U.S. patent application number 15/200977 was filed with the patent office on 2018-01-04 for cross member with inner flanges.
This patent application is currently assigned to TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA, INC.. The applicant listed for this patent is TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA, INC.. Invention is credited to Christopher M. HIGGINS, Brian T. THURGATE.
Application Number | 20180001931 15/200977 |
Document ID | / |
Family ID | 59276559 |
Filed Date | 2018-01-04 |
United States Patent
Application |
20180001931 |
Kind Code |
A1 |
HIGGINS; Christopher M. ; et
al. |
January 4, 2018 |
CROSS MEMBER WITH INNER FLANGES
Abstract
A cross member including a base including a first side wall
inclined at a first angle with the base and a second side wall
inclined at a second angle with the base creating a hollow portion
between the first side wall and a second side wall, a first outer
flange and a second outer flange projecting from the first side
wall and the second side wall, respectively, in a direction away
from the hollow portion, and a first inner flange projecting from a
top side of the first side wall into the hollow portion, wherein
the base, the first side wall and the second side wall, the first
outer flange and the second outer flange, and the first inner
flange form an open cross-section.
Inventors: |
HIGGINS; Christopher M.;
(Ann Arbor, MI) ; THURGATE; Brian T.; (Ypsilanti,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA,
INC. |
Erlanger |
KY |
US |
|
|
Assignee: |
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA, INC.
Erlanger
KY
|
Family ID: |
59276559 |
Appl. No.: |
15/200977 |
Filed: |
July 1, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B62D 25/2054 20130101;
B62D 21/03 20130101 |
International
Class: |
B62D 21/03 20060101
B62D021/03; B62D 25/20 20060101 B62D025/20 |
Claims
1. A cross member comprising: a base including a first side wall
inclined at a first angle with the base and a second side wall
inclined at a second angle with the base creating a hollow portion
between the first side wall and a second side wall; a first outer
flange and a second outer flange projecting from a top side of the
first side wall and the second side wall, respectively, in a
direction away from the hollow portion; and a first inner flange
projecting from the top side of the first side wall into the hollow
portion, wherein the base, the first side wall and the second side
wall, the first outer flange and the second outer flange, and the
first inner flange form an open cross-section, wherein the first
inner flange is offset from the first outer flange towards the base
to avoid contact with a floor attached to the first outer
flange.
2. The cross member according to claim 1, further comprising a
second inner flange projecting from the second side wall into the
hollow portion forming a symmetric cross-section.
3. (canceled)
4. The cross member according to claim 2, wherein the second inner
flange is offset from the second outer flange towards the base to
avoid contact with the floor attached to the second outer
flange.
5. A cross member comprising: a base including a first side wall
inclined at a first angle with the base and a second side wall
inclined at a second angle with the base creating a hollow portion
between the first side wall and a second side wall; a first outer
flange and a second outer flange projecting from a top side of the
first side wall and the second side wall, respectively, in a
direction away from the hollow portion; and a first inner flange
projecting from the top side of the first side wall into the hollow
portion, wherein the base, the first side wall and the second side
wall, the first outer flange and the second outer flange, and the
first inner flange form an open cross-section, wherein the first
outer flange is offset from the first inner flange towards the base
to avoid contact with a floor attached to the first inner
flange.
6. The cross member according to claim 2, wherein the second outer
flange is offset from the second inner flange towards the base to
avoid contact with the floor attached to the second inner
flange.
7. The cross member according to claim 2, wherein the first inner
flange and the second inner flange are separated by a gap to allow
installation of external components in the hollow portion.
8. A cross member comprising: a base including a first side wall
inclined at a first angle with the base and a second side wall
inclined at a second angle with the base creating a hollow portion
between the first side wall and a second side wall; a first outer
flange and a second outer flange projecting from a top side of the
first side wall and the second side wall, respectively, in a
direction away from the hollow portion; and a first inner flange
projecting from the top side of the first side wall into the hollow
portion, wherein the base, the first side wall and the second side
wall, the first outer flange and the second outer flange, and the
first inner flange form an open cross-section, wherein the first
side wall and the second side wall have a thickness less than a
thickness of the base.
9. The cross member according to claim 1, wherein the first angle
and the second angle is greater than 0.degree. and less than
90.degree..
10-20. (canceled)
21. The cross member according to claim 5, further comprising a
second inner flange projecting from the second side wall into the
hollow portion forming a symmetric cross-section.
