Rear Frame Cleaner Case Coupling for Vehicle Body
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Solution Overview
Problem
The existing body frame structure for saddle-ride vehicles with a whole plastic rear frame is costly due to low product yields and complex molding equipment, leading to increased size and complexity.
Innovation Solution
A body frame structure featuring a pair of side walls coupled by a fiber-reinforced plastic cleaner case with annularly continuous peripheral walls and protruding boss portions, which are reinforced by additional walls and fastening pieces, allowing for miniaturization and simplification of the molding apparatus while maintaining structural stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the whole rear frame is formed as a substantially box-shape including a pair of side walls, then the structural integrity is improved, but the molding equipment size and complexity increase
Solution Approach 1:
The rear frame is divided into separate components: a U-shaped main body and a cleaner case with boss portions, rather than forming the entire box-shaped structure in one piece. This segmentation allows each component to be molded separately with simpler equipment, then assembled together to achieve the required structural integrity.
Solution Approach 2:
The cleaner case is integrated with the rear frame structure by coupling it to the U-shaped main body through boss portions. This merging combines the cleaner case function with the structural support function, achieving both structural integrity and functional integration without requiring complex molding equipment.
2Strength
If the whole rear frame is formed as a substantially box-shape including a pair of side walls, then the structural integrity is improved, but the product costs increase due to low product yields
Solution Approach 1:
By segmenting the rear frame into the U-shaped main body and the cleaner case assembly, the manufacturing process can be optimized for each component. The cleaner case with integrated boss portions can be molded efficiently and assembled to the main body, improving overall product yield and reducing costs while maintaining structural integrity.
3Volume of moving object
If the cleaner case is miniaturized by having boss portions protrude partially from the peripheral wall, then the molding apparatus size is reduced, but the support stiffness must be maintained
Solution Approach 1:
The boss portions are formed of fiber-reinforced plastic, which provides high stiffness and strength in a compact structure. This composite material allows the boss portions to protrude only partially from the peripheral wall, miniaturizing the cleaner case while maintaining the required support stiffness for coupling to the side walls.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces product costs by increasing yields, simplifying the molding process, and enhancing structural support, while minimizing distortion and component count, facilitating efficient layout of additional components like harnesses and hoses.
Implementation Method 1
the pair of side walls (55) and the coupling block (41) being formed of fiber-reinforced plastic
Data Source
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AI summary
Problem To provide a body frame structure for a saddle-ride type vehicle which allows miniaturization and simplification of molding apparatus and also allows a reduction in product costs by increasing product yields. Solution A cleaner case (41) made of fiber-reinforced plastic couples left and right side walls (55) of a rear frame (5b). The cleaner case (41) has an annularly continuous peripheral wall (61) a and boss portions (63), each of the boss portions (63) protruding toward a corresponding one of opposed sides of the pair of side walls (55) from an outer surface of the peripheral wall (61a). The cleaner case (41) is fastened to the pair of side walls (55) at the boss portions (63).