U.S. patent application number 13/656525 was filed with the patent office on 2013-07-18 for rear-wheel drive, plug-in hybrid electric vehicle modular subframe assembly and method.
This patent application is currently assigned to Fisker Automotive, Inc.. The applicant listed for this patent is Fisker Automotive, Inc.. Invention is credited to Art Goudie, Mike Jones, Manfred Rumpel, Bill Stinnett, Eric Werner.
Application Number | 20130181485 13/656525 |
Document ID | / |
Family ID | 48141420 |
Filed Date | 2013-07-18 |
United States Patent
Application |
20130181485 |
Kind Code |
A1 |
Rumpel; Manfred ; et
al. |
July 18, 2013 |
REAR-WHEEL DRIVE, PLUG-IN HYBRID ELECTRIC VEHICLE MODULAR SUBFRAME
ASSEMBLY AND METHOD
Abstract
A rear subframe assembly, for use in a vehicle, includes a first
and second side member that are coupled to a front cross member, a
lower cross member, and an upper cross member. First and second
gussets are provided to reinforce joints between each of the first
and second side members and the front cross member. A motor mount
portion for mounting a motor thereon is located between the side
members and includes a first and second motor bracket each coupled
to the front cross member through an isolator and to one of the
side members through an isolator, the isolators for isolating the
motor from vibration. A fuel tank mounting portion for mounting a
fuel tank onto the subframe member is also provided.
Inventors: |
Rumpel; Manfred; (Anaheim,
CA) ; Jones; Mike; (Anaheim, CA) ; Goudie;
Art; (Anaheim, CA) ; Stinnett; Bill; (Anaheim,
CA) ; Werner; Eric; (Anaheim, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fisker Automotive, Inc.; |
Anaheim |
CA |
US |
|
|
Assignee: |
Fisker Automotive, Inc.
Anaheim
CA
|
Family ID: |
48141420 |
Appl. No.: |
13/656525 |
Filed: |
October 19, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61550006 |
Oct 21, 2011 |
|
|
|
Current U.S.
Class: |
296/203.04 ;
29/897.2 |
Current CPC
Class: |
Y02T 90/14 20130101;
B60K 1/00 20130101; B60K 15/067 20130101; B60G 2204/15 20130101;
B62D 63/025 20130101; B60K 2015/0638 20130101; B62D 25/08 20130101;
B62D 65/02 20130101; B60G 2300/50 20130101; B62D 21/11 20130101;
Y10T 29/49622 20150115; B60Y 2200/92 20130101; B60G 3/20 20130101;
B60K 15/07 20130101 |
Class at
Publication: |
296/203.04 ;
29/897.2 |
International
Class: |
B62D 25/08 20060101
B62D025/08; B62D 65/02 20060101 B62D065/02 |
Claims
1. A rear subframe assembly for a vehicle, the rear subframe
assembly comprising: a first side member, a second side member, a
front cross member configured to be coupled to the first and second
side members therebetween, a lower cross member configured to be
coupled to the first and second side members therebetween, and an
upper cross member configured to be coupled to the first and second
side members therebetween; a first gusset coupled to the first side
member and the front cross member and a second gusset coupled to
the second side member and the front cross member, the first and
second gussets for reinforcing joints between the first and second
side members and the front cross member; a motor mount portion
located between the first and second side members, the motor mount
portion having a first motor bracket coupled to the front cross
member through an isolator and to the first side member through an
isolator, and a second motor bracket coupled to the front cross
member through an isolator and to the second side member through an
isolator, the first and second motor brackets configured to couple
a motor thereon, the isolators for isolating the motor from
vibration; and a fuel tank mount that is configured to support a
fuel tank; wherein the position of the front cross member, the
upper cross member, and the lower cross member is generally in a
direction normal to the position of the side members; and wherein
the fuel tank mount is disposed above the motor mount portion.