22. The cross member according to claim 21, wherein the second
inner flange is offset from the second outer flange towards the
base to avoid contact with the floor attached to the second outer
flange.
23. The cross member according to claim 21, wherein the second
outer flange is offset from the second inner flange towards the
base to avoid contact with the floor attached to the second inner
flange.
24. The cross member according to claim 21, wherein the first inner
flange and the second inner flange are separated by a gap to allow
installation of external components in the hollow portion.
25. The cross member according to claim 5, wherein the first angle
and the second angle is greater than 0.degree. and less than
90.degree..
26. The cross member according to claim 8, further comprising a
second inner flange projecting from the second side wall into the
hollow portion forming a symmetric cross-section.
27. The cross member according to claim 26, wherein the second
inner flange is offset from the second outer flange towards the
base to avoid contact with a floor attached to the second outer
flange.
28. The cross member according to claim 26, wherein the second
outer flange is offset from the second inner flange towards the
base to avoid contact with a floor attached to the second inner
flange.
29. The cross member according to claim 26, wherein the first inner
flange and the second inner flange are separated by a gap to allow
installation of external components in the hollow portion.
30. The cross member according to claim 8, wherein the first angle
and the second angle is greater than 0.degree. and less than
90.degree..
31. The cross member according to claim 8, wherein the first inner
flange is offset from the first outer flange towards the base to
avoid contact with a floor attached to the first outer flange.
32. The cross member according to claim 8, wherein the first outer
flange is offset from the first inner flange towards the base to
avoid contact with a floor attached to the first inner flange.
Description
BACKGROUND
Field of the Disclosure
[0001] This application relates generally to improvements to a
structural member for application to a frame member of a vehicle.
More particularly, the present disclosure relates to improvements
relating to a cross member for supporting a load on a floor of the
vehicle.
Description of the Related Art
[0002] A cross member of a floor of a vehicle (e.g., a bed of a
cargo area of a truck) provides structural support for among other
things, a load acting downwards on the bed. For instance, the cross
member is designed to support the bed of the truck when heavy
objects are dropped onto the bed. The cross member spans the width
of the bed, and is disposed on the underside of the bed.
[0003] Conventionally, the cross member has a U-shaped
cross-section with outer flanges. The cross member structure
includes a pair of side walls, a base, and outer flanges. The side
walls are substantially perpendicular to the base and support
compression and bending caused due to the load acting in a vertical
direction, i.e., perpendicular to the base.
[0004] A vertical load can also cause buckling in the side walls of
the cross member. In order to prevent the buckling due to a
compressive stress, it is necessary to improve the stiffness
(rigidity) of the compression side. For that purpose, conventional
framework members for vehicles are provided with a number of
reinforcing members for the compression-side surface and the
vertical wall part. As a result, the mass and the cost are
unfavorably increased.
SUMMARY
[0005] According to an embodiment of the present disclosure, there
is provided a cross member. The cross member including a base
including a first side wall inclined at a first angle with the base
and a second side wall inclined at a second angle with the base
creating a hollow portion between the first side wall and a second
side wall, a first outer flange and a second outer flange
projecting from a top side of the first side wall and the second
side wall, respectively, in a direction away from the hollow
portion, and a first inner flange projecting from the top side of
the first side wall into the hollow portion, where the base, the
first side wall and the second side wall, the first outer flange
and the second outer flange, and the first inner flange form an
open cross-section.
[0006] Further, there is provided a cross member including a base,
a first side wall inclined at a first angle with the base and a
second side wall inclined at a second angle with the base creating
a hollow portion between the first side wall and a second side
wall. A first outer flange and a second outer flange projecting
from a top side of the first side wall and the second side wall,
respectively, in a direction away from the hollow portion is
formed. A third outer flange and a fourth outer flange projecting
from the base, respectively, is formed in a direction away from the
hollow portion. Furthermore, a first inner flange is projecting
from the top side of the first side wall into the hollow portion,
where the base, the first side wall and the second side wall, the
first outer flange and the second outer flange, the third outer
flange and the fourth outer flange, and the first inner flange form
an open cross-section.
[0007] Furthermore, there is provided a cross member including a
base, a first side wall inclined at a first angle with the base and
a second side wall inclined at a second angle with the base
creating a hollow portion between the first side wall and a second
side wall. A first outer flange and a second outer flange is
projecting from the base in a direction away from the hollow
portion. A first inner flange and a second inner flange is
projecting from a top side the first side wall and the second side
wall, respectively, into the hollow portion, where the base, the
first side wall and the second side wall, the first outer flange
and the second outer flange, and the first inner flange and the
second inner flange form an open cross-section.
