidity and collision protection of the vehicle.
Implementation Method 1
a rear floor integrally formed in a die-casting mode
Data Source
AI summary
A lower vehicle body rear structure includes a rear floor integrally formed in a die-casting mode, rear floor longitudinal beam rear sections fixedly connected to the rear floor, a shelf, and a spare tire cabin. Rear floor longitudinal beams arranged on the two sides of the rear floor, and a rear floor middle cross beam and a rear floor rear cross beam which are connected between the rear floor longitudinal beams are formed on the rear floor, and rear wheel covers connected to the rear floor longitudinal beams are respectively arranged on the two sides of the rear floor. The shelf is located above the rear floor, and the two ends of the shelf are connected to the rear wheel covers by means of connecting plates; and the rear floor, the shelf and the two connecting plates are connected to form an annular structure.