U.S. patent number 5,226,696 [Application Number 07/761,786] was granted by the patent office on 1993-07-13 for motor vehicle chassis.
This patent grant is currently assigned to Audi A.G.. Invention is credited to Norbert Enning, Ulrich Klages, Heinrich Timm.
United States Patent |
5,226,696 |
Klages , et al. |
July 13, 1993 |
Motor vehicle chassis
Abstract
A vehicle chassis constructed of metal frame elements which are
joined together by connecting node elements (connectors). The node
elements are configured as upwardly open molded pieces (shells)
When assembled, a bottom surface portion of each node element is
received in conforming notches disposed adjacent the outwardly
facing end surfaces of the joining ends of abutting frame elements
in such a manner that no part of the node element forms the inward
facing regions of the vehicle frame defining the windscreens and
door openings. Each node element is provided with side projections
(tangs) which extend beyond the notch portions of the adjoining
frame elements to increase surface contact area between the node
element and each frame element. A cover plate or the vehicle body
skin is provided to cover the upward facing end of the node
element.
Inventors: |
Klages; Ulrich (Ingolstadt,
DE), Enning; Norbert (Kipfenberg, DE),
Timm; Heinrich (Ingolstadt, DE) |
Assignee: |
Audi A.G. (DE)
|
Family
ID: |
6382093 |
Appl.
No.: |
07/761,786 |
Filed: |
September 20, 1991 |
PCT
Filed: |
March 19, 1990 |
PCT No.: |
PCT/EP90/00450 |
371
Date: |
September 20, 1991 |
102(e)
Date: |
September 20, 1991 |
PCT
Pub. No.: |
WO90/11369 |
PCT
Pub. Date: |
October 04, 1990 |
Foreign Application Priority Data
Current U.S.
Class: |
296/203.01;
296/29; 403/205; 403/403; 52/280 |
Current CPC
Class: |
B62D
23/005 (20130101); B62D 27/023 (20130101); Y10T
403/42 (20150115); Y10T 403/73 (20150115) |
Current International
Class: |
B62D
23/00 (20060101); B62D 27/02 (20060101); B62D
27/00 (20060101); B60R 027/00 () |
Field of
Search: |
;296/203,194,29,30,205
;403/205,403 ;29/897.2 ;52/280 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
331865 |
|
Sep 1989 |
|
EP |
|
945073 |
|
Jun 1956 |
|
DE |
|
2049567 |
|
Dec 1980 |
|
GB |
|
Other References
Ashley, Steve, "The Shape of Cars to Come", Mechanical Engineering
May 1991, pp. 37-38..
|
Primary Examiner: Stormer; Russell D.
Assistant Examiner: Hoge; Gary C.
Attorney, Agent or Firm: Dulin; Jacques M. Feix; Thomas
C.
Claims
We claim:
1. An improved motor vehicle chassis comprising in operative
combination:
a) a plurality of frame elements, said frame elements having end
portions joined abutted together to form contour profiles which
define frame boundary areas for window and door openings of a motor
vehicle chassis;
b) each of said end portions of said frame elements includes a
notch disposed along an outer surface thereof, said notches of
abutting end portions of said frame elements forming a single
relieved portion disposed facing away from said openings; and
c) at least one node element joining said plurality of frame
elements, said node element having a bottom surface contour which
conformingly overlies said relieved portion; and
2. An improved motor vehicle chassis as in claim 1 wherein:
a) said frame elements comprise cast metal sections; and
b) said node element is formed as a generally bowl shaped open
molded piece having a concave upward surface disposed to face away
from said openings when fastened to said relieved portion.
3. An improved motor vehicle chassis as in claim 2 which
includes:
a) at least one covering said node element; and
b) said plate having an exposed outer surface which conforms to the
surface contour of adjacent abutting frame elements.
4. An improved motor vehicle chassis as in claim 2 wherein said
concave upward surface of said node element is covered by a plate
member which forms part of the outer skin of said motor vehicle
body.
5. An improved motor vehicle chassis as in claim 2 wherein:
a) said notches are stepped; and
b) said node element includes laterally extending tangs dimensioned
to conformingly fit within the stepped portions of said notches to
produce a smooth outer contour surface curve.
6. An improved motor vehicle chassis as in claim 5 which
includes:
a) at least one plate which fit over and covering said node
element; and
b) said plate has an exposed outer surface conforming to the
surface contour of adjacent abutting frame elements.
7. An improved motor vehicle chassis as in claim 5 wherein said
concave upward surface of said node element is covered by part of
the outer skin of said motor vehicle body.
8. An improved motor vehicle chassis as in claim 1 wherein;
a) said frame elements comprise extruded aluminum sections; and
b) said node element is formed as a generally bowl shaped open
molded piece having a concave upward surface disposed to face away
from said openings when fastened to said relieved portion.
9. An improved motor vehicle chassis as in claim 8 which
includes:
a) at least one covering said node element; and
b) said plate having an exposed outer surface which conforms to the
surface contour of adjacent abutting frame elements.
10. An improved motor vehicle chassis as in claim 8 wherein said
concave upward surface of said node element is covered by a plate
member which forms part of the outer skin of said motor vehicle
body.
11. An improved motor vehicle chassis as in claim 8 wherein:
a) said notches are stepped; and
b) said node element includes laterally extending tangs dimensioned
to conformingly fit within the stepped portions of said notches to
produce a smooth outer contour surface curve.
12. An improved motor vehicle chassis as claim 11 which
includes:
a) at least one plate covering said node element; and
b) said plate has an exposed outer surface conforming to the
surface contour of adjacent abutting frame elements.
13. An improved motor vehicle chassis as in claim 11 wherein said
concave upward surface of said node element is covered by part of
the outer skin of said motor vehicle body.
14. An improved method for the assembly of a motor vehicle chassis
of the type constructed from a plurality of frame elements joined
together by node elements comprising the steps of:
a) providing a notch on an outwardly facing end portion of each
frame element used to form part of a frame boundary area for window
or door openings;
b) positioning the notched ends of corresponding frame elements
together so that abutting notches form a single relieved portion
disposed along an outward surface of said frame boundary area
facing away from said openings; and
c) securing a bottom surface of an open molded node element to
conformingly overlie said outward facing relieved portion.
15. An improved method for the assembly of a motor vehicle chassis
as in claim 14 including the step of:
a) covering said open molded node element with a plate member;
and
b) fastening said plate member to at least portions of said node
element.
Description
FIELD
The invention relates generally to a method and apparatus for
assembly of a motor vehicle chassis More particularly, the
invention relates to a method and apparatus for assembling a motor
vehicle chassis in which connectors or nodes are used to join
together cast metal frame elements. The connector nodes join
together the frame elements by fitting within specially provided
notched end portions of each frame element in such a manner as to
provide a smooth continuous seating surface for the windows and
doors. The joining technique also reduces by half the number of
structural joints which form part of the frame opening seating
surfaces of the windows and doors.
BACKGROUND
Automotive chassis which use nodes or connecting members to hold
together extruded light metal or cast metal frame sections are well
known in the art. Examples of automotive chassis using nodes to
connect tubular frame sections or elements are shown in Hasler et
al (U.S. Pat. No. 4,618,163) and UK Patent No. (GB 2 049 567).
In Hasler et al the frame elements comprise cast metal or extruded
light metal rods. The ends of the frame elements are aligned and
fitted within a conforming receiving ends of connecting members or
nodes. The openings for the doors and windscreens are formed by the
nodal connection of several cast metal frame elements and by the
segments of the node elements which also face the openings. This
results in the formation a joint for every union between a node
element and a frame element Thus, transitional regions between
adjoining frame elements contain at least two joints because of the
node element. Since a portion of each node element also forms a
part of the boundary of each opening, it is difficult to produce an
exact contour curve for the openings To ensure an exact contour
curve, a precise fit of the node to each receiving end of an
abutting frame element is required, as well as a stable fixation of
the node to each connected frame element during the assembly
process. This method results in a labor intensive and costly
assembly technique.
In the UK Patent, the frame elements are round tubular girders
which are held together by a tubular node elements or lugs. The
connectors have tubular flanges for sleeve-like connection to
corresponding girder ends. As in Hasler et al, a circumferential
joint is formed by the union of each girder to a connector so that
there exists at least two joints for every transitional region
between adjoining girders. As above, this technique results in an
undesirable number of joints along the boundary curves of the frame
which define the seating surfaces for the windscreen and door
openings thus rendering the final assembly of a chassis having
smooth contour curves difficult.
Accordingly, there is a definite need in the art for an improved
node-connected motor vehicle chassis wherein the node elements do
not form part of the seating surfaces for the windscreens and doors
so that the number of joints in these boundary areas of the chassis
is reduced by half, and a smooth contour curve for each
transitional region is achieved. There is also need for a method of
construction of such a motor vehicle chassis which is simple and
cost effective to implement.
THE INVENTION
OBJECTS
It is a primary object of the present invention to provide an
improved motor vehicle chassis of the type constructed of tubular
extruded or cast metal tubular members connected by node elements
wherein the number of joints between abutting frame elements facing
the seating surfaces for the door and window openings is reduced by
half;
It is another object of the invention to provide such an improved
motor vehicle chassis wherein the node elements join abutting frame
elements by bonding to corresponding notched ends of each adjoining
frame element in a manner such that the nodes themselves do not
form part of the seating surface for the window and door
openings;
It is another object of the invention to provide an improved
node-connected motor vehicle chassis wherein the nodes include side
projections for increasing the surface area of contact for bonding
to each frame element;
It is yet another object of the invention to provide an assembly
technique for an improved motor vehicle chassis of the type using a
plurality of connecting tubular frame elements and nodes whereby
the structural parts may be fastened together in a cost efficient
and simple manner; and
Still other objects will be evident from the specification drawings
and claims which follow.
DRAWINGS
The invention is described in more detail with reference to the
drawings in which;
FIG. 1 is a fragmentary schematic top plan view of a node element
of a car body showing the node connection for the juncture of a
front roof column to a front roof frame and a side roof frame;
FIG. 2 is a side elevation view in partial cross section taken
along the line and in the direction of arrows 2--2 of FIG. 1;
FIG. 3 is a partially exploded isometric view of FIG. 1; and
FIG. 4 is a partially exploded isometric view showing an alternate
embodiment of a stepped notch fitting for the node element.
SUMMARY
A method and apparatus for the construction of a motor vehicle
chassis of the type having openings for front and rear windscreens
and doors. The vehicle chassis is constructed of cast metal or
extruded aluminum frame elements which are joined together by
connecting node elements The node elements are preferably
configured as upwardly open molded pieces and are easily
manufactured by known molding techniques.
The node elements connect to the frame elements in a manner such
that they do not form part of the frame boundary defining the
seating surface for the windows and doors. This is accomplished by
providing outwardly disposed notches or recesses on the adjoining
ends of each frame element. When the adjoining frame elements are
butted against each other, the notches combine to form a relieved
portion dimensioned to conformingly receive the placement of the
node therewithin. The node may then be fastened in place by any
number of known fastening techniques and is preferably fastened by
a bonding adhesive. Smooth transitional curves are easily achieved
since only a single joint is formed between adjoining frame
elements in the boundary areas defining the sealing surface for the
windscreens and doors. Also, this technique substantially reduces
the problems associated with prior art designs of axial alignment
and fixation of adjoining frame elements within the lug-type
connectors since the frame elements of the present invention are
easily aligned by direct abutment to one another along a common
joint.
Additional side projections or flaps may be provided to the ends of
the node elements to increase the contact surface area for
connection to the frame elements This is a special advantage when
the structural parts are to be glued together.
A plate may be provided to cover the upwardly open facing surface
of each open molded node element The cover plate provides a
box-type construction to the open molded node element which
improves the overall strength of the vehicle chassis The cover also
provides a smooth base for lacquering the completed chassis. In an
alternative embodiment, the node cover plate may be formed as part
of the outer skin of the vehicle body.
DETAILED DESCRIPTION OF THE BEST MODE
The following detailed description illustrates the invention by way
of example, not by way of limitation of the principles of the
invention. This description will clearly enable one skilled in the
art to make and use the invention, and describes several
embodiments, adaptations, variations, alternatives and uses of the
invention, including what we presently believe is the best mode of
carrying out the invention.
FIG. 1 shows one juncture of an automobile chassis comprising a
node element 3 which is used to connect together three frame
members 5, 7 and 9. In this example, frame member 5 is a roof
support post (the inclined front left post), frame member 7 is a
lateral roof support brace (transverse post), and frame member 9 is
a longitudinal roof support brace 9 (front to rear longitudinal
post). The roof support post 5 and the longitudinal roof support
brace 9, along with other structural frame members (not shown in
the Figure), combine to form a boundary for opening 11 which is
used to accommodate a door (front door not shown). Similarly, the
roof support post 5 and lateral roof support brace 7 along with
other frame pieces (not shown) form a boundary for opening 13 which
accommodates the front windscreen (not shown). While the following
description specifically describes the novel node connection for
the frame elements comprising the front windscreen and door
openings, it is understood that the assemblies for the node
connectors for the frame elements which comprise the rear window
and rear side window openings are also possible without any
significant deviation from the teachings herein described.
