Integrated Aluminum Bracket for Lightweight Vehicle Rear Frames
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Solution Overview
Problem
Existing vehicle frame designs with multiple metal plate members increase assembly workload and weight, necessitating a more efficient and lightweight solution.
Innovation Solution
A bracket composed of an integrally-formed aluminum or aluminum alloy member with a bottom surface, side wall, upper joining portion, and internal rib configuration, reducing components and enhancing stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple metal plate members are used to compose the rear frame, then the structural flexibility and adjustability are improved, but the number of components increases and assembly workload increases
Solution Approach 1:
The patent merges multiple separate metal plate members into a single integrally-formed bracket made of aluminum or aluminum alloy. This unified structure eliminates the need for multiple discrete components while maintaining the necessary structural flexibility through the bracket's geometric design and internal rib configuration.
Solution Approach 2:
The integrally-formed bracket is designed to perform multiple functions simultaneously: it provides structural support, enables suspension member attachment via the bottom joining portion, facilitates framework member connection through the upper joining portion, and ensures structural rigidity through internal ribs. This multi-functional design replaces what previously required multiple specialized components.
2Adaptability or versatility
If multiple metal plate members are used to compose the rear frame, then the structural flexibility and adjustability are improved, but the assembly workload increases
Solution Approach 1:
By combining multiple assembly steps and component installations into a single integrally-formed bracket, the patent reduces the number of assembly operations required. The bracket arrives as one pre-fabricated unit rather than multiple pieces requiring sequential installation, directly reducing assembly workload.
Solution Approach 2:
The bracket is pre-fabricated with all necessary joining portions (bottom joining portion for suspension member attachment and upper joining portion for framework member connection) and internal ribs already integrated into the structure. This preliminary preparation of all structural features eliminates the need for field assembly of multiple components.
3Adaptability or versatility
If multiple metal plate members are used to compose the rear frame, then the structural flexibility and adjustability are improved, but the weight of the rear frame increases
Solution Approach 1:
The patent changes the material parameter from traditional steel or other heavy metals to aluminum or aluminum alloy, which has approximately one-third the density. This material substitution significantly reduces the weight of the rear frame while the integral design and internal rib structure maintain the necessary structural flexibility and rigidity.
4Device complexity
If the bracket is made as an integrally-formed member, then the number of components is reduced and assembly workload is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent employs advanced manufacturing parameters and processes, specifically aluminum die-casting or similar integral forming techniques, to produce the complex three-dimensional bracket structure in a single manufacturing step. This allows the integration of multiple features (side walls, internal ribs, joining portions) into one manufacturable component despite the geometric complexity.
Data Source
AI summary
A bracket is configured to be mounted in a vehicle and includes a bottom surface, a bottom joining portion, a side wall, an upper joining portion, and an internal rib. The bottom joining portion is arranged at the bottom surface and configured to join a suspension member to the bottom surface. The side wall is a wall-shaped portion protruding upward from an edge portion of the bottom surface and surrounding the edge portion. The upper joining portion is arranged at an upper end of the side wall and configured to be joined to a framework of the vehicle. The internal rib protrudes upward from the bottom surface. The bracket is an integrally-formed member and formed of aluminum or aluminum alloy.