Die-Cast Vehicle Skeleton with Severance Origin Point for Side Member Replacement

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Solution Overview

Problem

Existing vehicle skeleton structures with die-cast energy absorbing structures require replacement of all components upon collapse during a collision, making partial replacement difficult and inefficient.

Innovation Solution

A vehicle skeleton structure with a die-cast skeleton body and a severance origin point allows for easy replacement of side members by severing them at a designated point, incorporating an energy absorbing part that collapses during collisions and can be easily replaced, and using flange parts and attachment holes for mechanical fixation without welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the energy absorbing structure is formed by die casting as an integral component, then the structural strength and rigidity are improved, but the ease of repair deteriorates because all components must be replaced upon collapse

Engineering Contradiction:

Improvestructural strengthVSAvoidease of replacement

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The side member is divided into a non-energy absorbing part (floor part) and an energy absorbing part, with a severance origin point created between them. This segmentation allows the energy absorbing part to be severed and replaced independently while maintaining the integral die-cast structure's overall strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The energy absorbing part is extracted as a separable component from the integral die-cast skeleton body through the creation of a severance origin point. This extracted portion can be removed and replaced without affecting the main structural integrity of the floor part.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If the side member is designed as a single integral die-cast component, then the manufacturing precision is improved, but the ease of manufacture deteriorates due to the complexity of replacement procedures

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidease of replacement

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A severance origin point is preliminarily formed during the die-casting process itself, creating a predetermined weak point that facilitates future severance operations. This preliminary action simplifies subsequent repair manufacturing without compromising the original manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the side member includes an energy absorbing part that collapses during collision, then the safety is improved by absorbing collision loads, but the ease of repair deteriorates because the collapsed part cannot be easily replaced

Engineering Contradiction:

ImprovesafetyVSAvoidease of replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The side member is segmented into a non-energy absorbing part and an energy absorbing part separated by a severance origin point. This segmentation enables the collapsed energy absorbing part to be severed and replaced independently, maintaining safety functionality while improving repairability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The collapsed energy absorbing part is designed to be discarded (severed at the origin point) and replaced with a new component. The flange part enables this discarded component to be easily removed and a new one installed, recovering the safety function without extensive repair work.

Inventive Principle:

Principle #34Discarding and recovering

4Ease of repair

If mechanical fixation using flange parts and attachment holes is used instead of welding, then the ease of repair is improved, but the strength may deteriorate

Engineering Contradiction:

Improveease of replacementVSAvoidjoint strength

Core Design Contradiction:

Ease of repairVSStrength

Solution Approach 1:

The welding process is replaced with a mechanical fixation system using flange parts and attachment holes with bolts. This substitution improves ease of repair by eliminating thermal processes and complex welding procedures while maintaining sufficient joint strength through mechanical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables easy replacement of damaged side members, absorbs collision loads through energy absorption, and simplifies the repair process by allowing mechanical fixation, reducing the need for extensive work like welding.

Implementation Method 1

the side member is provided with an energy absorbing part configured to absorb energy by collapsing at a time of a vehicle collision

Methodology Applied

Scientific EffectEnergy absorption through collapse:

Data Source

PatentUS20240278844A1Vehicle skeleton structure

Publication Date: 2024.08.22 TOYOTA JIDOSHA KK

AI summary

A vehicle skeleton structure, including: a die-cast skeleton body formed integrally and including a floor part configuring a vehicle cabin floor portion and a side member disposed at both sides, in a vehicle width direction, of the floor part and extending in a vehicle front-rear direction; and a severance origin point, the severance origin point being formed at the skeleton body, and the severance origin point configuring a starting point when at least a part of the side member is severed.