Die-Cast Wheel House Structure for Collision Load Dispersion

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Solution Overview

Problem

Existing vehicle structures face challenges in achieving weight reduction while maintaining or enhancing strength to withstand collision loads, particularly in configurations where load transmission paths are similar to conventional designs.

Innovation Solution

A vehicle structure with integrally formed wheel houses and a floor panel, featuring concave and convex spherical surfaces and inclined ribs, disperses collision loads effectively through a network of ribs and reinforcing elements, reducing weight and local stress concentration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If wheel houses and floor panel are integrally formed by die casting, then weight is reduced, but strength against collision load may be compromised

Engineering Contradiction:
Improvevehicle weightVSAvoidstrength against collision load
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

The wheel house is designed with a spherical shell shape featuring concave and convex curved surfaces. This spherical geometry provides inherent structural strength and rigidity while minimizing weight, as curved surfaces efficiently distribute and disperse collision loads throughout the structure rather than concentrating stress at flat joints or corners.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention introduces inclined ribs that extend in the vehicle width direction from the frame connection portion. These ribs add a third dimension of structural reinforcement to the spherical shell, creating a composite structure that combines the weight efficiency of curved surfaces with the strength of rib reinforcement, thereby achieving both weight reduction and enhanced collision resistance.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Strength

If conventional vehicle structure is used, then strength is maintained, but weight reduction is limited

Engineering Contradiction:
Improvestrength against collision loadVSAvoidvehicle weight
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The wheel house and floor panel are merged into a single integral component formed by die casting. This consolidation eliminates the need for separate parts and connection joints, reducing overall weight while maintaining structural strength through the unified spherical shell design that distributes loads efficiently across the entire structure.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The spherical shell structure provides uniform strength distribution across all surfaces, with the inclined ribs providing localized reinforcement where collision loads are most likely to occur. This local quality enhancement allows the structure to maintain high strength characteristics while using material efficiently, achieving weight reduction without compromising safety.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20260062063A1Vehicle structure
Publication Date: 2026.03.05 HONDA MOTOR CO LTD
  • US20260062063A1 patent drawing
  • US20260062063A1 patent drawing
  • US20260062063A1 patent drawing

AI summary

A vehicle structure includes a structural body, in which a pair of wheel houses and a floor panel are integrally formed by die casting. The floor panel includes a frame connection portion, to which an inboard end portion of the frame is connected. Each wheel house includes: a concave surface portion that faces outward in a vehicle width direction; and a convex surface portion that is formed on a back side of the concave surface portion. The concave surface portion faces outward in the vehicle width direction, and a part of a wheel is housed therein. The concave surface portion has an inclined rib that is disposed above the frame connection portion, that extends from a lower portion of an outboard side toward an upper portion of an inboard side in the front-rear direction of the vehicle, and that rises toward an outer side in the vehicle width direction.