# US 10,501,124 B2 · Vehicle front structure and method for manufacturing same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,501,124 B2 - Document ID: US10501124B2 - Status: Granted - Kind: B2 - Application number: 15/764,799 - Filed: 2016-09-06 - Published: 2018-09-27 - Granted: 2019-12-10 - Earliest claimed: 2015-10-01 - Assignees: Kobe Steel, Ltd. - Applicants: Kobe Steel, Ltd. - Inventors: Shota Chinzei; Junya Naitou; Haruyuki Konishi; Naoto Takahashi - Web page: https://patentgrep.com/patent/US10501124B2 ## CPC - B62D 21/11: with resilient means for suspension {, e.g. of wheels or engine; sub-frames for mounting engine or suspensions} - B62D 25/088: {Details of structures as upper supports for springs or dampers} - B62D 27/023: {Assembly of structural joints} - B62D 29/007: {predominantly of special steel or specially treated steel, e.g. stainless steel or locally surface hardened steel} - B62D 29/008: {predominantly of light alloys, e.g. extruded} - B62D 65/02: Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components - B62D 25/08: Front or rear portions {(sub-frames for mounting engine or suspensions B62D21/11)} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) ## Abstract A vehicle front structure includes a front side member extending in a vehicle front-rear direction in a front portion of a vehicle body, an upper side member disposed above the front side member in a vehicle and extending in the vehicle front-rear direction, and a suspension tower joined to the front side member and the upper side member. The suspension tower is made of aluminum alloy integrally formed by press working. The vehicle front structure is capable of being reduced in weight and being more easily manufactured without introducing new equipment. ## Claims ### Claim 1 A vehicle front structure comprising: a front side member disposed in a front portion of a vehicle body and extending in a vehicle front-rear direction; an upper side member disposed above the front side member in a vehicle and extending in the vehicle front-rear direction; and a suspension tower formed by an upper wall, a front wall extending downward from a front end of the upper wall, a rear wall extending downward from a rear end of the upper wall, an external side wall extending downward from one side end of the upper wall, and an inner side wall extending downward from the other side end of the upper wall; wherein the suspension tower is joined to the front side member and the upper side member in such a manner that only the external side wall is connected to the upper side member and only the inner side wall is connected to the front side member; and the suspension tower is made of aluminum alloy integrally formed by press working. ### Claim 2 (depends on 1) The vehicle front structure according to claim 1, wherein the suspension tower and at least one of the front side member and the upper side member are joined by a self-piercing rivet driven from the suspension tower. ### Claim 3 (depends on 2) The vehicle front structure according to claim 2, wherein the at least one of the front side member and the upper side member is made of steel and has a tensile strength of less than 590 MPa. ### Claim 4 (depends on 1) The vehicle front structure according to claim 1, wherein at least one of the front side member and the upper side member is made of steel, and is joined to the suspension tower by being spot-welded to a pierce metal made of steel and embedded in the suspension tower so as to penetrate the suspension tower. ### Claim 5 (depends on 4) The vehicle front structure according to claim 4, wherein the at least one of the front side member and the upper side member has a tensile strength of 590 MPa or more. ### Claim 6 (depends on 1) The vehicle front structure according to claim 1, wherein the suspension tower is formed of JIS 5000 series aluminum alloy. ### Claim 7 A method for manufacturing a vehicle front structure, comprising: a press forming step of pressing aluminum alloy material to integrally form a suspension tower having an upper wall, a front wall extending downward from a front end of the upper wall, a rear wall extending downward from a rear end of the upper wall, an external side wall extending downward from one side end of the upper wall, and an inner side wall extending downward from the other side end of the upper wall; and a joining step of joining the suspension tower to a front side member disposed in a front portion of a vehicle and extending in a vehicle front-rear direction, and to an upper side member disposed above the front side member in a vehicle and extending in the vehicle front-rear direction in such a manner that only the external side wall is connected to the upper side member and only the inner side wall is connected to the front side member. ### Claim 8 (depends on 2) The vehicle front structure according to claim 2, wherein the suspension tower is formed of JIS 5000 series aluminum alloy. ### Claim 9 (depends on 3) The vehicle front structure according to claim 3, wherein the suspension tower is formed of JIS 5000 series aluminum alloy. ### Claim 10 (depends on 4) The vehicle front structure according to claim 4, wherein the suspension tower is formed of JIS 5000 series aluminum alloy. ### Claim 11 (depends on 5) The vehicle front structure according to claim 5, wherein the suspension tower is formed of JIS 5000 series aluminum alloy. ### Claim 12 A method for manufacturing a vehicle front structure, comprising: a press forming step of pressing aluminum alloy material to integrally form a suspension tower having an upper wall, a front wall extending downward from a front end of the upper wall, a rear wall extending downward from a rear end of the upper wall, an inner side wall extending downward from an inner side end of the upper wall, wherein a lower end portion of the side wall extends internally to form a joint portion; and a joining step of joining the suspension tower to a front side member disposed in a front portion of a vehicle and extending in a vehicle front-rear direction, and to an upper side member disposed above the front side member in a vehicle and extending in the vehicle front-rear direction in such a manner that only an external side portion of the upper wall is connected to the upper side member and only the joint portion of the side wall is connected to the front side member. ### Claim 13 (depends on 1) The vehicle front structure according to claim 1, wherein a dimension of the external side wall in the vehicle front-rear direction is substantially the same as a dimension of the upper wall in the vehicle front-rear direction, and a dimension of the inner side wall in the vehicle front-rear direction is substantially the same as a dimension of the upper wall in the vehicle front-rear direction.