FIGS. 2 and 3 illustrate in greater detail how the novel node
connection between adjacent frame members of the present invention
results in a reduced number of joints in the frame boundary region
which define the seating surfaces for the doors and front
windscreen. In FIG. 2, longitudinal roof support brace 9 abuts
inclined vertical roof support post 5 along a single joint 19. Each
frame member 5, 9 is provided with a notch 15a, 15b for receiving
the specially configured node element 3. Node element 3 is
preferably a plastic molded piece and is connected to the notches
15a, 15b of frame members 5 and 9 by known adhesive bonding
techniques. The node element may also be formed by known
superplastic shaping processes or may even be constructed out of
metal and may be formed by a metal casting process. Accordingly,
other methods for fastening may be used including but not limited
to screws, spot welding, rivets, and rivets used in combination
with adhesives, a technique known in the art as rivet bonding.
The node element 3 is also provided with side projections or flap
portions 17a, 17b which are disposed to overlap an upper surface of
each abutting frame member 5, 9. The flap portions 17a, 17b provide
for a larger contact surface area for connection with each abutting
frame members. A large contact area is desirable when the component
parts are to be glued or adhesive bonded to each other.
As is seen in FIGS. 2 and 3, the node element 3 only extends along
an upper outward facing surface of each frame member 5 and 9. This
results in the single joint abutment of the two frame members 5 and
9 at the bottom inward facing surface of each frame member. Also
note that only the cast metal frame elements 5, 7, and 9 directly
bound the windscreen and door openings 13 and 11, respectively.
This is a significant improvement over the prior art methods since
the number of joints between the frame elements is reduced by half
since the node element 3 no longer forms part of the inward facing
boundary area for the openings 11 or 13 Thus, a continuous and
exactly fitting curved metal surface for a door or window is
achieved in a simple way. The continuous curve of the contour also
permits the formation of an exact seating surface for a seal such
as a conventional rubber sealing member for a window (not
shown).
As is shown in FIG. 3, each frame member 5, 9 is also provided with
an inwardly extending flange member which combine to form a
continuous sealing flange 21 when the frame elements 5 and 9 are
joined together at joint 19. In this example, continuous sealing
flange 21 corresponds to the door seating surface. A rubber sealing
member (not shown) may be fitted over or to the continuous sealing
flange 21 in accordance with known methods for final assembly of
motor vehicles.
Construction of the node element 3 as an open molded piece (shell)
provides a simple method for securing adjoining frame members
together. As noted above, the prior art tubular chassis designs are
constructed by fitting the joining ends of frame elements within
lug-type connectors. In these designs, special care is required to
ensure proper angular and spatial alignment, and stable fixation of
the frame elements during the assembly process especially when the
final linking frame element is fitted within the connectors to
complete the frame. These problems are now overcome since the
single joint abutment of adjoining frame elements permits a simple
way to ensure proper axial alignment of the frame elements
Moreover, the sealing flange 21 and flats of the notches 15a, 15b
assist in the alignment process.
In order to reduce the number of outwardly visible joints, it is
desirable to cover the open end of the node elements 3. A covering
also creates a box construction which improves the strength of the
node element. For this purpose, a plate 25 may be provided to cover
the upward open facing surfaces of the node element 3 and any open
surfaces of the frame elements As is seen in FIG. 3, the plate 25
is configured to cover both the node element 3 and the lateral roof
support brace 7 and has a top surface configuration which smoothly
conforms to outer surface configuration of the adjoining frame
members 5 and 7. In an alternate embodiment, the plate element 25b
(shown in phantom) may be formed as part of the outer skin which
comprises the vehicle body, in this example the roof skin. Covering
the outwardly open node elements 3 by a plate or a continuously
formed outer skin also provides a uniformly smooth base for
application of a smooth lacquer finish to a fully assembled vehicle
chassis.
FIG. 4 shows an alternate embodiment for the fitting arrangement of
the node element within the notches 15a, 15b of frame elements 5
and 9. In this arrangement, each notch 15a, 15b is further provided
with a stepped or relieved area 50a, 50b having a depth dimension
sufficient to accommodate tangs 17a, 17b of node element 3. As is
evident from the FIGURE, a continuously smooth outer surface
contour for the frame members 5 and 9 is now formed without any
visible ridges or bumps (as in FIG. 3). This permits the placement
of a cover plate 25 (phantom) or outer vehicle body skin covering
25b to lie flat over the node element and to be bonded to the node
tangs 17a, b and/or ribs 5 and 9.
It should be understood that various modifications within the scope
of this invention can be made by one of ordinary skill in the art
without departing from the spirit thereof We therefore wish our
invention to be defined by the scope of the appended claims in view
of the specification as broadly as the prior art will permit
* * * * *