Patent Application
20230226591
Exemplary arrangements relate to vehicle frame components. Exemplary arrangements further relate to vehicle frame components that have increased strength and lower weight. Exemplary arrangements further relate to methods of making vehicle frame components.
Vehicles include frame components that provide rigidity to vehicle structures, such as the structures of motor vehicles. Vehicle structures provide load bearing capabilities during normal vehicle operation. Vehicle structures further provide rigidity as well as energy absorbing capabilities that protect occupants of the vehicle during a collision.
Vehicle frame components of vehicle structures may have many different configurations to accommodate the needs of different types of vehicles. These include vehicles propelled by internal combustion engines, electric motors and other types of propulsion systems. It is often desirable for vehicle frame components to be lighter in weight to provide greater energy efficiency.
Numerous different types of vehicle frame components and vehicle structures have been developed. However vehicle frame components and vehicle structures and the methods of making such structures may benefit from improvements.
Exemplary arrangements relate to frame components configured to be integrated in a vehicle body structure, and methods of manufacture thereof. Exemplary arrangements provide frame components that are included in vehicle structures such as for example, vehicle side frames, vehicle floor members and vehicle frame longitudinal members. Exemplary arrangements provide the capability of producing frame components and vehicle structures that have increased strength and lower overall weight.
Exemplary arrangements include a frame component that includes a first wall comprised of at least one metal sheet and a second wall comprised of at least one metal sheet. The walls are disposed away from one another to provide an interior gap between the walls. The interior gap extends between the inside surfaces of the first wall and the second wall. The sheets are operatively joined together such that the gap between the sheets is hermetically sealed.
A fluid connector is in operative connection with at least one of the first wall and the second wall. The fluid connector is configured to deliver pressurized fluid through the connector and a respective wall into the interior gap between the walls. The introduction of the pressurized fluid into the interior gap is operative to increase the strength of the frame component beyond that that would be achieved by the structure absent the delivered fluid. As used herein increased strength refers to a higher resistance force to deformation such as a compression, bending and/or torsion.
In some exemplary arrangements the fluid pressure is operative to permanently deform at least one of the first wall or the second wall. Such deformation caused by the delivery of the fluid into the interior gap further operates to provide wall profiles that have desirable properties. This may include for example increased strength as well as providing areas that are intended to be deformed to absorb energy in the event of a collision to protect the vehicle occupants. In some exemplary arrangements the controlled deformation of the walls of the frame component is carried out by the delivery of the fluid into the interior gap while one or more walls of the frame component is held by adjacent pressure plates or other structures that provide for controlled deformation of the wall surfaces and desired final internal or external contours. Such external contours may include flattened surface areas on the wall surfaces or desired contoured areas of the wall surfaces as may be usable to achieve desired properties of the vehicle structure in the areas of the frame component.
In other exemplary arrangements the frame component may include a pocket in the sealed interior area between the first wall and the second wall. In such exemplary arrangements the pocket includes an interior area that is bounded by a pocket wall. The fluid connector is configured to deliver the pressurized fluid into the pocket interior area. Further in some exemplary arrangements the delivery of pressurized fluid is operative to cause the pocket wall to permanently deform. The delivery of the pressurized fluid into the pocket, and in some arrangements the deformation of the pocket within the gap between the first and second walls is operative to increase strength of the frame component.
In some exemplary arrangements the first wall and the second wall have a variable transverse thickness in different regions across the frame component. The difference in transverse wall thickness in the various regions may be achieved in exemplary arrangements through forming or machining processes that are associated with forming the wall surfaces. Such processes in some arrangements may enable a single continuous sheet to have a transverse thickness that varies with unbroken smooth continuity from region to region. Alternatively or in addition, variable transverse thickness of the sheets may be achieved by providing multiple sheets joined in overlapping fixed relation to produce a wall of the frame component. In some arrangements the multiple sheets may be of the same material or may be comprised of different materials.
In exemplary arrangements the utilization of different transverse wall thickness in different regions, which are also referred to as areas, of the frame component enables selectively controlling the permanent deformation that is imparted to the walls as a result of the introduction of the fluid into the interior gap. Further varying the transverse thickness and properties of the walls in different regions enables selectively controlling the strength of the particular region as well as the magnitude and direction of forces that will cause deformation of the frame component during a collision to absorb energy.