[0008] The forgoing general description of the illustrative
implementations and the following detailed description thereof are
merely exemplary aspects of the teachings of this disclosure, and
are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate one or more
embodiments and, together with the description, explain these
embodiments. The accompanying drawings have not necessarily been
drawn to scale. Any values dimensions illustrated in the
accompanying graphs and figures are for illustration purposes only
and may or may not represent actual or preferred values or
dimensions. Where applicable, some or all features may not be
illustrated to assist in the description of underlying features. In
the drawings:
[0010] FIG. 1A is an elevation view of a cross member according to
an exemplary embodiment of the present disclosure.
[0011] FIG. 1B is a perspective view of the cross member according
to an exemplary embodiment of the present disclosure.
[0012] FIG. 1C is an elevation view of a cross member with one
inner flange according to an exemplary embodiment of the present
disclosure.
[0013] FIG. 1D is an elevation view of a cross member with outer
flanges at the bottom according to an exemplary embodiment of the
present disclosure.
[0014] FIG. 2 illustrates an assembly of the cross member and a
floor according to an exemplary embodiment of the present
disclosure.
[0015] FIG. 3 illustrates an assembly of the cross member and a
bracket according to an exemplary embodiment of the present
disclosure.
[0016] FIG. 4 is perspective view illustrating an assembly of the
cross member and the bracket according to an exemplary embodiment
of the present disclosure.
[0017] FIG. 5 illustrates an assembly of several cross members and
a floor of a truck according to an exemplary embodiment of the
present disclosure.
[0018] FIGS. 6A-6M illustrate different configurations of the cross
member according to an exemplary embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0019] The description set forth below in connection with the
appended drawings is intended as a description of various
embodiments of the disclosed subject matter and is not necessarily
intended to represent the only embodiment(s). In certain instances,
the description includes specific details for the purpose of
providing an understanding of the disclosed embodiment(s). However,
it will be apparent to those skilled in the art that the disclosed
embodiment(s) may be practiced without those specific details. In
some instances, well-known structures and components may be shown
in block diagram form in order to avoid obscuring the concepts of
the disclosed subject matter.
[0020] Reference throughout the specification to "one embodiment"
or "an embodiment" means that a particular feature, structure, or
characteristic described in connection with an embodiment is
included in at least one embodiment of the subject matter
disclosed. Thus, the appearance of the phrases "in one embodiment"
or "in an embodiment" in various places throughout the
specification is not necessarily referring to the same embodiment.
Further, the particular features, structures or characteristics may
be combined in any suitable manner in one or more embodiments.
Further, it is intended that embodiments of the disclosed subject
matter cover modifications and variations thereof.
[0021] Furthermore, the terms "approximately," "proximate,"
"substantially," and similar terms generally refer to ranges that
include the identified value within a margin of 20%, 10% or
preferably 5% in certain embodiments, and any values therebetween.
The term "top," "inner," "outer," and the like that may be used
herein merely describe points of reference and do not necessarily
limit embodiments of the present disclosure.
[0022] FIG. 1A is an elevation view of a cross member 100 according
to an exemplary embodiment. The cross member 100 is a support
element that provides reinforcement or support to a load bearing
member such as a floor of a truck. The cross member 100 has an open
cross-section which includes a base 101, side walls 103a and 103b
(also referred as side walls 103 hereinafter), outer flanges 105a
and 105b (also referred as outer flanges 105 hereinafter), and
inner flanges 107a and 107b (also referred as inner flanges 107
hereinafter).
[0023] The side walls 103a and 103b are formed at an angle with
respect to the base 101 forming a V-like shape and creating a
hollow portion 110 between the sidewalls 103a and 103b. Further,
the outer flanges 105a and 105b are formed at one end of the side
wall 103a and 103b, respectively. For example, the outer flange
105a extends away and the outer flange 105b extends away from the
hollow portion 110. In addition, the inner flanges 107a and 107b
are formed at one end (same end as the outer flanges 105) of the
side wall 103a and 103b, respectively. For example, the inner
flange 107a extends inwards and the inner flange 107b extends
inwards into the hollow portion 110. The outer flanges 105 and the
inner flanges 107 are parallel or substantially parallel to the
base 101.
[0024] The inner flanges 107 can be offset relative the outer
flange 105 in the z-direction. In one embodiment, the outer flanges
105 and the inner flanges 107 can also be located at an end of the
sidewalls 103 distal from the base 101. Further, referring to FIG.
