Rear Side Structure Integrated Casting for EV Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing rear side structures for vehicles, particularly in eco-friendly electric vehicles, face challenges in reducing weight and manufacturing cost due to the use of heavy materials and complex assembly processes, including the need for multiple components and high-strength bulkheads which increase weight and cost.
Innovation Solution
A rear side structure for vehicles that simplifies the connection of the rear side member, shock absorber mounting member, and reinforcement member using a low-pressure hollow casting method, reducing the number of components and weight while maintaining structural stiffness and crashworthiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple bulkheads are arranged in the rear side member to increase stiffness, then the structural stiffness is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent merges the rear side member, shock absorber mounting member, and reinforcement members into a single integrated component manufactured by low-pressure hollow casting. This eliminates the need for separate bulkheads and multiple assembly operations, reducing weight while maintaining structural stiffness through the monolithic construction that provides continuous load paths.
2Ease of manufacture
If the inner member and outer member are joined through SPR (self-piercing riveting), then the assembly is simplified, but the stiffness and crashworthiness of the rear side member are reduced
Solution Approach 1:
The patent eliminates the need for SPR joining by manufacturing the rear side member as a single integrated component using low-pressure hollow casting. This monolithic construction removes the weak interface created by riveting while maintaining ease of manufacture through direct casting of the complex geometry including bulkheads and mounting points.
3Strength
If the shock absorber mounting member and reinforcement members are attached at multiple mounting points, then the attachment stiffness is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent integrates the shock absorber mounting function directly into the rear side member structure through low-pressure hollow casting. The mounting points are formed as integral features of the monolithic component, eliminating separate reinforcement members and reducing weight while maintaining attachment stiffness through the continuous material structure.
4Adaptability or versatility
If multiple separate components are used in the rear side structure, then the design flexibility is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent combines multiple functional components (rear side member, shock absorber mounting member, reinforcement members) into a single integrated component manufactured by low-pressure hollow casting. This reduces the number of parts and assembly operations while maintaining design flexibility through the ability to cast complex geometries and integrate various functions into the monolithic structure.
Data Source
AI summary
An embodiment rear side structure for a vehicle includes a rear side member extending in a longitudinal direction of the vehicle, a shock absorber mounting member connected to the rear side member, and a rear wheelhouse panel connected to the shock absorber mounting member, wherein the shock absorber mounting member and the rear wheelhouse panel are joined so that the shock absorber mounting member and the rear wheelhouse panel form a wheel arch.