U.S. patent application number 15/096752 was filed with the patent office on 2017-10-12 for tab-and-slot frame members with a stringer.
The applicant listed for this patent is David R. Hall, Stephen R. Hall, Christopher Johnson. Invention is credited to David R. Hall, Stephen R. Hall, Christopher Johnson.
Application Number | 20170291655 15/096752 |
Document ID | / |
Family ID | 59999914 |
Filed Date | 2017-10-12 |
United States Patent
Application |
20170291655 |
Kind Code |
A1 |
Hall; David R. ; et
al. |
October 12, 2017 |
Tab-And-Slot Frame Members with a Stringer
Abstract
A frame may comprise a plurality of interlocking tab-and-slot
frame members forming a three-dimensional structure. A removable
stringer may be designed into one or more of the interlocking
tab-and-slot frame members. The stringers may be removed after
positioning and welding of tab-and slot frame members together.
Notches may also be designed into and formed as additional features
of a tab-and-slot frame member. Notches may serve as a guide for
bending tab-and-slot frame members and in the creation of tabs
and/or slots of the tab-and-slot frame members.
Inventors: |
Hall; David R.; (Provo,
UT) ; Hall; Stephen R.; (Draper, UT) ;
Johnson; Christopher; (Provo, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hall; David R.
Hall; Stephen R.
Johnson; Christopher |
Provo
Draper
Provo |
UT
UT
UT |
US
US
US |
|
|
Family ID: |
59999914 |
Appl. No.: |
15/096752 |
Filed: |
April 12, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B63B 2221/02 20130101;
B23K 26/38 20130101; B64C 1/061 20130101; B23K 31/02 20130101; B23K
2101/006 20180801; B62D 65/02 20130101; B63B 73/00 20200101; Y10T
29/49622 20150115; B62D 23/00 20130101; B63B 3/28 20130101; B23K
1/00 20130101; Y10T 29/49968 20150115; B62D 27/02 20130101; B64F
5/10 20170101 |
International
Class: |
B62D 65/02 20060101
B62D065/02; B62D 21/02 20060101 B62D021/02; B64F 5/00 20060101
B64F005/00; B62D 25/08 20060101 B62D025/08; B63B 3/28 20060101
B63B003/28; B64C 1/06 20060101 B64C001/06 |
Claims
1. A method of creating a frame, comprising: cutting or stamping
one or more generally flat sheets of metal into: a first
tab-and-slot frame member with at least one stringer portion, and a
second tab-and-slot frame member; welding the first tab-and-slot
frame member to the second tab-and-slot frame member; and removing
the at least one stringer portion after the welding is
complete.
2. The method of claim 1, wherein when the at least one stringer
portion is cut, two tab-and-slot sections of the first tab-and-slot
frame member are disconnected from each other.
3. The method of claim 1, wherein the at least one stringer portion
is discarded after being cut off.
4. The method of claim 1, wherein the at least one stringer portion
is more than 10 times longer in length than a material thickness of
the one or more generally flat sheets of metal.
5. The method of claim 1, wherein the frame is at least a portion
of a vehicle frame.
6. The method of claim 1, wherein the at least one stringer portion
is integrally formed between two sections of the tab-and-slot
member with at least one stringer portion.
7. The method of claim 6, wherein when the at least one stringer
portion is cut two tab-and-slot sections of the first tab-and-slot
frame member are disconnected from each other.
8. The method of claim 7, wherein the at least one stringer portion
serves to hold in position the two tab-and-slot sections of the
tab-and-slot frame member in which it is integrally formed when the
two tab-and-slot sections are welded.
9. The method of claim 1, wherein the flat sheets are laser cut or
stamped on a press.
10. The method of claim 6, wherein the at least one stringer
portion serves to prevent warping of the tab-and-slot frame member
in which it is integrally formed when welded.