In exemplary arrangements the pressurized fluid that is introduced into the sealed interior gap between the walls may be varied with the materials being used as well as the desired strength and other properties to be achieved by the frame component. Fluids that may be used in certain arrangements include air, nitrogen containing gases, inert gases, water-based liquids, petroleum-based liquids, non-Newtonian fluids, foams, fluid cement, fluid concrete, flowable natural materials (such as natural rubber) and fluid plastic polymers. In some exemplary arrangements the fluids may be configured to remain within and cure and harden after introduction to the gap, while in other arrangements the fluids introduced may remain in a gaseous or liquid state or may be removed. Different approaches may be taken to achieve the desired frame component properties. Further in exemplary arrangements the fluid connector which is utilized to introduce the fluid into the sealed interior area of the frame component may be in operative connection with a check valve, which prevents the fluid from flowing out of the gap. In other exemplary arrangements the connector may be associated with a relief valve arrangement that is configured to enable the fluid to escape in the event that the fluid pressure exceeds a set level. Of course numerous different approaches may be used.
In exemplary arrangements one or more of the frame components may be configured to be integrated into a vehicle structure that provides the desired strength and rigidity of the vehicle structure. In exemplary arrangements the frame component is integrated into vehicle structures that are part of a motor vehicle such as an internal combustion engine powered, electric or hybrid powered vehicle. In some exemplary arrangements the frame component is integrated into a vehicle side frame, which is configured to provide strength to a respective side surface of the vehicle. Such a vehicle side frame may include the structures that operatively bound an access opening to an interior area of the vehicle. In such exemplary arrangements commonly a pair of vehicle side frames are utilized, and multiple portions of the vehicle structure may include respective frame components integrated therein.
In other exemplary arrangements the exemplary frame component may be integrated into a vehicle structure such as a floor member. In exemplary arrangements the floor member may comprise a plurality of structures such as annular structures that provide a lower platform or other support of the vehicle structure. For example in some arrangements such floor members may provide the support and/or housing structures for items such as batteries, fuel tanks, motors, engines or other similar vehicle components. Such floor members may also provide the structures that operatively bound the vehicle passenger compartment. Such floor members may include multiple different portions depending on the nature of the vehicle. In exemplary arrangements each of the different structures of the floor member may include frame components which provide enhanced strength and/or desired controlled deformation or other properties.
In other exemplary arrangements exemplary frame components may be integrated into other structures such as vehicle frame longitudinal members. Such vehicle frame longitudinal members may include central portions that are configured to be positioned in a central area of the vehicle. Such frame longitudinal members may further include a front portion that is configured to be directed from the central portion and toward the front of the vehicle. Other exemplary arrangements may include rear portions configured to be directed from the central portion and toward the rear of the vehicle. Other exemplary arrangements may include transition portions and/or annular portions which provide certain properties and/or facilitate controlled deformation. Such transition portions may be positioned intermediate of the central portion and the front portion and/or the rear portion. In exemplary arrangements one or more frame components of exemplary arrangements may be integrated into the vehicle structures associated with the vehicle frame longitudinal member.
Of course it should be understood that these are only some examples of vehicle structures in which frame components of exemplary arrangements may be integrated. Exemplary frame components may be integrated into other vehicle structures as well depending on the particular vehicle construction. For example exemplary frame components may be integrated into door structures, roof structures, roll bars, cargo beds, compartment bounding structures, body panels and other vehicle structures. Further it should be understood that in some exemplary arrangements vehicles may comprise one or more of the exemplary vehicle side frame, vehicle floor member and vehicle frame longitudinal member structures that are discussed herein. In exemplary arrangements one or more of such structures that are included as parts of a single vehicle may each include one or more of the vehicle frame component structures as described herein.
In exemplary arrangements the exemplary frame component structures may be produced utilizing methods which result in frame components and vehicle structures which have the desired features and properties for the particular vehicle structure. In exemplary arrangements the methods may include producing a preform structure. For purposes hereof a preform structure shall be considered to be a structure having the preliminary shape, transverse thickness and materials of the desired frame component. In an exemplary arrangement the method is carried out by joining in engaged relation a first wall comprising at least one metal sheet and a second wall comprising at least one further metal sheet, such that the first wall and the second wall bound a hermetically sealed interior gap between the walls. The exemplary method further includes delivering via a fluid connector, pressurized fluid into the interior gap and through the first wall or the second wall. The delivered fluid is operative to increase the strength of the frame component.
In further exemplary methods the delivered fluid may be operative to permanently deform one or both of the first wall and the second wall to provide desired surface contours. In some exemplary methods pressure plates or other bounding structures may be utilized during deformation to achieve desired surface contours. Likewise different regions of the walls may have different transverse thicknesses and/or different material properties to achieve desired deformation and frame component configurations.
