Vehicle Front Structure With Wrought Reinforcement Against Tensile Breakage
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Solution Overview
Problem
Existing vehicle front portion structures using die-cast connecting members are prone to breakage under tensile loads during collisions due to low tensile strength, compromising the transmission of impact loads to other structural components.
Innovation Solution
A vehicle front portion structure with a connecting member comprising a cast inner portion and a wrought outer portion, reinforced by a wrought member at the tensile load-bearing regions, to enhance tensile strength and prevent breakage during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cast member is used for the connecting member, then high flexibility of shaping and ease of joining are achieved, but tensile strength is low and breakage occurs under tensile loads during collisions
Solution Approach 1:
The connecting member is constructed as a composite structure combining a cast member (providing shaping flexibility and ease of joining) and a wrought member (providing high tensile strength). The wrought member is coupled to the cast member via a coupling portion, creating a hybrid structure that leverages the advantages of both material types to resolve the contradiction between ease of manufacture and tensile strength.
Solution Approach 2:
The connecting member is divided into two distinct segments: a cast member portion and a wrought member portion. This segmentation allows each segment to be optimized for its specific function - the cast member for joining flexibility and the wrought member for tensile load-bearing capacity - thereby resolving the technical contradiction.
2Adaptability or versatility
If a cast member is used for the connecting member, then high flexibility of shaping is achieved, but the connecting member may break under tensile loads during collisions
Solution Approach 1:
By combining cast and wrought members in a composite structure, the design achieves both shaping flexibility (from the cast member) and breakage resistance (from the wrought member), resolving the contradiction between adaptability and reliability.
Solution Approach 2:
The segmentation of the connecting member into cast and wrought portions allows each material type to perform its optimal function - the cast member providing geometric flexibility and the wrought member providing structural reliability under tensile loads.
3Reliability
If a reinforcing portion is added to the connecting member, then breakage is suppressed, but device complexity increases
Solution Approach 1:
The reinforcing portion is implemented as a separate wrought member segment coupled to the cast member, rather than integrating reinforcement into the cast member design. This segmentation approach suppresses breakage while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
The coupling portion acts as an intermediary element that connects the cast member and wrought member, enabling the reinforcing function to be added without directly complicating the design of either component. This mediator approach resolves the contradiction between reliability improvement and device complexity.
Data Source
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AI summary
A reinforcing plate (62) is provided between an inner central portion that structures a portion of a connecting member (38) and a rear end portion of a dash cross-member (20). The reinforcing plate (62) is a wrought member and is joined (at a join portion (63)) to both the inner central portion and a rear wall portion of the dash cross-member (20) via joining members (51). Because the wrought member has high tensile strength, when the reinforcing plate (62) is provided at the join portion (63) of the connecting member, a tensile load acting on the join portion (63) may be borne by the reinforcing plate (62), and breakage of the connecting member may be suppressed. Therefore, an impact load transmitted from a front side member through the connecting member may be transmitted to the dash cross-member (20) and rockers (12).