1C, only one inner flange may be included at a top side of the side
walls to form a first cross member 100C. Alternatively or in
addition, referring to FIG. 1D, the outer flanges 105 can be formed
projecting from the base 101 to form a second cross member 100D. It
can be understood by a person skilled in art that several
variations of the configuration can be achieved by varying the
location of one or more outer flanges at the top side of the side
walls, one or more outer flanges projecting from the base, and one
or more inner flanges. FIGS. 6A-6M illustrate possible variations
in the configurations of the cross member 100. Additional
variations in configuration the cross member 100 are possible as
well. In certain situations with space limitations, for example,
when supporting the floor close to the edge of the floor; the cross
members such as in FIGS. 6E, 6F, and 6I can be more useful compared
to the cross members in FIG. 6A, 6B or 6D.
[0025] The cross member 100 can have a variable thickness and
length. For example, the base 101 has a thickness t.sub.B and a
length L.sub.B. The side walls 103a and 103b have a thickness
t.sub.w1 and t.sub.w2, respectively, and are inclined at an angle
.theta..sub.w1 and .theta..sub.w2, respectively, with respect to
the base 101. The angles of the side walls 103 can be greater than
0.degree. and less than 90.degree.. The side walls 103 inclined at
an angle to the base 101 are less likely to buckle and more likely
to spread outwards or open up compared to vertical sides wall that
are inclined at approximately 90.degree., since the side walls 103
will experience a bending moment at a connection with the base 101
due to the force acting on the outer flanges 105. However, a floor
is attached to the outer flanges 105 that can keep the shape of the
side walls 103 intact under loading conditions.
[0026] The outer flanges 105a and 105b have a thickness t.sub.o1
and t.sub.o2, respectively, and a length L.sub.o1 and L.sub.o2,
respectively. The outer flanges 105 are at a height H from the base
101. The lengths L.sub.o1 and L.sub.o2 can vary depending on the
space limitation, for example, L.sub.o2 can be comparatively
shorter than L.sub.o1 when the cross member 100 is attached at an
edge of the floor 200. Similarly, the angles .theta..sub.w1 and
.theta..sub.w2 of the side walls 103 due to space constraints.
[0027] The inner flanges 107a and 107b have a thickness of t.sub.i1
and t.sub.i2, respectively, and a length L.sub.i1 and L.sub.i2,
respectively. Furthermore, a gap L.sub.G is maintained between the
inner flanges 107a and 107b to form an open cross section of the
cross member 100. The gap L.sub.G can allow assembly of additional
components within the hollow portion 110. The lengths L.sub.i1 and
L.sub.i2 can vary depending on the space limitation or components
installed in the hollow portion 110, for example, L.sub.i2 can be
comparatively shorter than L.sub.i1.
[0028] The thickness and length, respectively, of the outer flanges
105 can be substantially similar. Also, the thickness and length,
respectively, of the inner flanges 107 can be substantially
similar. Furthermore, the side walls 103 can have a substantially
similar thickness and angles, respectively. As such, the cross
member 100 can have a substantially symmetric cross-section.
However, the present disclosure is not limited to aforementioned
lengths, thickness, and angles and variations in the aforementioned
dimensions are possible. For example, an asymmetric cross-section
can be formed by constructing the side wall 103a thicker than the
side wall 103b, by constructing the angles angle .theta..sub.w1 and
.theta..sub.w2 different from each other, or a combination
thereof.
[0029] The side walls 103 can have a thickness less than that of
the base 101. Additional material can be added to the base 101, the
outer flanges 105, the inner flanges 107 or a combination thereof,
to increase the area moment of inertia (I-value hereinafter). The
I-value of the cross member 100 can be greater than the I-value of
a U-shaped cross member having a generally uniform wall and
substantially similar total mass as the cross member 100.
Alternatively or in addition, the I-value of the cross member 100
can be increased, while keeping the total mass substantially
unaffected, by adding material to the outer flanges 105 and (or)
the inner flanges 107. For instance, the length, thickness, or both
of the outer flanges 105 and/or the inner flanges 107 can be
increased. As such, material can be spread away from the centroid C
providing greater stability and structural strength to the cross
member 100 relative to cross members having uniform wall thickness
and substantially similar mass.
[0030] The cross member 100 can be made of lesser volume of
material compared to a U-shaped cross-member. In such case, the
cross member 100 will have a lower mass with an equivalent I-value
compared to the U-shaped cross member. For example, the cross
member 100 and the U-shaped cross member may have similar I values,
but the cross member 100 may be formed of less material, for
instance, over 10% mass saving can be realized.