Further in some exemplary arrangements a hermetically sealed pocket may extend between the walls in the interior gap. Fluid may be delivered into the pocket in various methods so as to provide added strength. Alternatively or in addition in some further methods the fluid introduced into the pocket may cause permanent deformation of the pocket wall that bounds the pocket within the interior gap. Numerous additional or different method steps may be utilized for purposes of producing the desired frame components and vehicle structures.
Additional features and relationships of exemplary arrangements are described in further detail in the appended drawings and the following Detailed Description.
Referring now to the drawings and particularly to
In the exemplary arrangement the side frame 22 has an annular structure as shown in
The exemplary vehicle side frame 22 includes a front pillar portion 1. The front pillar portion is connected to a roof frame portion 2. The roof frame portion 2 extends to a rear pillar portion 3. The rear pillar portion extends to a sill portion 4, which is connected to the front pillar portion. In an exemplary arrangement these portions are connected to one another and form an annular frame structure. Of course it should be understood that this particular vehicle side frame structure is exemplary and in other arrangements other configurations may be used.
In exemplary arrangements a frame component of a vehicle side frame is comprised of an inner wall 6 and outer wall 7. Each of the inner wall and the outer wall are comprised of at least one metal sheet. In some exemplary arrangements the at least one metal sheet of each of the walls does not have a uniform cross-sectional thickness across the entire structure. Rather in some exemplary arrangements each of the areas (which are also referred to herein as regions) shown with different hashing, have a transverse cross-sectional wall thickness that is different from other regions of the particular wall. This exemplary approach of having different transverse cross-sectional wall thicknesses in different regions of each of the walls may be referred to herein as a patchwork arrangement. This approach of regions of variable transverse wall thickness are used in exemplary arrangements to provide desired strength properties and areas for controlled deformation and energy absorption of the exemplary vehicle side frame members.
As represented in
In this exemplary arrangement of the vehicle side frame 22 each of the metal sheets 6, 7 that comprise the walls have varying thicknesses in the different regions of the vehicle side frames to achieve desired functional characteristics. As a result the vehicle side frame has different properties of strength and rigidity in the regions having the higher transverse sheet thicknesses. In the exemplary arrangement the variations in thickness of the at least one metal sheet that comprises the respective walls 6, 7 may be achieved in different ways. This may include for example using approaches such as press forming, rolling and joining multiple sheets having different thicknesses. Such joining may be accomplished through numerous different methods such as by welding, gluing, melting or other different attachment and joining approaches.
In other exemplary arrangements varying sheet thicknesses for the walls that bound the frame component of vehicle side frame structure may not be utilized. For example in some arrangements the wall thicknesses of each of the walls may be uniformly the same, or may begin as a preform structure in which the wall thicknesses on each side thereof are uniformly the same. However it should be understood that in alternative arrangements the walls may be made of different materials and may have different transverse thicknesses to achieve the desired properties of the vehicle structure. Further in other exemplary arrangements multiple overlying metal sheets may be utilized to form respective walls of the exemplary frame component structure. Such sheets may be of different thicknesses and materials depending on the properties that are desired for the particular vehicle frame structure.
In exemplary arrangements vehicle frame structures include at least one frame component that is configured to be integrated in a vehicle structure to provide added strength. Such an exemplary frame component 26 is shown for example in
In the exemplary arrangements the frame component that is integrated into the side frames or other structures includes a sealed interior gap 28. The exemplary sealed interior gap extends intermediate of the inside faces of the first wall 6 and the second wall 7. In exemplary arrangements the hermetically sealed interior gap is formed by the walls being hermetically sealed in operatively joined connection. In exemplary arrangements the walls may be joined in hermetically sealed connection by welding or other sealing or joining methods.
The exemplary frame component 26 further includes a fluid connector 8. The exemplary fluid connector which may be alternatively referred to herein as a valve element, provides a connector that enables a fluid such as a gas or liquid to pass therethrough and through one of the walls and into the interior gap 28. As shown in the exemplary arrangement in
Further in some exemplary arrangements the fluid connector 8 may be in operative connection with a valve element schematically indicated 30. In some exemplary arrangements the valve element 30 may provide the function of a check valve. The exemplary check valve may enable the pressurized fluid to be delivered into the sealed interior gap 28 while preventing the escape of fluid therefrom. In such arrangements the check valve may help to assure that the fluid that is delivered into the hermetically sealed interior gap is retained therein for purposes of increasing the strength of the frame component and the associated vehicle structure in which the frame component is integrated.
