Single-Piece Rear Torque Box for Vehicle Structural Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle rear structures face challenges in achieving a balance between providing adequate space, desired performance characteristics, lightweight design, ease of manufacturing, and cost-effectiveness while integrating components like spare tire compartments and battery packs.
Innovation Solution
A simplified rear vehicle structure featuring a pair of single-piece rear torque boxes, rocker panels, and rear rails, with integral vehicle seat mounts and a battery pack enclosure, fabricated from lightweight materials like aluminum or steel, which are easy to manufacture and assemble, and provide enhanced torsional and rigidity characteristics without additional reinforcements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-component rear structures are used, then structural strength and rigidity are achieved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple structural components (torque box, seat mounts, suspension mounts, and reinforcement elements) into a single integrated rear torque box assembly. This merging of functions reduces the number of separate parts that need to be manufactured and assembled, directly addressing the contradiction between achieving structural strength and reducing manufacturing complexity.
2Stability of the object's composition
If additional reinforcements are added to achieve desired rigidity, then torsional stiffness is improved, but vehicle weight increases
Solution Approach 1:
The integrated torque box design combines reinforcement elements and mounting structures into a unified component, achieving the desired torsional stiffness through the overall structural configuration rather than adding separate reinforcement parts. This approach maintains rigidity while avoiding the weight penalty of additional components.
Solution Approach 2:
The rear torque box serves multiple functions simultaneously: it provides torsional stiffness, acts as a mounting structure for seats and suspension components, and integrates reinforcement elements. This multi-functionality eliminates the need for separate reinforcement parts, achieving rigidity without increasing vehicle weight.
3Adaptability or versatility
If multiple separate components are used for rear structure, then design flexibility is maintained, but assembly time and manufacturing cost increase
Solution Approach 1:
By integrating multiple functional elements into a single rear torque box assembly, the patent reduces the number of assembly operations required. The integrated design maintains design flexibility through configurable mounting points and attachment mechanisms while significantly improving assembly efficiency by reducing part count.
4Weight of moving object
If lightweight materials are used, then vehicle weight is reduced for better fuel economy, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs aluminum or aluminum alloy materials, changing the material parameter from traditional steel to lightweight aluminum. This material substitution reduces vehicle weight while the integrated design and standardized manufacturing processes help manage the associated precision requirements through consistent fabrication methods.
Data Source
AI summary
A rear structure for a vehicle is provided, the structure including (i) a pair of single piece rear torque boxes; (ii) a pair of rocker panels mechanically coupled to the rear torque boxes; (iii) a pair of rear rails mechanically coupled to the rear torque boxes; and (iv) at least one cross-member interposed between and mechanically coupled to the rear torque boxes.