11. A frame comprising: a first tab-and-slot member with at least
one integrally formed removable temporary assembly support; a
second tab-and-slot member; and a body portion of the frame
comprising: welds between the first tab-and-slot member and the
second tab-and-slot member.
12. The frame of claim 11, wherein when the at least one integrally
formed removable temporary assembly support is removed, two
tab-and-slot sections of the first tab-and-slot frame member are
disconnected from each other.
13. The frame of claim 11, wherein the at least one integrally
formed removable temporary assembly support is removed before
accessory components are attached to the frame.
14. The frame of claim 11, wherein the at least one integrally
formed removable temporary assembly support is more than 10 times
longer in length than a material thickness of the first
tab-and-slot frame member.
15. The frame of claim 11, wherein the frame is at least a portion
of a vehicle frame.
16. The frame of claim 11, wherein the at least one integrally
formed removable temporary assembly support is integrally formed
between two sections of the first tab-and-slot frame member.
17. The frame of claim 16, wherein when the at least one integrally
formed removable temporary assembly support is removed, two
tab-and-slot sections of the first tab-and-slot frame member are
disconnected from each other.
18. The frame of claim 17, wherein the at least one integrally
formed removable temporary assembly support serves to hold in
position the first tab-and-slot frame member when the two
tab-and-slot sections are welded.
19. The frame of claim 11, wherein the first tab-and-slot frame
member and the second tab-and-slot frame member are made from
generally flat sheets of metal which are laser cut or stamped on a
press.
20. The frame of claim 16, wherein the at least one integrally
formed removable temporary assembly support serves to prevent
warping of the first tab-and-slot frame member when welded.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of U.S.
patent application Ser. No. 14/662,712 filed Mar. 19, 2015, which
claims priority to U.S. Provisional application No. 61/968,321
filed Mar. 20, 2014, both of which are incorporated herein by
reference for all that they contain.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to frames for
vehicles such as automobiles, boats, airplanes, and the like. More
specifically, the present invention relates to tab-and-slot frame
member design features.
[0003] A vehicle frame, also known as a chassis, may provide a
supporting structure for a vehicle. Such frames must typically be
strong enough to withstanding the static and dynamic loads
experienced by the vehicle. Elements that may apply loads to a
vehicle may include the weight of the vehicle body itself plus any
passengers and/or cargo. As a vehicle travels, it may also be
subjected to torsional loads created by traveling over uneven
surfaces, lateral loads created by steering the vehicle, torque
created by the engine and transmission, longitudinal loads created
by acceleration and breaking, and sudden impacts from collisions.
In order to withstand such loads, vehicle frames are traditionally
large, heavy, expensive and difficult to manufacture.
[0004] All other vehicle components such as lights, seats,
upholstery, handles, radios, and speakers may be attached to the
frame. Attachment has traditionally been accomplished by fasteners
welded to the frame. This welding may increase the difficulty of
manufacture as well as adding to the overall weight of the
vehicle.
[0005] Various attempts have been made to reduce the cost and
difficulty of manufacturing these large structural bodies. For
example, U.S. Pat. App. No. 2008/0169680 to Hedderly describes a
vehicle body assembly having a set of castings. Each member of the
set of castings interlocks with another member of the set of
castings to create a vehicle body structure. Another example is
disclosed in U.S. Pat. No. 8,398,159 to Hall that describes a
vehicle frame comprising a plurality of frame members including at
least two side plate members interlocked with a bottom plate member
and a vertically loaded plate member. The side plate members
support the bottom plate member and the vertically loaded plate
member through a plurality of tab and slot connections.
[0006] In view of the foregoing, what is needed are methods of
designing and constructing of vehicle frames that will enable a
vehicle frame to be customized during an initial build according to
specific components or parts installed in the vehicle.
BRIEF SUMMARY OF THE INVENTION
[0007] This invention has been developed in response to the present
state of the art and, in particular, in response to the problems
and needs in the art that have not yet been fully solved by
currently available systems and methods. Accordingly, improved
systems and methods have been developed to design and construct
custom vehicle frames. Features and advantages of different
embodiments of the invention will become more fully apparent from
the following description and appended claims, or may be learned by
practice of the invention as set forth hereinafter.