In other exemplary arrangements the valve element 30 may comprise a pressure relief valve. In such exemplary arrangements the pressure relief valve may be operative to release the fluid from the gap in the event that the pressure thereof exceeds a set relief pressure. Such a valve element in exemplary arrangements may provide for controlled release of the pressure as a result of deformation of the frame component in a collision or in other circumstances where it may be desirable to release the fluid provide controlled deformation of the frame component structure. Of course it should be understood that this arrangement is exemplary and other arrangements other approaches may be used.
In some exemplary arrangements of the frame component 26 the walls are joined in operatively hermetically sealed engagement via a seal generally indicated 12. In the exemplary arrangement shown the outer and inner edges of the walls are joined through suitable welding and/or other sealing methods as necessary to achieve a fluid tight, hermetically sealed interior area. This may be done for example in the fabrication of a suitable preform structure of the vehicle side frame or other vehicle structure that includes the frame component. However in other arrangements other structures may be utilized in intermediate relation of the walls to provide a suitable sealed enclosure for the interior gap.
In some exemplary arrangements a sealing process step is performed by joining the edges of the walls 6, 7, each of which comprise at least one metal sheet. The sealing process is carried out after the walls have been matched in aligned and overlying relation with one another. In exemplary arrangements the sealing step is performed on the circumferential edges of the matched walls 6, 7 of the vehicle side preform which include the frame component structure. In some exemplary arrangements sealing may be performed by welding the corresponding edges together resulting in the formation of the circumferential welds. In exemplary arrangements by sealing the circumferential edges a leakproof hermetic sealed interior gap 28 is formed between the inner surfaces of the walls of the frame component of the vehicle side preform. Of course it should be understood that this approach to joining the walls in hermetically sealed relation is exemplary and in other arrangements other process steps, structures and materials may be used. For example the at least one sheet which comprises each respective wall, or in some cases intermediate structures which bound the sealed interior gap, may be joined by approaches that include welding, soldering, gluing, bending, pressing, molding, caulking or other suitable approaches for achieving hermetically sealed operative connection of the first wall and the second wall.
In exemplary arrangements in producing an exemplary vehicle side frame that includes one or more of the exemplary frame component structures that provide increased strength and other suitable properties, the walls 6, 7 may be joined in operative connection at the circumferential edges. Further additional sealing steps or structures may be added or applied to achieve a sealed interior gap 20 between the walls that is in hermetically sealed connection. Such sealing may include the application of suitable seal materials or the use of other sealing steps to assure that the interior gap of the frame component comprises a hermetic inner empty space that is leakproof with respect to the fluid that is to be introduced into the sealed interior area. Various approaches may be taken in exemplary arrangements to achieve these properties, and the approaches utilized may vary with the particular type of pressurized fluid that is to be delivered into the sealed interior gap.
In exemplary arrangements in the method of producing the frame component which provides additional strength and/or other properties to the vehicle structure in which it is integrated, an external source of pressurized fluid is connected to the fluid connector 8 through a suitable supply conduit. In some exemplary arrangements the fluid may comprise compressed air at an elevated pressure. However in other exemplary arrangements the fluid may include other types of gases such as an inert gas or nitrogen containing gas. In other exemplary arrangements the fluid may include a water-based liquid, a petroleum-based liquid, a non-Newtonian fluid, a fluid cement, fluid concrete, a flowable natural material such as liquid rubber, a fluid plastic such as a fluid plastic polymer, or a foam material. For example in some exemplary arrangements the fluid plastic that is delivered through the connector 8 may comprise a one, two or three component foam (such as a flex 140 type). In various exemplary arrangements the fluid may be of a type that remains in its initial gaseous or liquid state after being introduced into the sealed interior gap. In other exemplary arrangements the introduced liquid may cure which results in the fluid having other properties. For example in some exemplary arrangements the fluid may harden as it cures into a suitable solid or semi solid material which is housed within the sealed interior gap to provide the desired properties. In other arrangements the fluid may deform or coat the surfaces bounding the interior gap and then be removed.
In exemplary arrangements the fluid that is delivered into the sealed interior gap may be delivered in various ways to assure that a defined pressure and/or a defined quantity of the material is delivered into the interior gap. Various approaches for introducing the fluid material may be utilized to assure that the interior gap achieves the desired internal pressures as may be desired to achieve the additional strength of the frame component in its location within the particular vehicle structure.