2. The rear subframe assembly of claim 1, wherein the fuel tank is
coupled to the rear subframe assembly by at least one strap.
3. The rear subframe assembly of claim 1, wherein the subframe
assembly is coupled to a vehicle frame as a separate assembly.
4. The rear subframe assembly of claim 1, further comprising an
upper control arm and a lower control arm that are configured to be
coupled to one of each side member.
5. The rear subframe assembly of claim 1, wherein a portion of the
fuel tank mount that provides support for the fuel tank is
concave.
6. The rear subframe assembly of claim 1, wherein the motor is
configured to be mounted between the lower and upper cross
members.
7. A rear subframe assembly for a vehicle, the rear subframe
assembly comprising: a first and second side member; a front cross
member, a lower cross member, and an upper cross member configured
to be coupled to the first and second side members therebetween;
wherein the front cross member and the side members each include at
least one motor mount thereon; wherein a motor is configured to be
coupled to the motor mounts included on the front cross member and
the side members; wherein the position of the front cross member,
the upper cross member, and the lower cross member is generally in
a direction normal to the position of the side members; and wherein
a fuel tank is configured to be disposed above the motor.
8. The rear subframe assembly of claim 7, wherein the motor mounts
are configured to isolate the motor from vibration.
9. The rear subframe assembly of claim 7, further comprising a fuel
tank mount that is configured to support the fuel tank; wherein a
portion of the mount that provides support for the fuel tank is
concave.
10. The rear subframe assembly of claim 7, further comprising a
first motor bracket and a second motor bracket; wherein the motor
is configured to be coupled between the motor brackets; and wherein
a front portion of each motor bracket is coupled to a motor mount
on the front cross member, and a rear portion of the motor bracket
is coupled to a motor mount on one of each side member.
11. The rear subframe assembly of claim 7, wherein the fuel tank is
coupled to the rear subframe assembly by at least one strap.
12. The rear subframe assembly of claim 7, wherein the subframe
assembly is coupled to a vehicle frame as a separate assembly.
13. The rear subframe assembly of claim 7, wherein the motor is
configured to be mounted between the lower and upper cross
members.
14. A method for assembling a rear subframe assembly, the method
comprising: coupling one end of each of a front cross member and a
lower cross member to either of a first side member and a second
side member, so that the position of each cross member is generally
normal to the side members; coupling a first motor bracket to the
front cross member and the first side member, and coupling a second
motor bracket to the front cross member and the second side member;
coupling a motor to the first motor bracket and the second motor
bracket therebetween; coupling an upper cross member to the first
and second side members, so the upper cross member is disposed on
an opposite side of the motor as the lower cross member; and
coupling a fuel tank to either of the side members, the motor
brackets, or the upper cross member, so the fuel tank is disposed
on an opposite side of the motor as the lower cross member.
15. The method of claim 14, the method further comprising coupling
the side members to a structure of a vehicle.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application No. 61/550,006filed Oct. 21, 2011.
The foregoing provisional patent application is incorporated by
reference herein in its entirety.
BACKGROUND
[0002] The present disclosure relates generally to a subframe
assembly for a vehicle, and more particularly to a modular subframe
assembly for a plug-in hybrid electric vehicle (PHEV).
DESCRIPTION OF THE PRIOR ART
[0003] Vehicles, such as a passenger motor vehicle, include a
suspension system for supporting the vehicle and isolating it from
road variation, while providing desirable handling and maneuvering
capabilities. Passenger vehicle body frames typically include a
ladder-type construction or a unibody structure. Such known vehicle
body structures have been used for many years and are well known in
the art.
[0004] The demand for more safe and efficient vehicles has driven
the automotive industry to reduce the weight of vehicles without
reducing or sacrificing structural integrity. The need for safer
vehicles also creates a demand for vehicles that are more able to
withstand impact collisions, and which also have improved handling
and driving performance. Various specific attempts have been made
to substitute different materials for part or all of the vehicle
frame. Although materials such as aluminum or composites have
lightweight advantages, structural stiffness and/or integrity is
typically sacrificed.