[0008] Consistent with the foregoing, a method of constructing a
custom vehicle frame with tab-and-slot frame members is disclosed.
Such a method includes: cutting or stamping one or more generally
flat sheets of metal into first and second tab-and-slot frame
members; welding the first and second tab-and-slot frame members
together; and cutting off a stringer attached to the first
tab-and-slot frame member.
[0009] The first tab-and-slot frame member may have at least one
stringer portion used to position and prevent warping of the
tab-and-slot member when it is welded to another tab-and-slot frame
member.
[0010] A body portion of a vehicle frame may comprise two or more
interlocking tab-and-slot frame members forming a three-dimensional
structure. A body portion of the frame may be formed from two or
more interlocking tab-and-slot frame members. The two or more
interlocking tab-and-slot frame members may comprise generally flat
plates or bent plates. Such plates may be laser cut or stamped from
larger plates. Such plates may also be formed of aluminum.
Tab-and-slot frame members may be held together by a plurality of
tab-and-slot connections which may further be welded in place. A
tab-and-slot frame member is hereby defined as generally flat, thin
member which connects to other tab-and-slot frame members, by way
of tabs and slots, to form a three-dimensional structure. The
connection between the tab-and-slot frame members is generally a
tab or edge of the member which connects to another member by
sliding into a slot or groove, or by recessing into a groove. The
connection points of two or more tab-and-slot frame members may be
welded or brazed together.
[0011] A portion of the tab-and-slot frame members may include a
stringer. A stringer is a temporary support used to stabilize two
sections of a tab-and-slot frame member while it is fitted to other
tab-and-slot frame members. One or more stringers may be used on
one or more tab-and-slot frame members. Stringers are especially
needed where tab-and-slot frame members are prone to twisting due
to weld heat or where exact positioning is need in frame
construction. Stringers may be designed into the original build of
a tab-and-slot frame member. This may be accomplished by designing
stringer patterns into the original tab-and-slot design patterns.
The design patterns may then be cut out or pressed out of a flat
plate to form a tab-and-slot frame member with a stringer.
Tab-and-slot frame members may be bent into various shapes and
angles. A bending notch locating a bending position may be designed
into a tab-and-slot frame member allowing the tab-and-slot frame
member to be easily positioned to bend and easily bent.
Tab-and-slot frame members, may have an attachment device disposed
thereon. The attachment device may comprise a hole or several holes
disposed in one or several of the plurality of interlocking
tab-and-slot frame members forming a portion or a whole body of the
frame. When several holes are present, they may be coaxial. The
hole may comprise a threaded rivet secured therein formed of steel.
The hole may also comprise a bolt secured therein.
[0012] A vehicle component such as a light, seat, handle, lock,
wheel, motor, transmission, drive train, tractor implement, snow
plow, weapon, tool, armor, or shock may be secured to one or more
tab-and-slot frame members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that the advantages of the invention will be
readily understood, a more particular description of the invention
briefly described above will be rendered by reference to specific
embodiments illustrated in the appended drawings. Understanding
that these drawings depict only typical embodiments of the
invention and are not therefore to be considered limiting of its
scope, the invention will be described and explained with
additional specificity and detail through use of the accompanying
drawings.
[0014] FIG. 1a thru 1c are front views of embodiments of
tab-and-slot frame members in accordance with an embodiment of the
present invention.
[0015] FIGS. 2a and 2b are front and perspective views
respectively, of a tab-and-slot frame member in accordance with the
invention.
[0016] FIG. 3 is a front view of an embodiment of a tab-and-slot
frame member in accordance with an embodiment of the invention.
[0017] FIGS. 4a and 4b are front views of tab-and-slot frame
members in accordance with an embodiment of the invention.