In some exemplary arrangements such as for example the arrangement shown schematically in
In exemplary arrangements of the vehicle side frame structure 22, frame components which are deformed and strengthened through the introduction of pressurized fluid are included in the front pillar portion 1, the roof frame portion 2, the rear pillar portion 3 and the sill portion 4. Of course it should be understood that the selection of the particular wall thicknesses, extent of deformation, dimensions and configurations of the frame components integrated in the vehicle side frame structure are selected to achieve the desired operational and safety parameters. These include the rigidity and strength of the structure as well as the inclusion of controlled deformation zones within the vehicle side frame structure and other structures to which the vehicle side frame is operatively connected. Various approaches may be taken to achieve the desired capabilities of the particular vehicle structure.
In exemplary arrangements the introduction of the fluid to the hermetically sealed interior gap area of the frame component may be done at room temperatures, or in other environments or conditions. Different environmental conditions for the process of producing the particular frame components and vehicle structures may depend on the particular materials and fluids that are utilized. For example in the making of a vehicle side frame such as is shown in
Another exemplary arrangement of a vehicle structure comprising a vehicle side frame 32 is shown in
In the exemplary arrangement vehicle side frame 32 includes flattened regions 9 that extend on the inner wall 6 and on the outer wall 7 of the frame component structure. In this exemplary arrangement the flattened regions have a substantially flat external surface. The exemplary flattened regions 9 enable the attainment of desired properties of the vehicle side frame. Such flattened regions may also provide suitable mounting areas for structures included in the particular vehicle.
In the exemplary arrangements the flattened regions of the walls is achieved through permanent deformation of the walls while such walls are positioned intermediate of pressure plates 13 or other similar structures that restrict the amount of deformation and which determine the final configuration of the walls of the frame component structure. In exemplary arrangements during the introduction of the pressurized fluid into the sealed interior gap 28, the force of the pressure plates acting against the deforming walls 6, 7 cause the walls to deform in a manner that corresponds to an abutting portion of the pressure plates. This is represented for example in
In some exemplary arrangements the pressure plates may be operated to provide a controlled force in a direction towards the immediately adjacent wall of the frame component of the vehicle side frame preform. During the step of delivering the pressurized fluid into the sealed interior gap 28, the frame component 26 is held in intermediate relation of the pressure plate 13 and a fixed plate structure or alternatively a pair of opposed movable pressure plates. In accordance with exemplary arrangements the walls of the exemplary frame components are deformed to have flattened regions 9 of the desired configurations in the regions where the surfaces of the pressure plates 13 are engaged with the respective outer surfaces of the walls 6, 7. This is represented for example by the flattened regions 9 shown on the frame component 26 shown on the right side of
In some exemplary arrangements it may be desirable to provide frame components that are deformed in a free manner without flattened regions in certain areas of the vehicle structure such as the vehicle side frame. This may be done to achieve the particular desired properties in the area of the frame component. For example in
Further it should be understood that in exemplary arrangements different materials as well as differing transverse wall thicknesses may be utilized in different frame components to achieve desired wall configurations and properties of the particular area of the frame component in the vehicle structure. Additionally the nature of the pressurized fluid that is introduced into the sealed interior gap 28, as well as the amount, properties and pressure conditions of the fluid that is retained in the sealed interior gap after the manufacturer of the frame component has been completed may enable tailoring the particular properties of the frame component and the vehicle structure to that desired for the particular vehicle application.
Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
The exemplary vehicle side frame 34 includes portions similar the vehicle side frames 22 and 32 previously discussed. These include a front pillar portion 1, a roof frame portion 2, a rear pillar portion 3 and a sill portion 4. In addition vehicle side frame 34 further includes a central pillar portion 5. The exemplary central pillar portion 5 extends intermediate of the front pillar portion and the back pillar portion. The central pillar portion 5 further extends in operatively engaged relation with each of the roof portion and the sill portion. In the exemplary arrangement the pillar portion 5 may serve to divide the vehicle access opening 24 which is bounded by the vehicle side frame. This may be done for example to provide a pair of side-by-side openings into areas of a vehicle passenger compartment. Alternatively this arrangement may be suitable for providing an opening into a passenger compartment with a vertical reinforcement that supports the roof portion above a passenger area as well as a storage area. Further it should be understood that while in the exemplary arrangement the pillar portion 5 extends substantially vertically, in other exemplary arrangements the central pillar portion may extend at different angles across the vehicle access opening depending on the desired strength or other characteristics that are desired.
