Vehicle Structure With Closed-Loop Mechanical Fastening
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Solution Overview
Problem
Existing vehicle structures require welding at critical coupling points, which can compromise rigidity and durability, and there is a need for a simpler configuration that enhances these properties without increasing weight.
Innovation Solution
A vehicle structure where the A-pillar lower portion, side sill, and body front cross member form a closed loop with a joint member, using mechanical fastening instead of welding, ensuring multiple surface contacts and forming a solid coupling state with the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to couple the frame and body, then coupling strength is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical fastening system consisting of fasteners that physically connect the frame and body through threaded engagement. This substitution eliminates the need for welding while maintaining coupling strength and reducing weight.
2Strength
If welding is used to couple the frame and body, then coupling strength is improved, but device complexity increases
Solution Approach 1:
The patent replaces the welding process with a mechanical fastening system using standardized fasteners. This substitution simplifies manufacturing by eliminating complex welding procedures, equipment requirements, and post-weld treatments while maintaining coupling strength through proven mechanical engagement.
Solution Approach 2:
The coupling system is segmented into discrete components: the fastener body, threaded engagement portion, and coupling elements. This segmentation allows for independent manufacturing, quality control, and assembly of each component, reducing overall manufacturing complexity compared to monolithic welding processes.
3Weight of moving object
If a simple configuration without welding is used, then weight is reduced and manufacturing is simplified, but rigidity and durability may be compromised
Solution Approach 1:
The patent employs a composite coupling system where the fastener combines different material properties and structural features: a threaded engagement portion for mechanical interlocking and a coupling portion for structural connection. This composite approach maintains rigidity and durability while eliminating welding and reducing weight.
Solution Approach 2:
The fastener incorporates a curved or rounded coupling portion that distributes mechanical loads more evenly across the joint interface. This geometric feature enhances structural rigidity by reducing stress concentration points while maintaining a simple, lightweight design without requiring welding.
Data Source
AI summary
A vehicle structure includes a joint member having an upper side coupled to an A-pillar lower portion. The joint member has a rear coupled to a side sill and has a side coupled to a body front cross member. The A-pillar lower portion has a closed cross-section structure and has a lower end in surface contact with and coupled to the joint member. The side sill has a closed cross-section structure and has a front end in surface contact with and coupled to the joint member. The body front cross member has a closed cross-section structure and has a side end in surface contact with and coupled to the joint member.