Rear Lower Member Casting for Multi-Directional Crash Load Paths
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Solution Overview
Problem
Existing vehicle front structures have limited load paths, leading to uneven distribution and transfer of collision loads or collision energy, and require complex manufacturing processes with increased costs and reduced production yield due to the use of multiple components with closed cross-sections.
Innovation Solution
A rear lower member with a unitary one-piece structure featuring one or more closed cross-sections, manufactured through casting processes, which securely connects the front side member, front pillar, and side sill, thereby defining load paths in various directions, including longitudinal, height, and inclined directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a load transfer member has an open cross-section, then the manufacturing process is simple, but the cross-sectional secondary moment of force is low when loads are applied in various directions
Solution Approach 1:
The patent merges multiple components (front side member, rear lower member, side sill) into an integrated load transfer member with a closed cross-section. This integration creates a continuous load path that provides high cross-sectional secondary moment of force in various directions while maintaining manufacturing simplicity through a unified structure that eliminates the need for complex assembly processes.
2Strength
If a load transfer member has a closed cross-section, then the strength is high, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent combines multiple structural components into a single integrated load transfer member with a closed cross-section. This merging approach achieves high strength and rigidity while simplifying the manufacturing process by eliminating the need for complex assembly operations, fasteners, and joining processes that would be required for multi-component constructions.
3Strength
If multiple components are coupled to form a load transfer member, then the closed cross-section is achieved, but the coupling strength is low and overall strength decreases
Solution Approach 1:
The patent merges the front side member, rear lower member, and side sill into a single continuous load transfer member. This eliminates coupling joints and associated weaknesses, providing uniform strength throughout the structure. The integrated design ensures that load is transferred continuously without interruption at connection points, maximizing both strength and reliability.
4Device complexity
If the load path is limited to the longitudinal direction, then the structure is simple, but the collision load cannot be uniformly distributed in various directions
Solution Approach 1:
The patent extends the load path from a single longitudinal direction to multiple dimensions by creating a closed cross-sectional structure that provides continuous load paths in longitudinal, lateral, and vertical directions. This multi-dimensional load path configuration enables uniform distribution of collision loads applied from various directions, improving energy absorption and structural reliability.
Data Source
AI summary
According to an embodiment, a vehicle front structure includes a front pillar and a front side member positioned forward of the front pillar and extending in a longitudinal direction of a vehicle. A side sill is connected to a lower end of the front pillar and a rear lower member connected to a rear portion of the front side member, a front portion of the side sill, and a middle portion of the front pillar.