In this exemplary arrangement the frame component 26 extends in each of the front pillar portion 1, the central pillar portion 5, the rear or back pillar portion 3 and the sill portion 4. In the exemplary arrangement the frame component includes the first or inner wall 6 and the second or outer wall 7 as shown in the cross-section taken along line 9-9 in
In exemplary arrangements the use of the pocket structures in the sealed interior gap may be utilized to produce different properties of the frame component depending on what is desired. In the exemplary arrangement shown in
Further in exemplary arrangements the pocket may be deformed by the introduction of the pressurized fluid (which in exemplary arrangements may comprise a gas such as air) that is introduced into the pocket interior area 38. In exemplary arrangements the permanent deformation of the pocket wall 36 as well as in some arrangements one or more of the walls 6, 7, may provide for local deformation configurations that provide the desired cross-sectional shape and other properties in the area of the frame component.
Further in other exemplary arrangements in which the pressurized fluid is configured to remain in the pockets 10, may provide other desired properties of the exemplary frame component and the vehicle structure in which the pockets are integrated. Additionally the characteristics of the fluid material which remains within the pockets may help to achieve desired properties and characteristics for the particular areas in which the frame components are integrated. In addition the changes that result from the deformation of the pockets and/or the bounding walls of the sealed interior gap 28 may additionally provide features and strength properties which are desirable for the particular vehicle frame structure. These exemplary approaches enable the vehicle structure to have characteristics and properties that are best suited to the particular design needs while maintaining a suitably light weight.
A further exemplary arrangement of a vehicle side frame 40 is shown in
In exemplary arrangements the hermetically sealed pockets 10 into which the non-Newtonian fluid is delivered may be assembled as a separate structure that is installed in the vehicle side frame at the time that the preform structure is produced. In other alternative arrangements the configuration of the sealed pockets may be permanently deformed by the introduction of a pressurized fluid initially, which initial fluid is then removed and replaced in the pockets by the non-Newtonian fluid after the final configuration of the metal frame components have been formed. This may be accomplished through the fluid connector 8 and other valve elements like those that have been previously discussed. Thus in such exemplary arrangements the fluid connector 8 serves to introduce pressurized fluid into the pocket interior area 38 through the frame component wall 6 and the pocket wall 36 to provide for wall deformation if desired, thereafter the initial fluid may be removed and the suitable non-Newtonian filler 11 introduced and sealed in place.
Of course it should be understood that in exemplary arrangements the filler 11 that is introduced into the exemplary pockets 10 is not limited to a non-Newtonian fluid. In some exemplary arrangements the filler introduced may provide the desired strength properties, sound deadening properties and/or antivibration properties. For example in some exemplary arrangements the filler material 11 may include a one, two or three component foam or other deformable solid or semi-solid material.
Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
A further alternative exemplary vehicle side frame 42 is shown in
In this exemplary arrangement the vehicle side frame 42 includes a plurality of frame components 26. Each of the frame components include respective walls 6 and 7 which bound a sealed interior gap 28 in the manner like that previously described. Further the frame components include a pocket 10 that extends in the lower portion of the front pillar portion 1 and the sill 4. A further frame component extends in the rear or back portion 3 and the rear most central pillar 5 as well as the rear portion of the sill 4. Similar to the prior described arrangements each pocket includes a pocket wall 36 that bounds a pocket interior area 38. A respective fluid connector 8 is operative to deliver pressurized fluid into each of the respective pockets.
In exemplary arrangements the respective frame components may have pocket walls that comprise metal sheet that is permanently deformable responsive to fluid pressure. Alternatively in other exemplary arrangements the pocket walls may comprise flexible material that is not permanently deformable. In some exemplary arrangements the pocket interior areas 38 may be filled with a filler 11 that provides additional strength to the particular regions of the vehicle structure in which the frame components extend. In other exemplary arrangements the pocket interior areas may house a foam material that provides soundproofing, antivibration and/or additional strength properties. Further it should be understood that in some exemplary arrangements the frame components may house different types of filler materials depending on the desired properties of the particular frame component. As a result a single vehicle structure may include multiple frame components that house different types of filler materials or other fluid materials to achieve the desired strength and other properties.
Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
Exemplary arrangements of vehicle structures that include frame components of the exemplary arrangements were produced in accordance with the manufacturing methods described herein. The produced vehicle structures were then subject to comparative tests to determine properties of vehicle structures of exemplary arrangements compared to similar vehicle structures produced by prior art existing methods.