[0031] The cross member 100 can be made from various materials
including but not limited to aluminum, cast iron, and steel. The
cross member 100 can be manufactured using various manufacturing
processes, for example, extrusion, casting, molding, injection
molding (e.g., when the cross member 100 is made of plastic
material). The manufacturing process can impose limitation on the
minimum or maximum dimensions of the cross member 100 discussed
earlier.
[0032] FIG. 1B illustrates a perspective view of the cross member
100 according to an exemplary embodiment of the present disclosure.
The cross member 100 is manufactured using the extrusion process.
The cross member 100 has a length L; the inner flanges 103 and the
outer flanges 105 extend along the entire length L. In certain
embodiments, additional components can be attached to the cross
member 100 in a sliding manner or can be fixed using fasteners such
as screw, nuts and bolts, or adhesive. The inner flanges 107 and/or
the outer flanges 105 can be modified to attach an additional
component, to reduce the weight, etc. For example, a portion of the
inner flanges 107 and/or the outer flanges 105 can be cut out.
Holes may be drilled in the inner flanges 107, the outer flanges
105, the base 101, or a combination thereof to attach additional
components to the cross member 100.
[0033] FIG. 2 illustrates an assembly of the cross member 100 and a
floor 200 according to an exemplary embodiment. The floor 200 can
be welded to the outer flanges 105 of the cross member 100. The
outer flanges 105 can be fixed to the underside of the floor 200 by
spot weld or other joining technology. The inner flanges 107
separated from the floor 200 by gaps G.sub.1, and G.sub.2, since
the inner flanges 107 are slightly offset relative to the outer
flanges 105. The construction of the inner flanges 107 can provide
several advantages in an assembled condition.
[0034] The gaps G.sub.1, and G.sub.2 can prevent the inner flanges
107 from coming in contact with the floor 200 and prevent any
potential noise that may be generated due to a surface-to-surface
contact (e.g., metal-to-metal contact), under normal operating
conditions. In case of an excess loading condition or while driving
on an uneven road, the inner flanges 107 can provide extra support
to the floor 200 as the floor 200 may buckle.
[0035] The floor 200 can be attached to one of the outer flanges
105a or 105b, one inner flange 107a or 107b, both the inner flanges
107, or a combination thereof. Accordingly, the offset between the
outer flange 105 and the inner flange 107 may be modified.
[0036] The floor 200 can be removably attached to the cross member
100 using fasteners such as screws, and bolts. Further, rubber
inserts may be added to reduce any noise that may be generated
during operation due to use of fasteners.
[0037] FIG. 3 illustrates an assembly of the cross member 100 and a
bracket 300 according to an exemplary embodiment. The bracket 300
can be placed in the hollow portion 110 between the side walls 103
and rest on the base 101. The bracket 300 can be included to
provide additional support to the floor 200, for example, by
sharing a load F acting vertically downwards on the floor 200.
[0038] FIG. 4 is a perspective view illustrating an assembly of the
cross member and the bracket 300 according to an exemplary
embodiment. The bracket 300 can be installed along the length of
the cross member 100. Further, the bracket 300 can be fixed or
installed in a sliding manner to the cross member 100.
[0039] FIG. 5 illustrates an assembly of several cross members and
a bed 500 of a truck according to an exemplary embodiment. The
cross members 100a, 100b, and 100c can be attached underneath the
bed 500 of a cargo area of the truck. The cross members 100a and
100b can be arranged at a distance d.sub.1 apart; while the cross
members 100b and 100c can be separated by distance d.sub.2. The
cross members 100a, 100b and 100c can be arranged equidistance
(i.e., d.sub.1 substantially equal to d.sub.2) from each other.
Alternatively or in addition, the cross members 100a, 100b and 100c
can be arranged at a non-uniform distance (i.e., d.sub.1
substantially different from d.sub.2) from each other.
[0040] While certain embodiments have been described, these
embodiments have been presented by way of example only, and are not
intended to limit the scope of the present disclosures. Indeed, the
novel methods, apparatuses and systems described herein can be
embodied in a variety of other forms; furthermore, various
omissions, substitutions and changes in the form of the methods,
apparatuses and systems described herein can be made without
departing from the spirit of the present disclosures. The
accompanying claims and their equivalents are intended to cover
such forms or modifications as would fall within the scope and
spirit of the present disclosures.
* * * * *