[0005] Fuel tanks for conventional vehicles have traditionally been
mounted directly to a body structure of the vehicle. In the case of
a PHEV, a traditional body-mounted fuel tank location seriously
compromises the amount of space available for a drive battery.
Therefore, there exists a need for a more suitable space for the
fuel tank of a PHEV, which does not compromise the available space
for a drive battery.
[0006] Another disadvantage associated with conventional vehicle
frames and subassemblies relates to design space for vehicle
components, which is restricted as a result of required design
clearances for part variation and part movement. Design space is
further restricted due to the isolating properties of rubber
subframe mounts which allow a subframe to move. As a result of
restricted design space, the size of a traditionally body-mounted
fuel tank is accordingly restricted and the vehicle's effective
drive distance is reduced. Therefore, there exists a need for a
more suitable space for the fuel tank of a vehicle which allows for
a larger fuel tank in order to accommodate more fuel and increase
the vehicle's effective drive distance.
[0007] A further disadvantage associated with conventional vehicle
frames relates to the method in which vehicle components are
assembled to the vehicle frame. Typically, vehicle components, such
as the vehicle driveline components and vehicle suspension
components, are installed to the vehicle frame individually. As a
result, the time it takes to fully assemble the vehicle is
increased. Therefore, there exists a need for a method of
assembling a subframe assembly to a vehicle frame assembly which
reduces the overall time it takes to assemble the vehicle frame
assembly.
SUMMARY
[0008] Accordingly, it is the object of the present disclosure to
provide a subframe assembly for a vehicle that increases the space
available for a fuel tank, thereby allowing the vehicle to
accommodate a fuel tank with greater volume. A further object of
the present disclosure is to provide a subframe assembly for a
vehicle that can be easily assembled to the vehicle frame assembly,
thereby reducing the overall assembly time and the number of steps
it takes to assemble the vehicle frame assembly.
[0009] Generally, the present disclosure relates to a rear subframe
assembly and architecture that represents a dramatic improvement
over known devices. More particularly, the present disclosure
relates to a rear subframe assembly for a rear-wheel drive PHEV. In
various embodiments, compatibility with various electric driveline
configurations, fuel tanks, powertrain components, and other
vehicle components is greatly enhanced. In various embodiments, the
structural stiffness and durability of the vehicle body frame is
increased. In various embodiments, driveline isolation from noise
and vibration is improved. In various embodiments, occupant and
fuel tank protection is enhanced. In various embodiments, overall
vehicle assembly is simplified and improved.
[0010] According to various embodiments, a rear subframe assembly
for a vehicle comprises a first side member (left side member), a
second side member (right side member), a front cross member, a
lower cross member, an upper cross member, a first and second
gusset, a motor mount portion, and a fuel tank mount portion. The
first and second side members are positioned generally parallel to
a longitudinal direction of the vehicle. The cross members are
positioned generally normal to a longitudinal direction of the
vehicle. The front cross member is positioned in a generally
forward location of the rear subframe assembly, as the rear
subframe assembly is configured to be mounted to a structure of a
vehicle.
[0011] According to various embodiments, the first and second side
members are coupled to the front cross member, the bottom cross
member, and the top cross member.
[0012] According to various embodiments, the first gusset is
coupled to the first side member and the front cross member, and a
second gusset is coupled to the second side member and the front
cross member. At least one function of the first and second gussets
is to reinforce the joints defined by the first and second side
members and the front cross member.
[0013] According to various embodiments, the motor mount portion is
located between the first and second side members. The motor mount
portion comprises a first motor bracket, a second motor bracket, a
motor, and isolators. The first and second motor brackets are each
coupled to the front cross member and either of the left or right
side members through isolators. At least one function of the first
and second motor brackets is to couple a motor thereon. At least
one function of the isolators is to isolate the motor from
vibration.
