U.S. patent application number 13/239592 was filed with the patent office on 2013-01-31 for vehicle support frames with interlocking features for joining members of dissimiliar materials.
This patent application is currently assigned to Ford Global Technologies LLC. The applicant listed for this patent is Michael M. Azzouz, Ari Garo Caliskan, Xiaoming Chen, Yuksel Gur, John Edward Huber, Sunil K. Kasaragod, Parameswararao Pothuraju, David Anthony Wagner, Jeffery Wallace. Invention is credited to Michael M. Azzouz, Ari Garo Caliskan, Xiaoming Chen, Yuksel Gur, John Edward Huber, Sunil K. Kasaragod, Parameswararao Pothuraju, David Anthony Wagner, Jeffery Wallace.
Application Number | 20130026793 13/239592 |
Document ID | / |
Family ID | 47596633 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130026793 |
Kind Code |
A1 |
Wagner; David Anthony ; et
al. |
January 31, 2013 |
Vehicle Support Frames with Interlocking Features for Joining
Members of Dissimiliar Materials
Abstract
The present disclosure relates to various vehicle cross-member
assemblies and methods of manufacturing the same. The various
vehicle cross-member assemblies have rails composed of dissimilar
materials.
Inventors: |
Wagner; David Anthony;
(Northville, MI) ; Azzouz; Michael M.; (Livonia,
MI) ; Caliskan; Ari Garo; (Canton, MI) ;
Kasaragod; Sunil K.; (Canton, MI) ; Chen;
Xiaoming; (Canton, MI) ; Huber; John Edward;
(Novi, MI) ; Gur; Yuksel; (Ann Arbor, MI) ;
Pothuraju; Parameswararao; (Canton, MI) ; Wallace;
Jeffery; (Walled Lake, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wagner; David Anthony
Azzouz; Michael M.
Caliskan; Ari Garo
Kasaragod; Sunil K.
Chen; Xiaoming
Huber; John Edward
Gur; Yuksel
Pothuraju; Parameswararao
Wallace; Jeffery |
Northville
Livonia
Canton
Canton
Canton
Novi
Ann Arbor
Canton
Walled Lake |
MI
MI
MI
MI
MI
MI
MI
MI
MI |
US
US
US
US
US
US
US
US
US |
|
|
Assignee: |
Ford Global Technologies
LLC
|
Family ID: |
47596633 |
Appl. No.: |
13/239592 |
Filed: |
September 22, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61512559 |
Jul 28, 2011 |
|
|
|
Current U.S.
Class: |
296/203.01 ;
156/196; 156/227; 228/173.4 |
Current CPC
Class: |
B23K 2101/006 20180801;
B23K 2103/14 20180801; B32B 37/1284 20130101; B23K 2103/20
20180801; Y10T 29/49622 20150115; Y10T 156/1002 20150115; Y10T
29/49956 20150115; B23K 2103/10 20180801; B23K 31/02 20130101; B62D
21/02 20130101; Y10T 29/49826 20150115; B23K 26/28 20130101; B23K
33/008 20130101; B23K 33/006 20130101; B23K 2103/04 20180801; B23K
2103/08 20180801; B23K 2103/42 20180801; B23K 2103/15 20180801;
Y10T 156/1051 20150115; B23K 2103/172 20180801; B23K 2103/16
20180801; B23K 2101/28 20180801; B23K 2101/185 20180801; B23K
2103/18 20180801 |
Class at
Publication: |
296/203.01 ;
228/173.4; 156/196; 156/227 |
International
Class: |
B62D 21/00 20060101
B62D021/00; B29C 65/56 20060101 B29C065/56; B29C 65/52 20060101
B29C065/52; B23K 31/02 20060101 B23K031/02 |
Claims
1. A method of manufacturing a vehicle cross-member assembly,
comprising: journaling an interconnecting member composed of a
first material onto a first rail composed of a second material; and
welding the interconnecting member to a second rail composed of a
different material than the first rail.
2. The method of claim 1, further comprising adhering the
interconnecting member to the first rail.
3. The method of claim 1, further comprising: press-fitting the
interconnecting member and the first rail together.
4. The method of claim 3, wherein the press-fitting includes:
forming at least one set of crimps in the interconnecting member
and first rail.
5. The method of claim 4, wherein the forming at least one set of
crimps includes forming the crimps so that a longitudinal center
line of the crimps extends parallel to a lateral axis of a
vehicle.
6. The method of claim 4, wherein the forming at least one set of
crimps includes forming the crimps so that a longitudinal center
line of the crimps extends parallel to a longitudinal axis of a
vehicle.
7. A vehicle cross-member assembly, comprising: a first rail
composed of a first material; a second rail composed of a second
material; and an interconnecting member composed of the second
material adhered to the first rail and journaled onto the first
rail; wherein the interconnecting member is welded to the second
rail.
8. The assembly of claim 7, further comprising: at least one set of
crimps commonly formed in the interconnecting member and first
rail.
9. The assembly of claim 8, wherein a longitudinal center line of
the crimps extends along a lateral axis of a vehicle.
10. The assembly of claim 9, wherein a longitudinal center line of
the crimps extends along a longitudinal axis of a vehicle.
11. A method of manufacturing a vehicle cross-member assembly,
comprising: forming a hem-lock between a first rail having a first
material composition and an interconnecting member having a second
material composition; and welding the interconnecting member to a
second rail having a different material composition than the first
rail.
12. The method of claim 11, wherein the forming a hem-lock
includes: forming a plurality of flanges in one of the
interconnecting member or first rail; and folding the flanges over
an edge of the other of the interconnecting member or first
rail.
13. The method of claim 12, wherein the forming a plurality of
flanges includes removing material from a corner of the
interconnecting member or first rail.
14. The method of claim 12, further comprising: applying adhesive
between the interconnecting member and first rail.
15. A vehicle frame assembly, comprising: a first rail having a
first material composition; a second rail having a second material
composition; and an interconnecting member hem-locked to the first
rail and welded to the second rail.
16. The vehicle frame assembly of claim 15, wherein the first rail
is configured to extend longitudinally with respect to the
assembly; and wherein the second rail is configured to extend
laterally with respect to the assembly.
17. The vehicle frame assembly of claim 16, wherein the
interconnecting member or first rail comprises a plurality of
flanges.
18. The vehicle frame assembly of claim 17, further comprising a
notch formed between at last two of the plurality of flanges.
19. The vehicle frame assembly of claim 17, wherein the plurality
of flanges are formed in the interconnecting member and fold into
the first rail.
20. The vehicle frame assembly of claim 17, wherein the plurality
of flanges are formed in the first rail are fold onto the
interconnecting member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims the benefit of
U.S. Patent Provisional Ser. No. 61/512,559 titled "Vehicle Support
Frames with Interlocking Features for Joining Members of Dissimilar
Materials" filed Jul. 28, 2011, which is hereby incorporated by
reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to vehicle support frames
with members having dissimilar materials and methods for
manufacturing the same.
BACKGROUND
[0003] Conventional vehicle support frames can be composed of
different materials including, for example, steel, aluminum and
reinforced polymer composites. Vehicle manufacturers attempt to
strike the balance between weight reduction and structural
rigidity. It is desirable to design lightweight cross-members for
full-sized light truck frames. Aluminum cross-members can be
designed to achieve up to 50% weight reduction while still meeting
performance targets. Aluminum cross-members have high potential for
building lightweight truck frames. Joining aluminum members to
steel frame rails also presents challenges especially when both
parts are closed-section tubular components. Additionally, it can
be costly to retool existing manufacturing facilities to handle
complex techniques of joining dissimilar materials.
[0004] Some existing references within the art teach the use of
mechanical fasteners to secure two rails made of dissimilar
materials together. These techniques, however, are less desirable.
These mechanical features include fasteners, which can increase
costs and manufacturing complexity. One patent reference teaches
the use of an overlapping configuration for the rails of dissimilar
materials. A first and second structural member sandwiches one end
of a third structural member and adhesive is applied there between.
The second structural member is thereafter welded to the first
structural member. U.S. Patent Publication No. 20090188206, titled
"System and Method for Joining Dissimilar Materials" teaches an
overlapping configuration which is more suitable for
collinear-structural-member connection as opposed to intersecting-
or angled-structural-member connection, i.e., side rail to
cross-member connections. Accordingly, a method of manufacturing a
vehicle cross-member assembly does not appear to be disclosed
therein.
[0005] Another patent publication, U.S. Patent Publication No.
2006/0032895, titled "Method for Joining Axle Components" discusses
joining two tubes composed of the same or dissimilar material using
magnetic forming. This process uses a forming band placed at an
opposite end of an electromagnetic actuator in order to form
multiple tubes; therefore, more limited configurations are
available for this assembly. For example, a sleeve or forming band
between multiple tubes does not appear to be taught. This process
is more expensive and requires more energy than most welding and/or
mechanical locking techniques.
[0006] Therefore, it is desirable to have improved interconnecting
techniques for joining two structural members composed of
dissimilar materials.
SUMMARY
[0007] The present disclosure addresses one or more of the
above-mentioned issues. Other features and/or advantages will
become apparent from the description which follows.
[0008] One exemplary embodiment relates to a method of
manufacturing a vehicle cross-member assembly, the method includes
the steps of: journaling an interconnecting member composed of a
first material onto a first rail composed of a second material; and
welding the interconnecting member to a second rail composed of a
different material than the first rail.
[0009] Another exemplary embodiment relates to a vehicle
cross-member assembly, having: a first rail composed of a first
material; a second rail composed of a second material; and an
interconnecting member composed of the second material adhered to
the first rail and journaled onto the first rail. The
interconnecting member is welded to the second rail.
[0010] Another exemplary embodiment relates to another method of
manufacturing a vehicle cross-member assembly, the method
including: forming a hem-lock between a first rail having a first
material composition and an interconnecting member having a second
material composition; and welding the interconnecting member to a
second rail having a different material composition than the first
rail.
[0011] Another exemplary embodiment relates to another vehicle
frame assembly, including: a first rail having a first material
composition; a second rail having a second material composition;
and an interconnecting member hem-locked to the first rail and
welded to the second rail.
[0012] One advantage of the present disclosure is that it enables
the use of welding techniques to join two or more frame assembly
components composed of dissimilar materials. This disclosure
teaches the use of an interconnecting member between frame
components that can be attached to one rail using one joining
technique and connected to another rail using a simple mechanical
attachment technique, e.g., welding.
[0013] Another advantage of the present disclosure is that it
teaches the manufacture and use of light-weight vehicle structural
frames that can be utilized with vehicles of different sizes,
including full-sized truck frames. The weight reduction for the
disclosed frame assemblies compared to contemporary structural
frames can be as great as 50%. Fuel efficiency and performance can
be enhanced by the use of the disclosed frame assemblies.
[0014] Another advantage of the present disclosure is that it
teaches joining techniques for structural members having dissimilar
material composition and a closed-section configuration. Structural
members can be positioned at any angle with respect to each
other.
[0015] Another advantage of the present disclosure is that it
teaches the use of aluminum structural members in a vehicle frame
that can be used in relatively heavy duty applications, e.g.,
pick-up trucks.
[0016] Joining a longitudinal rail and lateral rail composed of
dissimilar materials will be explained in greater detail below by
way of example with reference to the figures, in which the same
reference numbers are used in the figures for identical or
essentially identical elements. The above features and advantages
and other features and advantages of the present teachings are
readily apparent from the following detailed description of the
best modes for carrying out the invention when taken in connection
with the accompanying drawings. In the figures:
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a top perspective view of a vehicle support frame
assembly.
[0018] FIG. 2 is a perspective view of a cross-member and
interconnecting member according to one step of an exemplary method
of manufacturing a vehicle support frame assembly.
[0019] FIG. 3 is a perspective view of the cross-member and
interconnecting member of FIG. 2 according to another step in the
method of manufacturing.
[0020] FIG. 4 is a perspective view of the cross-member and
interconnecting member of FIG. 2 according to another step in the
method of manufacturing.
[0021] FIG. 5 is a perspective view of the cross-member and
interconnecting member of FIG. 2 according to another step in the
method of manufacturing.
[0022] FIG. 6 is a perspective view of another exemplary
interconnecting member and cross-member.
[0023] FIG. 7 is a cross-sectional view of the interconnecting
member and cross-member of FIG. 6 through line 7-7.
[0024] FIG. 8 is a perspective view of another exemplary
interconnecting member and cross-member.
[0025] FIG. 9 is a cross-sectional view of the interconnecting
member and cross-member of FIG. 8 through line 9-9.
[0026] FIG. 10 is a cross-sectional view of the interconnecting
member and cross-member of FIG. 8 taken along line 10-10.
[0027] FIG. 11 is a perspective view of another exemplary
embodiment of an interconnecting member and cross-member.
[0028] FIG. 12 is a cross-sectional view of the interconnecting
member and cross-member of FIG. 11 taken along line 12-12.
[0029] FIG. 13 is a perspective view of another exemplary
embodiment of an interconnecting member and cross-member.
[0030] FIG. 14 is a cross-sectional view of the interconnecting
member and cross-member of FIG. 13 taken along line 14-14.
[0031] FIG. 15 is a perspective view of another exemplary
embodiment of an interconnecting member and cross-member.
DETAILED DESCRIPTION
[0032] Referring to the drawings, wherein like characters represent
examples of the same or corresponding parts throughout the several
views, there are shown vehicle support frames having joined
structural members composed of different materials. Particularly,
lighter weight aluminum cross-members are joined to steel side
rails in most embodiments. The aluminum and steel members are
joined through an interconnecting member juxtaposed therebetween.
The disclosed interconnecting members mitigate several challenges
incumbent with joining dissimilar materials by teaching one facet
of attachment between the interconnecting member and cross-member
and another form of attachment between a side rail and
interconnecting member. In some embodiments, one end of the
interconnecting member is joined to the cross-member using
mechanical interlocking features (e.g., adhesives or crimping). The
attachment techniques used to attach the side rail to the assembly
at another end of the interconnecting member is different from the
prior, e.g., MIG welding. By utilizing a combination of different
attachment techniques and an interconnecting member, structural
members of incompatible material composition for a single
attachment technique can be robustly joined.
[0033] Any combination of differing attachment techniques can be
used including, for example, the use of adhesives, brazing,
welding, crimping, riveting, hydro-forming or soldering. The
disclosed interconnecting members facilitate the use of lower
weight materials in vehicle support frames. The teachings herein
are applicable to any type of vehicle frame including frames for
pickup trucks, vans, minivans, sports utility vehicles, sedans,
coupes, commercial vehicles, and all utility vehicles.
[0034] Referring now to FIG. 1, there is shown therein a vehicle
support frame 10. The illustrated support frame 10 is configured
for use in a pickup truck. Support frame 10 (as shown) is taken
from the rear section of the truck frame, which supports the truck
bed (not shown). Side rails (or structural members) 20 and 30
extend longitudinally with respect to the assembly and the vehicle.
In the shown embodiment, side rails 20, 30 can be composed of steel
and formed via any standard forming process, e.g., stampings,
hydro-forms, or roll forming. The rearward ends of the side rails
are interconnected through a forward steel cross-member 70 and a
rearward steel cross-member 40. Attached to cross-member 40 is a
tow hitch 50. Each end of the rails 20 and 30 are fitted with a
side bracket 60 for interconnecting cross-member 40 with the rails
and for connecting the rails to other vehicle structure (e.g., the
truck bed, rear fascia or bumper, etc.).
[0035] At the frontward end of the support frame 10, shown in FIG.
1, there is another steel cross-member 70 intersecting each side
rail 20, 30. As shown, side rail 30 is welded to cross-member 70.
