Vehicle Support Frames with Interlocking Features for Joining Members of Dissimiliar Materials
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.
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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 FIELDThe present disclosure relates to vehicle support frames with members having dissimilar materials and methods for manufacturing the same.
BACKGROUNDConventional 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.
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.
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.
Therefore, it is desirable to have improved interconnecting techniques for joining two structural members composed of dissimilar materials.
SUMMARYThe present disclosure addresses one or more of the above-mentioned issues. Other features and/or advantages will become apparent from the description which follows.
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.
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.
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.
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.
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.
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.
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.
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.
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:
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.
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.
Referring now to
At the frontward end of the support frame 10, shown in
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.
The cross-member 90 and interconnecting member 120 of
Referring now to
As shown in
Referring now to
An end of cross-member 330 is crimped with the interconnecting member 320, as shown in
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
Turning now to the illustrated embodiment of
In the illustrated embodiment of
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.
Referring now to
In
Now with reference to
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
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
Crimps can be formed in different positions with respect to the first rail (or cross-member). For example, as shown in
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
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.
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.
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.
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.
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.
Type: Application
Filed: Sep 22, 2011
Publication Date: Jan 31, 2013
Applicant:
Inventors: David Anthony Wagner (Northville, MI), Michael M. Azzouz (Livonia, MI), Ari Garo Caliskan (Canton, MI), Sunil K. Kasaragod (Canton, MI), Xiaoming Chen (Canton, MI), John Edward Huber (Novi, MI), Yuksel Gur (Ann Arbor, MI), Parameswararao Pothuraju (Canton, MI), Jeffery Wallace (Walled Lake, MI)
Application Number: 13/239,592
International Classification: B62D 21/00 (20060101); B29C 65/56 (20060101); B29C 65/52 (20060101); B23K 31/02 (20060101);