Evaluation of the exemplary vehicle side frames shown in
As shown in Table 1 the side frames made in accordance with the exemplary arrangements described herein, is lighter in weight than the exemplary side frames manufactured via prior art technology. The side frame of the exemplary arrangements made from a 0.8 mm thick wall sheets also demonstrated higher compressive rigidity along both the vertical axis Z and the horizontal axis X.
Similar comparative tests based on numerical calculations were performed for a vehicle side frame manufactured in accordance with the manufacturing methods including the frame components structures described herein, and compared to a vehicle side frame which was previously commercially produced. In this case the comparison was to vehicle side frame of a Renault® Twizy (Model 45 of 2015). This vehicle side frame from this commercial vehicle is shown in
As shown in the above table, the vehicle side frame made in accordance with the exemplary methods described herein is lighter in weight than the prior art commercial vehicle side frame. Further the vehicle side frame made in accordance with the exemplary methods and including the exemplary frame components hereof (made using wall sheets having a transverse thickness of 1.2 mm), also demonstrated higher strength in the form of compressive rigidity both along the vertical axis Z and the horizontal axis X.
As shown in
As shown in
In the exemplary arrangement the components of the floor member are initially fabricated and connected to provide a preform which has an integral frame component comprised of a pair of walls, each of which comprise at least one metal sheet. As in the previously described arrangements the steel sheets define a first or inner wall 106 and a second or outer wall 107. A cross-sectional view of an exemplary floor member 120 is shown for example in
As described in connection with the vehicle structures including the vehicle side frames, some exemplary floor members may include different transverse sheet wall thicknesses in different regions of the floor member. Similarly different regions of exemplary floor members may comprise different types of metal sheets as well as other materials. Further as can be appreciated in other exemplary arrangements other features like those previously described may be utilized in connection with providing frame components that are integrated in the exemplary floor members.
In some exemplary arrangements the first wall 106 and the second wall 107 are arranged in alignment with respect to each other. The sheets are joined in operative connection and bound an interior gap 128 which is hermetically sealed. As in the previously discussed arrangements the gap initially comprises an empty space between the inside's surface of the walls of the floor member. In exemplary arrangements a fluid connector 108 is arranged in connection with one of the walls. The exemplary fluid connector 108 enables pressurized fluid to be introduced into the interior gap 128 between the walls 106, 107 of the floor member.
As in the previously discussed arrangements the fluid connector 108 may be configured to enable the delivery of pressurized fluid such as a liquid or gas through the respective wall of the frame member and into the interior gap. The pressurized fluid may be introduced via a supply connector from an external source of pressurized fluid. Further as previously discussed the exemplary fluid connector may be in operative connection with a valve structure such as a check valve which prevents the release of fluid pressure from the interior gap. Alternatively the fluid connector may be in operative connection with the relief valve which enables fluid above a particular pressure to escape. Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
In an exemplary manufacturing method of making the exemplary floor member 120, the outer edges and inner edges of the respective sheets are operatively connected in a manner that provides a hermetically sealed interior gap 128 between the walls. This is done through the formation of a seal 122. In exemplary arrangements the seal may be formed at the edges of the walls by joining the circumferential edges of the walls together via welding or other methods. Further as previously discussed other joining in sealing methods may be used to assure the formation of a leakproof hermetically sealed interior gap between the walls of the floor member. For example in other exemplary arrangements pressure welding, soldering, gluing, bending, pressing, coating, caulking or other joining and sealing methods may be utilized.
In the exemplary methods of manufacture of a vehicle floor member after the preform is produced and the walls have been operatively connected so that the hermetically sealed interior gap 128 has been formed, pressurized fluid is introduced into the gap through the fluid connector 108. In some exemplary arrangements the pressurized fluid may include air provided by a compressor or other suitable source of elevated air pressure. Of course it should be understood that other types of pressurized fluids may be used. These may include for example gases such as nitrogen containing gases or inert gases. Other pressurized fluids may include water-based fluids, petroleum-based fluids, non-Newtonian fluids, foams, fluid cement, fluid concrete, fluid plastics or other materials. In some exemplary arrangements the pressurized fluid may include a one, two or three component foam (for example flex 140 type), flowable natural material such as a liquid rubber or other suitable materials. Further as can be appreciated in exemplary arrangements in which permanent deformation of the walls or other structures of the preform is to be accomplished, a generally incompressible fluid or fluid with less compressibility is advantageously utilized to more effectively control the speed, uniformity and amount of deformation.
