Integrated Resin Front End Structure for Vehicle Weight Reduction
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Solution Overview
Problem
The existing front end structure for vehicles, which includes a combination of resin and metal components, has a high number of components and room for weight reduction while maintaining strength and rigidity.
Innovation Solution
An integrated front end structure with a frame portion, vehicle body mounting portion, and duct portion formed from resin materials, where the duct portion is located above the vehicle body mounting portion, and includes a partition portion to guide external air effectively, reducing the thickness of the frame portion to enhance cooling performance and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame portion is formed using a combination of resin and metal components, then the strength and rigidity can be ensured, but the number of components increases and weight reduction is limited
Solution Approach 1:
The patent merges the frame portion and duct portion into a single integrally formed resin component. This eliminates the need for separate metal reinforcements and multiple assembly steps, reducing component count while maintaining structural integrity through the integral design that allows force distribution across the entire structure.
Solution Approach 2:
The patent employs resin materials with enhanced mechanical properties (such as fiber-reinforced resins) to replace the traditional resin-metal composite structure. This allows a single resin component to achieve the strength and rigidity previously requiring metal elements, thereby reducing component complexity while meeting structural requirements.
2Strength
If the frame portion is formed using a combination of resin and metal components, then the strength and rigidity can be ensured, but the weight of the front end structure cannot be sufficiently reduced
Solution Approach 1:
By integrating the frame and duct into a single resin component, the patent eliminates heavy metal parts and their associated fasteners and joints. The unified resin structure achieves comparable strength through optimized geometry and material selection, resulting in significant weight reduction for the front end structure.
Solution Approach 2:
The patent changes the material parameter from metal to resin with enhanced mechanical properties, and optimizes structural parameters such as wall thickness distribution and rib configurations. These parameter changes enable the resin component to achieve the required strength and rigidity while significantly reducing weight compared to metal alternatives.
3Weight of moving object
If the thickness of the frame portion is reduced to reduce weight, then the weight decreases, but the strength and rigidity may be compromised
Solution Approach 1:
The patent applies local quality by varying the thickness of the resin frame portion in different regions. Thinner sections are used where strength requirements are lower, while thicker sections with reinforced ribs are positioned at critical load-bearing areas. This localized thickness optimization reduces overall weight while maintaining necessary strength and rigidity where required.
Data Source
AI summary
What is provided is a front end structure which can secure a strength and rigidity of a frame portion and reduce a weight thereof. The front end structure includes a frame portion (45), a vehicle body mounting portion (46), and a duct portion (42). The frame portion is formed to cover outer peripheral portions of a radiator and a condenser disposed in front of the vehicle body. The vehicle body mounting portion is provided on the frame portion and is connected to a front end of a front side frame (23) which extends in a forward and rearward direction of a vehicle body. The duct portion is continuous with the front end of the frame portion, and at least a part thereof is disposed above the vehicle body mounting portion and forms a continuous flow path between the duct portion and the condenser in a vertical direction. The frame portion, the vehicle body mounting portion, and the duct portion are integrally formed.