Rear Body Frame Casting Layout for Smaller Molds and High Rigidity
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Solution Overview
Problem
The challenge is to downsize the mold projection surface while ensuring rigidity in the manufacturing of a rear vehicle body frame member by integrating rear suspension tower portions and ribs, which are large components.
Innovation Solution
The method involves coupling rear suspension tower portions in the vehicle width direction with a rib that protrudes forward or rearward and molding them in a posture where the projection surface is minimized by setting the mold division direction up-down, allowing for reduced mold size and enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame member is molded with the rib in a conventional orientation to prioritize reinforcing effect, then rigidity is improved, but the mold projection surface area increases
Solution Approach 1:
The patent applies dimensionality change by rotating the frame member 90 degrees around the vehicle width direction axis, changing the orientation of the rib from protruding in the vehicle width direction to protruding in the up-down direction. This allows the mold division direction to be set along the vehicle width direction, minimizing the projection surface area while maintaining the rib's reinforcing function in a different spatial configuration
Solution Approach 2:
The patent introduces asymmetry in the molding process by selectively orienting the rib in the up-down direction rather than symmetrically in the vehicle width direction. This asymmetric orientation allows the mold to capture the frame member from a direction that minimizes projection area while still providing the necessary structural reinforcement
2Ease of manufacture
If the mold division direction is set to minimize projection surface, then manufacturing cost is reduced, but the rib's reinforcing effect may be compromised
Solution Approach 1:
The patent resolves this contradiction by changing the spatial dimension in which the rib provides reinforcement. Instead of having the rib protrude in the vehicle width direction (conventional), it protrudes in the up-down direction, allowing the mold to divide along the vehicle width direction with minimized projection area while the rib still effectively reinforces the frame member against impact loads
3Device complexity
If rear suspension tower portions are coupled by intermediate coupling portion, then number of parts is reduced, but the frame member becomes a large component requiring oversized mold
Solution Approach 1:
The patent addresses the oversized mold issue by changing the orientation of the coupled frame member structure. By rotating the assembly so that the rib protrudes in the up-down direction rather than the vehicle width direction, the projection surface area in the mold's parting direction is minimized, allowing the use of a smaller mold despite the integrated multi-component structure
Data Source
AI summary
A vehicle body frame member that is integrally molded by casting in a state where a right rear suspension tower portion and a left rear suspension tower portion are coupled by a coupling portion is integrally molded with at least one rib in a manner to protrude forward or rearward in a vehicle. The vehicle body frame member is cast in a posture in which the rib protrudes upward or downward.