One-Piece Aluminum Side Member for EV Weight Reduction
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Solution Overview
Problem
Eco-friendly electric vehicles face weight increases due to heavy batteries, and existing manufacturing methods for rear side members, such as high-vacuum die casting, result in complex structures with numerous components, leading to increased weight and manufacturing costs.
Innovation Solution
A vehicle side member is designed with a one-piece construction using low-pressure casting, integrating main, front-side, rear-side, and damper mounting portions, reducing the number of components and weight through a unitary structure made of aluminum, with reinforcing ribs and an annular closed wall construction for enhanced stiffness and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If high-vacuum die casting is used to manufacture the rear side member, then the complicated shape can be achieved, but the number of components increases and weight increases
Solution Approach 1:
The patent integrates the rear side member with front-side mounting portion, rear-side mounting portion, and damper mounting portion into a single integrated component manufactured by low-pressure die casting. This merging of multiple components into one reduces the total number of parts and assembly operations while maintaining the complicated shape required by the vehicle's structural requirements.
2Strength
If multiple reinforcing members and auxiliary members are attached to form closed transverse cross-section, then structural strength is improved, but the number of components increases and weight increases
Solution Approach 1:
The reinforcing members and auxiliary members are integrated into the rear side member as integral features formed during the low-pressure die casting process. The closed transverse cross-section is created as part of the main component rather than through assembly of separate pieces, reducing component count while maintaining structural strength.
Solution Approach 2:
The integrated rear side member is designed with internal cavities and wall structures that segment the material distribution to provide reinforcement where needed. The closed transverse cross-section creates structural rigidity through the geometry of the cast component itself, eliminating the need for additional reinforcing members.
3Weight of moving object
If aluminum materials are used for lightweight construction, then vehicle weight is reduced, but manufacturing complexity increases
Solution Approach 1:
Multiple components that would traditionally be manufactured separately and assembled are merged into a single aluminum component produced by low-pressure die casting. This integration simplifies the manufacturing process by eliminating multiple casting operations, assembly steps, and associated quality control requirements, while still achieving lightweight construction.
Data Source
AI summary
A vehicle side member includes: a main member portion which extends in a longitudinal direction of a vehicle; a front-side mounting portion which is one-piece construction with a front portion of the main member portion; a rear-side mounting portion which is one-piece construction with a rear portion of the main member portion; and a damper mounting portion which is one-piece construction with the main member portion, and in which a top end of a damper is received and mounted.