Radiator Support Closed-Loop Structure for Rigidity
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Solution Overview
Problem
Radiator support assemblies in vehicles face challenges with rigidity and strength due to their open cross-sectional structure, which can lead to weakened connections between side, upper, and lower members, and result in increased weight and manufacturing costs.
Innovation Solution
A radiator support assembly design that forms a closed-loop configuration with overlapping internal surfaces between the upper, side, and lower members, using curved surfaces and flanges for enhanced connection and reinforcement, eliminating the need for separate brackets and reducing the number of parts, thereby increasing strength and reducing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an open cross-sectional structure is used for radiator support side members, then manufacturing cost is reduced, but rigidity and strength deteriorate
Solution Approach 1:
The invention merges the side member, upper member, and lower member into a single integrated closed-loop structure. This integration maintains manufacturing efficiency while achieving superior rigidity and strength compared to separate open-section components, directly resolving the contradiction between ease of manufacture and structural strength.
Solution Approach 2:
The invention transitions from a two-dimensional open cross-sectional structure to a three-dimensional closed-loop structure. This dimensional change creates a hollow cylindrical configuration that provides enhanced moment of inertia and resistance to bending and torsion, thereby improving rigidity and strength without significantly increasing manufacturing complexity.
2Strength
If separate brackets are used for mounting parts, then connection strength is improved, but device complexity and weight increase
Solution Approach 1:
The invention eliminates separate mounting brackets by integrating the mounting function directly into the closed-loop structure. The upper, side, and lower members are joined to form a unified structure that provides both structural support and mounting capabilities, reducing part count and simplifying the overall assembly while maintaining connection strength.
Solution Approach 2:
The closed-loop structure serves multiple functions simultaneously: it provides structural rigidity, acts as a mounting platform for various parts, and eliminates the need for separate brackets. This multi-functionality reduces device complexity while maintaining or improving connection strength.
3Weight of stationary object
If open cross-sections are used for side, upper, and lower members, then weight is reduced, but connection continuity and strength deteriorate
Solution Approach 1:
The invention combines the side member, upper member, and lower member into a continuous closed-loop structure. This merging creates seamless connection continuity between members while maintaining lightweight characteristics, as the integrated design eliminates the need for heavy reinforcement at connection points required in separate open-section designs.
Solution Approach 2:
The transition to a three-dimensional closed-loop configuration provides inherent structural continuity that open cross-sections cannot achieve. The hollow cylindrical structure distributes stresses uniformly throughout the loop, ensuring connection continuity without adding excessive weight.
Data Source
AI summary
A radiator support assembly may include a radiator support upper member including an upper internal surface, a radiator support side member including a side internal surface and provided in pairs, and a radiator support lower member including a lower internal surface, wherein the radiator support upper member, the radiator support side member and the radiator support lower member are joined so that the upper internal surface, the side internal surface and the lower internal surface form a single closed-loop.