The vehicle support frame 10 also includes a subassembly 80 for
mounting spare tires. Subassembly 80 includes two laterally
extending aluminum cross-members 90. Cross-members 90 support a
subframe 100 for a spare tire. A winch (not shown) secures the tire
to the subframe through orifice 110. The illustrated subframe 100
is stamped. The subframe 100 can also be formed, for example, via
die casting or other forming techniques. Subframe 100 is composed
of aluminum but can also be composed of different materials, e.g.,
aluminum, an aluminum alloy, steel, or a polymer.
[0036] Aluminum cross-members 90 are configured to secure the
subframe 100 onto the side rails 20 and 30. Cross-members 90 extend
laterally with respect to the frame assembly and vehicle.
Cross-members 90 are fitted with an interconnecting member 120, as
discussed hereinbelow. Interconnecting members 120 are attached to
the cross-members through the use of one attachment technique and
also attached to the side rail using a different attachment
technique. In the illustrated embodiment, interconnecting members
120 are adhered to cross-members. Interconnecting members are
further attached to the side rails 20 and 30 via MIG welding.
[0037] The cross-member 90 and interconnecting member 120 of FIG. 1
are further discussed with respect to FIGS. 2 through 5. One method
of joining the aluminum cross-member and steel interconnecting
member is shown. The method includes: (1) forming the
interconnecting member, which in this case is a steel plate having
a length approximately equal to the perimeter of the aluminum tube
(as shown in FIG. 2); (2) applying adhesive to one side of the
plate and the tube (as also shown in FIG. 2); (3) wrapping the
plate around the aluminum tube (as shown in FIG. 3); and (4)
forming the tube and plate against a mandrel to form a mechanical
interlock therebetween (e.g., at least one crimp as shown in FIG.
5).
[0038] Referring now to FIG. 2, there is shown therein cross-member
90 and an interconnecting member in the form of a steel plate 120
pre-assembly. Cross-member 90 is a hollow rectangular tube.
Interconnecting member 120 is a flat steel plate. The dimensions of
the cross-member 90 and interconnecting member can vary according
to structural demands and performance characteristics. In this
embodiment, the cross-member has rounded corners 130. As shown in
FIG. 2, edge 140 of the cross-member and edge 150 of the
interconnecting member are aligned. On an outer surface 160 of the
cross-member 90 an adhesive 170 is applied. Any type of adhesive
can be used, e.g., a one- or two-part epoxy. The steel plate 120
also has the adhesive 170 applied to surface 180.
[0039] As shown in FIG. 3, interconnecting member 120 is formed
over the end of cross-member 90. Interconnecting member 120 can be
formed, for example, using a stamping process or mandrel. As shown
in FIG. 4, interconnecting member 120 is formed against
cross-member 90 so as to be flush with surface 160 of cross-member.
Interconnecting member 120 is folded around the entire perimeter of
cross-member 90. A mandrel 190 is inserted in the cross-member 90.
Mandrel 190 has formed therein two recesses 200 (as shown in FIG.
5). Interconnecting member 120 and cross-member 90 are formed
against mandrel 190, as shown in FIG. 4. An external die (not
shown) is applied to the interconnecting member 120 and
cross-member 90 to form a crimp 210 (or impression) therein. A
mechanical interlock, in this case the crimp 210, is thereby formed
in interconnecting member 120 and cross-member 90. Mandrel 190 is
then removed, as shown in FIG. 5. Two crimps 210 are formed in the
interconnecting member 120 and cross-member 90 in this embodiment.
Interconnecting member 120 is thereafter welded to a steel side
rail (e.g., 20 or 30 as shown in FIG. 1).
[0040] Referring now to FIGS. 6-7, there is shown therein another
exemplary embodiment of a portion of a vehicle cross-frame assembly
300. The assembly 300 includes a side rail 310, interconnecting
member 320 and a cross-member 330. In this embodiment, the
interconnecting member 320 is a sleeve that encircles one end of
the cross-member 330. Side rail 310 is fitted or intersected with
sleeve 320 and cross-member 330. The interconnecting member 320 and
side rail 310 are composed of steel. Cross-member 330 is composed
of aluminum.
