Integrated Vehicle Body Structure for Mold-Safe Suspension Towers
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Solution Overview
Problem
Existing vehicle body structures face challenges in securing a large up-down direction dimension for the suspension tower portion to accommodate a strut type suspension or larger suspension stroke, as the mold for the upper wall portion of the suspension tower interferes with the upper member portion when pulled out in the vehicle width direction.
Innovation Solution
The vehicle body structure integrates a cross member with a pair of wheel arches, where each wheel arch includes a suspension tower portion with an upper wall and an apron upper member portion positioned lower than the upper wall, allowing the mold to be pulled out without interference, and incorporates reinforcing ribs for improved rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the upper member portion is disposed at the vehicle width direction outer side of the suspension tower portion, then the wheel arch structure can be simplified, but the mold for the upper wall portion of the suspension tower portion interferes with the upper member portion when pulled out, preventing successful molding
Solution Approach 1:
The apron upper member portion is designed to extend in the vehicle front-rear direction rather than solely in the vehicle width direction. This dimensional reorientation allows the upper member portion to be positioned at the outer side of the suspension tower portion while avoiding interference with the mold pulling out process, as the apron upper member extends perpendicular to the mold withdrawal direction
2Volume of moving object
If the upper wall portion of the suspension tower portion is made higher to accommodate strut type suspension or larger suspension stroke, then the suspension accommodation space is improved, but the mold for the upper wall portion interferes with the upper member portion when pulled out
Solution Approach 1:
The apron upper member portion is configured to extend in the vehicle front-rear direction, creating a spatial separation from the upper wall portion that extends in the vehicle width direction. This dimensional differentiation allows the upper wall portion to be positioned at a higher elevation for suspension accommodation while the apron upper member extends forward, preventing mold interference during withdrawal
Solution Approach 2:
The wheel arch structure is divided into distinct functional portions: the suspension tower portion with the upper wall portion for suspension accommodation, and the apron upper member portion for structural support and molding ease. This segmentation allows each portion to be optimized independently - the upper wall portion can be made higher for suspension stroke while the apron upper member is positioned to facilitate mold removal
Data Source
AI summary
A vehicle body structure includes: a cross member portion; and a left and right pair of wheel arches that are integrally formed with the cross member portion. The left and right pair of wheel arches are each include: a suspension tower portion including an upper wall portion that extends in a vehicle front-rear direction and the vehicle width direction, and to which a shock absorber is connected, and an apron upper member portion that extends in the vehicle front-rear direction, and that is formed along a peripheral end portion of the upper wall portion such that a portion of the apron upper member portion formed along the suspension tower portion is at a height that is lower than or equal to that of the upper wall portion and bypasses the shock absorber toward a vehicle width direction inner side in a plan view.