[0014] According to various embodiments, at least one function of
the fuel tank mount portion is to provide support for a fuel tank.
According to other embodiments, the fuel tank is disposed above the
motor mount portion. The fuel tank mount portion may be concave-
shaped to receive the fuel tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a vehicle body frame having
a rear suspension subframe assembly according to an embodiment of
the disclosure.
[0016] FIG. 2 is a front perspective view of a rear subframe
assembly with powertrain components according to an embodiment of
the disclosure.
[0017] FIG. 3 is a front perspective view of a rear subframe
assembly without powertrain components according to an embodiment
of the disclosure.
[0018] FIG. 4 is a rear perspective view of a rear subframe
assembly with powertrain components according to an embodiment of
the disclosure.
[0019] FIG. 5 is a rear perspective view of a rear subframe
assembly without powertrain components according to an embodiment
of the disclosure.
[0020] FIG. 6 is a rear bottom view of a rear subframe assembly
decked into a vehicle according to an embodiment of the
disclosure.
[0021] FIG. 7 is a front view of a rear subframe assembly according
to an embodiment of the disclosure.
[0022] FIG. 8 is a rear view of a rear subframe assembly according
to an embodiment of the disclosure.
[0023] FIG. 9 is a left side view of a rear subframe assembly
according to an embodiment of the disclosure.
[0024] FIG. 10 is plan view of a rear subframe assembly according
to an embodiment of the disclosure.
[0025] FIG. 11 is a bottom view of a rear subframe assembly
according to an embodiment of the disclosure.
[0026] FIG. 12 is a perspective view of a rear subframe assembly
with a fuel tank attachment according to an embodiment of the
disclosure.
[0027] FIG. 13 is a perspective view of a rear subframe assembly
with an electric motor attachment according to an embodiment of the
disclosure.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)
[0028] Referring to FIG. 1, a vehicle body frame 20 is shown. The
vehicle body frame 20 includes a number of components, including a
rear subframe assembly 30. It should be noted that the vehicle body
frame 20 is shown for the four-door vehicle 10'. However, the
features of the vehicle body frame 20 are meant to apply to the
two-door vehicle 10 and other variations of passenger vehicles.
[0029] Referring now to FIGS. 2-13, the rear subframe assembly 30
is shown. The rear subframe assembly 30 includes two side members
31, 32 (left and right), a front cross-member 34, a lower
cross-member 36, and an upper cross-member 38. The two side members
31, 32 are positioned parallel to a longitudinal direction of the
vehicle 10, 10', and the forward cross-member 34, the lower
cross-member 36, and the upper cross-member 38 are positioned
normal to a longitudinal direction of the vehicle 10, 10'.
[0030] In particular embodiments, the side members 31, 32 may be
cast and machined aluminum, the forward cross-member 34 may be
extruded aluminum, the lower cross-member 36 may be extruded
aluminum, and the upper cross-member 38 may be cast aluminum. In
other embodiments, any one or more of these components may be made
of any suitable material, and may be manufactured in a variety of
ways.
[0031] The side members 31, 32 may be configured to couple to one
or more of the upper cross-member 38, attachments 42 for a fuel
tank 40, control arms 52 for a suspension system 50, and
attachments 62 for an electric motor assembly 60. In various
embodiments, the side members 31, 32 are configured to couple to
the vehicle body frame 20. A first end of the upper cross member 38
is configured to couple to the left side member 31, and a second
end of the upper cross member 38 is configured to couple to the
right side member 32. The upper cross member is configured to be
removably coupled (e.g. bolted) to the side members 31, 32. The
components of the suspension system 50 couple (e.g., bolt) to the
side members 31, 32 at machined locations to ensure dimensional
accuracy.