[0018] FIG. 5 is a perspective view showing attachment positions of
tab-and-slot frame members to a vehicle body in accordance with an
embodiment of the invention.
[0019] FIG. 6 is a perspective view showing attached tab-and-slot
frame members to a vehicle body in accordance with an embodiment of
the invention.
[0020] FIGS. 7a-7f are front views of optional features of
tab-and-slot frame members is accordance with an embodiment of the
invention.
[0021] FIGS. 8a-8c are top, side and perspective views
respectively, of optional features of tab-and-slot frame members is
accordance with an embodiment of the invention.
[0022] FIGS. 9a and 9b are top views of optional features of
tab-and-slot frame members in accordance with an embodiment of the
invention.
[0023] FIG. 10 is a perspective view of optional features of
tab-and-slot frame member assembly is accordance with an embodiment
of the invention.
DETAILED DESCRIPTION
[0024] It will be readily understood that the components of the
present invention, as generally described and illustrated in the
Figures herein, could be arranged and designed in a wide variety of
different configurations. Thus, the following more detailed
description of the embodiments of the invention, as represented in
the Figures, is not intended to limit the scope of the invention,
as claimed, but is merely representative of certain examples of
presently contemplated embodiments in accordance with the
invention. The presently described embodiments will be best
understood by reference to the drawings.
[0025] FIG. 1a, shows a twisted tab-and-slot frame member which has
been welded 102 without a stringer 106. The two section 108 and 110
were not supported by a stringer while being welded 104 causing the
warping and twisting 104. When a tab-and-slot frame member warps
and twists because of heat it causes unwanted deviations and
inconsistencies in frame design. FIG. 1b solves the problems of
warping and twisting by providing a stringer portion 106 which
temporarily connects sections 108 and 110 together for welding and
poisoning purposes. After welding, stringer portion 106 may be
removed as is shown in FIG. 1c. Multiple tab-and-slot frame members
may be welded to the tab-and-slot frame member shown in FIG. 1b
while preserving the original shape and spacing of sections 108 and
110. Welds may connect additional tab-and-slot frame members
perpendicularly, parallel, or at an angle to a front, rear, or side
face or edge of a tab-and-slot frame member. Without the stringer
106, each weld to another tab-and-slot member would cause a
position deviation and additional warping of the tab-and-slot
member sections 108 and 110. FIG. 1c shows a welded tab-and-slot
frame member with the stringer removed. The tab-and-slot frame
member of FIG. 1c held shape and position even after welding
because of stringer 106 of FIG. 1b.
[0026] FIGS. 2a and 2b show a tab-and-slot frame member 200 with
optional features. Hole 210 may be used to fasten on accessory
components which are supported by a frame, the frame may be created
by interlocking and welding tab-and-slot frame members together.
The interlocking frame members may interlock and be welded at tab
202, slot 204, or slot 212. Stringer 206 may serve to support
sections 214 and 216 while being welded to other tab-and-slot
members. Stringers are especially useful when tab-and-slot frame
members have thin or narrow features as shown in FIGS. 2a and 2b. A
material thickness 208 may be in a range from 0.040 to 0.750 of an
inch depending on the application of a frame created. For instance,
a tank frame built from tab-and-slot members may have a
tab-and-slot material thickness of 0.750 of an inch and a small
airplane frame built from tab-and-slot members may have a material
thickness of 0.040 of an inch. Other automobiles, motorcycles,
trucks, and heavy equipment may have a material thickness in the
range of 0.040 to 0.750 of an inch.
[0027] FIG. 3 shows a top view of a simple tab-and-slot member 300
comprising two sections 302 and 304 connected by a stringer portion
306. Stringer portion 306 may provide a spacing between sections
302 and 304 which aid in the construction of a plurality of
tab-and-slot frame members into a three-dimensional frame. Stringer
portion 306 may also provide necessary rigidity while welding
sections 302 and 304 to other tab-and-slot members to prevent
twisting of sections 302 and 304. Stringer portion 306 may be
removed after welding and/or positioning is complete.