[0041] An end of cross-member 330 is crimped with the
interconnecting member 320, as shown in FIGS. 6 and 7. A first
crimp 340 and a second crimp 350 are commonly formed in the
cross-member 330 and interconnecting member 320. The vehicle
defines a longitudinal axis, L1, as designated in FIG. 6. In this
embodiment, crimps 340, 350 define a longitudinal centerline, e.g.,
L2 and L3, on the outer surface of the interconnecting member 320.
Crimps are formed so that the longitudinal center lines of the
crimps, L2 and L3, extend parallel to the longitudinal axis of the
vehicle, L1. Crimps 340 and 350 are also formed so that when the
cross-member 330 and interconnecting member 320 are inserted in the
side rail 310, crimps 340, 350 are enclosed by side rail 310. In
the shown embodiment, crimps 340, 350 are position proximate a
center-section of the side rail 310, as shown in FIG. 7.
[0042] In other embodiments, crimps can be positioned outside of
the intersection between the cross-member 330 and side rail 310.
Crimps 340, 350, as shown in FIG. 6, extend 360 degrees across the
outer surface of the interconnecting member 320 and cross-member
330. Crimps 340, 350 form a mechanical interlock between
interconnecting member 320 and cross-member 330. In another
embodiment, interconnecting member 320 is secured onto the
cross-member 330 by the use of an adhesive applied to an
overlapping section of interconnecting member and cross-member,
e.g., as discussed with respect to the embodiment shown in FIGS.
2-5. Adhesive can be activated via a brazing process, otherwise
thermally, by humidity, electrically or by other attachment
processes. At location 360 on the interconnecting member 320, for
example, the interconnecting member is attached to the side rail
310 via welding. Side rail 310 and interconnecting members 320 are
composed of steels that have compatible weld qualities or
characteristics.
[0043] Turning now to the illustrated embodiment of FIGS. 8-10,
there is shown therein another exemplary embodiment of a portion of
a vehicle support frame assembly 400. The assembly 400 includes a
side rail 410, interconnecting member 420 and a cross-member 430.
Interconnecting member 420 is a sleeve that encircles one end of
the cross-member 430. Side rail 410 is intersected with
interconnecting member 420 and cross-member 430. The
interconnecting member 420 and side rail 410 are composed of steel
for compatibility of attachment through weld. Cross-member 430 is
composed of a lighter weight material, e.g., aluminum.
[0044] In the illustrated embodiment of FIGS. 8-10, the
cross-sectional area of the interconnecting member 420 and
cross-member 430 is reduced where the interconnecting member is
crimped at 440 as shown in FIG. 9. A plurality of crimps 450 are
commonly formed in the cross-member 430 and interconnecting member
420, as shown in FIG. 10. A vehicle defines a lateral axis, L4, as
designated in FIG. 8. In this embodiment, crimps 450 define a
longitudinal centerline, e.g., L5, on the outer surface of the
interconnecting member 420. Crimps are formed so that the
longitudinal center lines of the crimps, L5, extends parallel to
the lateral axis of the vehicle, L4.
[0045] In other embodiments, crimps 450 can be positioned outside
of the intersection between the cross-member 430 and side rail 420.
In another embodiment, interconnecting member 420 is secured onto
the cross-member 430 by the use of an adhesive applied to an
overlapping section of interconnecting member 420 and cross-member
430.
[0046] Referring now to FIGS. 11-12, there is shown therein another
exemplary embodiment of a portion of a vehicle frame assembly 500.
In this embodiment, an interconnecting member 510 and side rail 520
of common material selection are shown. Cross-member 530 is
composed of aluminum. Side rail 520 is intersected with
interconnecting member 510 and cross-member 530, as shown.
Interconnecting member 510 extends over an end of the cross-member
530. Interconnecting member 510 includes four flanges 540. Flanges
540 are formed by removing material at the corners 550 of
interconnecting member 510 thereby forming a notch in corner 550.
Flanges 540 are folded over the edge of cross-member 530 (or into
the cross-member) thereby creating a hem-lock at the folded edge
555 of each flange 540 between the interconnecting member 510 and
cross-member 530. The flange 540 and cross-member 530 are attached
at hem-lock 555. At another location on the interconnecting member,
e.g., 560, interconnecting member 510 can be welded (or otherwise
attached) to side rail 520, as shown in FIGS. 11-12. In this
embodiment, interconnecting member 510 is further secured onto the
cross-member 530 by the use of an adhesive 570 applied between the
overlapping sections of interconnecting member 510 and cross-member
530.
[0047] In FIGS. 13-14, there is shown a portion of another
alternative embodiment of a vehicle frame assembly 600. The frame
assembly 600 has a hem-lock 605 between a cross-member 610 and
interconnecting member 620. Interconnecting member 620 and a side
rail 630 are of a material selection that facilitates joining
through welding (e.g., steel to steel, high-carbon steel to
low-carbon steel, and steel to tungsten). Cross-member 610 is
composed of a light weight material, such as aluminum or titanium.
Side rail 620 is fitted or intersected with interconnecting member
620 and cross-member 610, as shown in FIGS. 13-14. Cross-member 610
extends through an end of the interconnecting member 620.
Cross-member 610 includes four flanges 640. Flanges 640 are formed
by removing material at corners 650 of cross-member 610 thereby
forming a notch in corner 650. Flanges 640 are formed over the edge
of interconnecting member 620 (or onto the interconnecting member)
thereby creating a hem-lock 605 at said edge between the
interconnecting member 620 and cross-member 610. The hem-locks 605
between flange 640 and interconnecting member 620 are the locations
at which the interconnecting member and cross-member are attached.
At another location on the interconnecting member, e.g., 660,
interconnecting member 620 can be welded (or otherwise attached) to
side rail 630, as shown in FIG. 14. Interconnecting member 620 is
further secured onto the cross-member 610 by the use of an adhesive
670 applied between the overlapping sections of interconnecting
member 620 and cross-member 610.
[0048] Now with reference to FIG. 15, there is shown therein a
perspective view of a portion of another vehicle support frame
assembly 700. More than one interconnecting member can be utilized
at one end of the cross-member in the frame assemblies. Shown in
FIG. 15 is a cross-member 710 with multiple interconnecting members
720 attached thereto. Interconnecting members 720 are composed of
steel. Cross-member 710 is composed of aluminum. On surface 730 of
the cross-member 710, interconnecting member 720 is affixed to the
cross-member. On surface 740 of the cross-member 710,
interconnecting member 720 is affixed to cross-member 710. In this
embodiment, interconnecting members 720 are oblong in
configuration. Interconnecting members 720 included a beveled edge,
e.g., 750. In other embodiments, interconnecting members 720 have
different configurations, e.g., rectangular shapes, straight edges,
and jagged surfaces. In another embodiment, a mechanical interlock
is formed between the interconnecting members 720 and cross-member
710, e.g., crimps, impressions, concavities, protrusions, hem-locks
or other attachment schemes. Interconnecting members 720 are welded
to a side rail after insertion therein.
[0049] There is also taught herein methods of manufacturing a
vehicle cross-member assembly. One method includes the steps of:
(i) journaling an interconnecting member composed of a first
material onto a first rail composed of a second material (e.g., as
shown in FIGS. 2-4); and (ii) welding the interconnecting member to
a second rail composed of a different material than the first rail
(e.g., as taught with respect to FIGS. 2-5). The interconnecting
member can be journaled onto the first rail using available forming
techniques including, e.g., stamping, cold-forming, press-fitting
or hydro-forming. The method also includes adhering the
interconnecting member to the first rail. Adhering the
interconnecting member to the first rail can include applying an
adhesive or bonding agent, for example, to the interconnecting
member and/or first rail. Adhesives can also be applied between any
of the interconnecting members and cross-member or the
interconnecting member and the side rails. Any type of adhesive can
be used, e.g., a one- or two-part epoxy is compatible with the
illustrated designs. The ends of the interconnecting member and
cross-member can also have a brazing material included therebetween
to enhance their connection and serve as corrosion mitigation. The
ends of the mixed material overlapping joint can have a polymer or
other sealing material.
[0050] In one embodiment of the aforementioned method, the method
includes press-fitting the interconnecting member and the first
rail together (e.g., as shown in FIGS. 4-5). During the
press-fitting process an additional crimp can be formed in the
interconnecting member and/or first rail or cross-member, as also
shown in FIGS. 4-5.
[0051] Crimps can be formed in different positions with respect to
the first rail (or cross-member). For example, as shown in FIGS.
6-7, one method of manufacturing a vehicle cross-member assembly
includes forming the crimps so that a longitudinal center line of
the crimps extends parallel to a longitudinal axis of the vehicle.
In another exemplary embodiment of the method of manufacturing a
vehicle cross-member assembly the method includes forming the
crimps so that a longitudinal center line of the crimps extends
parallel to a lateral axis of the vehicle, e.g., as shown in FIGS.
8-10. Crimps can be formed using available forming techniques,
e.g., stamping, cold-forming, press-fitting or hydro-forming.
[0052] The manufacture of other types of vehicle cross-member
assemblies is also disclosed herein. One method of manufacturing a
vehicle cross-member assembly includes the following steps: (i)
forming a hem-lock between a first rail having a first material
composition and an interconnecting member having a second material
composition (e.g., shown in FIGS. 11-14); and (ii) welding the
interconnecting member to a second rail having a different material
composition than the first rail. In one embodiment of this method,
the method includes forming a plurality of flanges in the
interconnecting member (as shown in FIG. 11) or the first rail (as
shown in FIG. 13) and folding the flanges over an edge of the other
of the interconnecting member or first rail. At the corner of the
flanges material is removed, e.g., as shown in FIGS. 11 and 13.
Material can be removed, for example, by stamping, lathing, milling
or other removal techniques. In the embodiments, shown in FIGS.
11-14 an adhesive is applied between the interconnecting member and
cross-member (or rail). Any type of adhesive or bonding material
can be used. The adhesive can be applied before or after
assembly.
[0053] It will be appreciated that the members illustrated (e.g.,
the interconnecting members, side rails and cross-members) can be
composed of various materials including, for example, steel,
aluminum, magnesium, titanium, tungsten and reinforced polymer
composites. Attachment techniques for the sleeve to the side rail
is not limited to MIG welding but can include laser welding, spot
welding, brazing, the use of a fastener, soldering, clinging or
crimping. Sleeves and rails can be formed using manufacturing
techniques including, molding, casting, lathing, hydro-forming,
stamping or an extrusion processes.
[0054] The material composition of each member can be changed from
those disclosed with respect to the illustrated embodiments. For
example, in some embodiments the cross-member is composed of
titanium or a reinforced polymer. Any one of the side rails or
interconnecting members can commonly be composed of the same
material or different material. As taught, the weld-compatibility
of the interconnecting member and the side rail are taken into
consideration. In other embodiments the interconnecting member is
coupled to the side rail using a different attachment technique
(e.g., mechanical interlocking and/or the use of adhesives) and the
interconnecting member is welded to the cross-member. In another
embodiment, the interconnecting member is formed with the side rail
and a subsequent weld between the side rail and interconnecting
member is unneeded. It should also be appreciated that the terms
"material" and "material composition" are inexact approximations.
Any items referred to as having a same material composition
includes any items with substantially the same material
composition, material properties, or performance
characteristics.
[0055] It will also be appreciated that interconnecting members can
be of any size, shape or configuration and are not limited to
sleeves or bars. For example, in other embodiments, interconnecting
members are rectangular in shape and clamped on to a receptor in
the cross-member to provide a surface for subsequent welding.
[0056] While the best modes for carrying out the invention have
been described in detail, those familiar with the art to which this
invention relates will recognize various alternative designs and
embodiments for practicing the invention within the scope of the
appended claims.
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