[0032] According to various embodiments, a first end of the front
cross member 34 is configured to couple to a front end of the left
side member 31, and a second end of the front cross member 34 is
configured to couple to a front end of the right side member 32. A
first end of the lower cross member 36 is configured to couple to a
portion of the left side member 31, and a second end of the lower
cross member 36 is configured to couple to the right side member
32. In various embodiments, the lower cross member 36 is positioned
rearward of the front cross member 34. In various embodiments, the
front and lower cross-members 34, 36 are fixtured and welded to the
side members 31, 32 and reinforced using gussets 72, (e.g.,
triangular-shaped sheet aluminum welded gussets). According to
other embodiments, the front and lower cross-members 34, 36 are
configured to be coupled to the side members 31, 32 with fasteners
(e.g. rivets, bolts).
[0033] As shown in FIG. 3, the rear subframe assembly 30 may
include a concave lower bracket 74 for receiving the fuel tank 40.
The fuel tank 40 may be secured to the rear subframe assembly 30
with the attachments 42. For example, the attachments 42 may be
coupled to a corresponding gusset 72 and a corresponding side
member 31, 32. In various embodiments, the fuel tank 40 is at least
partially disposed above the electric motor assembly 60.
[0034] As shown in FIG. 13, the electric motor assembly 60 may
attach to the rear subframe assembly 30 via the attachments (or
motor brackets) 62 that couple (e.g., bolt) to a left and a right
side of an electric motor housing. The attachments 62 are
configured to be coupled to the rear subframe assembly 30 through
four motor mounts (e.g. longitudinal rubber isolators) 76. For
instance, at least one isolator 76 may be coupled to the forward
cross-member 34 and at least one isolator may be coupled to a
corresponding side member 31, 32.
[0035] As shown in FIG. 2, the rear subframe assembly 30 may be
isolated using four traditional pressed-in voided bushings 78 with
bolted attachment to body structural rails of the vehicle frame
body. In other embodiments, the rear subframe assembly 30 may be
isolated to the vehicle frame body in any suitable manner.
[0036] In various embodiments, the electric motor assembly 60 is
isolated from vibration relative to the body structure at two
levels. In particular embodiments, the electric motor assembly 60
is isolated from vibration with two levels of rubber mounts
relative to the body structure: a first level at the attachments 62
and a second level at the bushings 78. In particular embodiments,
the fore-and-aft and left-right distances between the isolators 76
at the attachments 62 to the rear subframe assembly 30 are
maximized. The greater distances between isolators 76 provides a
competitive level of driveline isolation (e.g., noise, vibration,
harshness, etc.) compared to other rear-wheel-drive vehicles. The
rigid attachment of the fuel tank 40 to the rear subframe assembly
30 allows for greater clearances between the fuel tank 40 and other
components of the vehicle which accommodates a larger fuel tank
having greater achievable fuel volume. Another benefit of a rigid
attachment of the fuel tank 40 to the rear subframe assembly 30 is
that relative motion between vehicle components is minimized which
provides added protection of the fuel tank 40 during rear crash
events.
[0037] In various embodiments, the rear subframe assembly 30
accommodates a large overall static weight of the sub-assembly
(e.g., >850 lbs), high stiffness targets (e.g., approximately
100 Hz first torsional mode), and large dynamic loads from
suspension attachments during real-world events, such as pothole
impacts, and the like. In some embodiments, the rear subframe
assembly 30 permits significant sub-assembly of most rear chassis
components, and simplifies the assembly decking operation. In
various embodiments, the rear subframe assembly 30 incorporates an
isolated electric motor assembly 60 and a non- isolated fuel tank
40.
[0038] The previous description of the disclosed embodiments is
provided to enable any person skilled in the art to make or use the
present disclosure. Various modifications to these embodiments will
be readily apparent to those skilled in the art, and the generic
principles defined herein may be applied to other embodiments
without departing from the spirit or scope of the disclosure. Thus,
the present disclosure is not intended to be limited to the
embodiments shown herein but is to be accorded the widest scope
consistent with the principles and novel features disclosed
herein.
* * * * *