[0028] FIG. 4a shows a tab-and-slot frame member 400 with two
stringer portions 406 and 408. Sections 402 and 404 are held in
position while being weld to other tab-and-slot frame members. In
FIG. 4b, stringer portions 406 and 408 have been removed.
[0029] FIG. 5 shows a vehicle frame 500 comprising a plurality of
interlocking tab-and-slot frame members forming a three-dimensional
structure. The three-dimensional structure may be designed to
support the vehicle's mechanical components and body while
withstanding the static and dynamic loads experienced by the
vehicle. These static and dynamic loads may include the weight of
the vehicle body, passengers, and cargo loads; vertical and
torsional twisting created by traveling over uneven surfaces;
transverse lateral forces created by road conditions, side winds,
and steering of the vehicle; torque created by the engine and
transmission; longitudinal tensile forces created by acceleration
and compression forces created by braking of the vehicle; and
sudden impacts from collisions.
[0030] As can be seen, some of the plurality of interlocking
tab-and-slot frame members may comprise generally flat plates while
others may comprise bent plates. Such plates may be held together
by a plurality of tab-and-slot connections. Such tab-and-slot
connections may provide support to the three-dimensional structure
as well as hold the three-dimensional structure together while it
is being welded. By holding the three-dimensional structure
together while it is being welded, the tab-and-slot connections may
obviate a jig and lead to easier and less expensive manufacture.
The tab-and-slot connections, along with the rest of the plates,
may be formed by laser cutting or stamping the plates out from
larger plates. Additionally, the plates may be formed of aluminum
to minimize the weight of the vehicle. Certain tab-and-slot frame
members such as 502 and 504 may comprise stringers 506 and 206 (of
FIG. 2). These stringers may serve as a "designed in" positioning
system allowing easy alignment and easy welding of sections 510 and
512 without additional alignment tools. FIG. 5 shows an un-welded
view of tab-and-slot frame members.
[0031] FIG. 6 shows a welded view of the tab-and-slot frame members
of FIG. 5. The welded portions 606 connect sections 602 and 604 to
other tab-and-slot frame members of a vehicle frame 600. The
stringers shown in FIG. 5 have been removed after welding was
complete.
[0032] FIGS. 7a-7f shows tab-and-slot optional design-in features.
The shown design-in features may include notches 702, 706, 710,
714, 718, and 722 of various shapes and sizes which serve to
provide a bending line 704, 708, 712, 716, 720, and 724. The
notches provide position of a bend which is designed into a
tab-and-slot frame member and a weakened bend line making a bend
easier to make in a correct location.
[0033] FIGS. 8a-8c shows notches 804 which were designed into a
tab-and-slot frame member 800. FIG. 8a is shows a tab-and-slot
frame member which has not been bent. FIGS. 8b and 8c show bent
tab-and-slot frame members. It is of particular mention to note
that tabs 808, 810, and 812, of tab-and-slot frame member 806, were
formed as a result of notches 804 and being bent. Additionally,
notches 804 of FIG. 8c may be used as a slot for receiving one or
more tabs of another tab-and-slot frame member. The notches may
serve a purpose of creating tabs and slots, creating bending
location points, bending lines, and a weaker bending location in a
correct location on a tab-and-slot frame member.
[0034] FIGS. 9a and 9b show a tab-and-slot frame member 900 before
being bent 9b and after being bent 9a.
[0035] FIG. 10 shows an example of an embodiment of a body of a
frame 1000 created by interlocking tab-and-slot frame members to
form the frame 1000. In this embodiment, two frame members 1012 and
1008 may be disposed parallel to each other and may each comprise a
hole 1014 coaxial with the other. A component such as a control
arm, may be secured to one or more tab-and-slot frame members of
the frame 1000 as well as other tab-and-slot frame members 1006 and
1010.
[0036] The method disclosed herein may be embodied in other
specific forms without departing from their spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *