Hollow Cast Vehicle Rear Component with Closed Cross-Section
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Solution Overview
Problem
Existing vehicle rear part components are heavy and lack sufficient strength and rigidity, limiting weight reduction and performance improvements.
Innovation Solution
A hollow vehicle rear part component with a main body, tower, and suspension member attachment, featuring a closed cross-sectional structure with inclined cylindrical recesses and triangular columnar cross sections, which integrates with the rocker and rear pillar to enhance strength and rigidity while accommodating suspension devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cast product with plate member structure is used for the rear frame and cross member, then the structural integrity is maintained, but the vehicle weight increases and strength-to-weight ratio deteriorates
Solution Approach 1:
The patent applies thin-walled hollow structural members with closed cross-sections instead of thick plate members. The hollow structure provides sufficient structural integrity while significantly reducing material usage and weight. The thin-walled design maintains strength through geometric optimization rather than relying on material thickness.
Solution Approach 2:
The patent integrates multiple functional components (rear frame, sustainer, cross member) into a single cast aluminum alloy structure. This composite approach combines the advantages of different structural elements into one optimized component, achieving both weight reduction and maintained structural integrity through integrated design.
2Strength
If the member thickness is increased to improve strength and rigidity, then the structural performance is enhanced, but the vehicle weight increases
Solution Approach 1:
The patent employs closed cross-sectional shapes (circular or elliptical) for the hollow members instead of flat plate structures. The curved, closed-section geometry provides superior bending and torsional rigidity compared to flat sections of equivalent weight, achieving enhanced strength-to-weight ratio through geometric optimization.
Solution Approach 2:
The hollow tubular structure acts as a thin-walled shell that resists bending and torsional loads efficiently. The closed cross-section distributes stresses uniformly around the perimeter, providing high rigidity with minimal wall thickness, thus improving strength without increasing weight.
3Ease of manufacture
If a simple cast structure is used for the rear part component, then the manufacturing process is simplified, but the strength and rigidity in the front-rear direction are insufficient
Solution Approach 1:
The patent integrates the rear frame, sustainer, and cross member into a single monolithic cast structure. This merging of components eliminates the need for separate manufacturing and assembly processes while creating an optimized load-path structure that enhances front-rear direction strength and rigidity through integrated geometry.
Solution Approach 2:
The closed cross-sectional geometry of the cast structure provides inherent bending and torsional stiffness in the front-rear direction. The curved hollow sections resist deformation more effectively than open sections, achieving enhanced rigidity while maintaining manufacturing simplicity through a single-cast process.
Data Source
AI summary
The rear structural member is a hollow member composed of a main body, a tower, and a suspension member attachment, the main body, the tower, and the suspension member attachment are integrally cast, and the tower has a closed cross-sectional structure composed of a right side plate, a left side plate, a front plate, and a rear plate.