In some exemplary arrangements the introduction of the pressurized fluid into the sealed interior gap 128 between the walls is operative to permanently deform the metal sheets of which the exemplary walls are made. For example in some exemplary arrangements the exemplary metal sheets may be deformed through the introduction of the pressurized fluid to provide deformation of the respective walls such as is shown in
Further in exemplary arrangements of the floor member 120 the geometrical dimensions of the front bumper portion 104 in connection with the front frame portion 101, and the rear frame portion 102 and the rear bumper portion 104 are selected by the requirements for rigidity and strength of such areas. For example in some exemplary arrangements such portions of the frame member may be constructed in a manner suitable for providing controlled deformation zones that serve to absorb energy and protect the occupants of the vehicle in a collision. Further as previously discussed the configurations of frame members may have different wall thicknesses in different regions as well as different structures to provide for the desired properties. Further the fluid introduced into the sealed interior gap may further provide properties of enhanced strength of the different materials and structures as well as other properties that are desirable in the use and operation of the vehicle.
In exemplary manufacturing methods the introduction of the pressurized fluid into the sealed interior gap 128 is done at room temperatures. However in other exemplary arrangements other manufacturing environments may be utilized including carrying out the process at higher temperatures in which the materials utilized may have different properties.
In some exemplary arrangements the manufacture of the exemplary floor member is carried out at a process temperature of approximately 20° C. The pressurized fluid introduced into the sealed interior gap comprises air which is delivered at a pressure of about 2 bars. In exemplary arrangements the pressure hold time provided is approximately 30 seconds and the period during which deformation is carried out was approximately one minute which is required to equalize the pressure throughout the sealed interior gap of the preform. Further the exemplary deformation time for deformation of the wall structures is approximately 1.5 minutes.
Of course it should be understood that this particular structure and manufacturing method is exemplary and in other arrangements other approaches may be used.
A further exemplary arrangement of a vehicle floor member 122 is shown in
In this exemplary arrangement the vehicle floor member 122 includes opposed walls that do not have a uniform transverse thickness across the entire vehicle floor member. Rather in this exemplary arrangement the walls have different regions of various transverse thicknesses in a patchwork structure as desired to impart different properties to different areas of the vehicle floor member.
As shown for example in
As a result in this exemplary arrangement the inner wall 106 and the outer wall 107 of the exemplary frame components included in the vehicle floor member 122 comprise metal sheets that have various regions with different transverse thicknesses. The various thicknesses of the walls of the exemplary arrangement enables the floor member to have desired functional characteristics including desired strength and rigidity in the regions having the increased sheet thicknesses. In exemplary arrangements the different thicknesses of the different regions of the walls 106, 107 may be achieved through different methods. These may include for example press forming, rolling, joining together multiple sheets of different thicknesses and other methods for providing different transverse thicknesses as desired in the different regions. Of course these approaches are exemplary and in other arrangements other approaches may be used.
Further in the exemplary arrangement of the vehicle floor member 122 the frame longitudinal ribs 114 extend operatively between the front frame portion 101 and the rear frame portion 102. In the exemplary arrangement the longitudinal ribs 114 divide the generally annular storage opening. The exemplary longitudinal ribs extend substantially parallel with respect to the corresponding side frame portions 103 that in this exemplary arrangement are integrated therewith. However it should be noted that in other arrangements longitudinal ribs similar to ribs 114 may comprise structures that are assembled independent from the remaining portions of the vehicle floor member. In such arrangements the longitudinal ribs may be structures that are mounted in fixed engagement to respective regions of the front frame portion 101 and the rear frame portion 102 of the floor member. Such independently mounted longitudinal ribs are shown for example in
In those exemplary arrangements in which the longitudinal ribs are assembled as a member separate from the other portions of the floor member, the longitudinal ribs may be a member which includes one or more frame components which provide the desired properties of the exemplary arrangements described herein. In such cases such longitudinal frame members may include wall structures, hermetically sealed interior gap structures, pocket structures and fluid connectors for introducing fluid under pressure into the sealed interior gap areas. Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
Exemplary arrangements may also include floor members which have different regions that are comprised of different materials as well as different transverse wall thicknesses. For example
In the exemplary arrangement shown in
Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
A further exemplary arrangement of a vehicle floor member 126 is shown in
Unlike the exemplary vehicle floor members 120 and 124, vehicle floor member 126 includes a reinforcing pillar 160. The exemplary reinforcing pillar 116 extends in the region of the front bumper portion 104 and/or the rear bumper portion 105. In this exemplary arrangement a front reinforcing pillar extends across the generally annular front bumper portion from the outer portion of the front bumper portion 104 to the front frame portion 101. Further in this exemplary arrangement a second or rear reinforcing pillar 116 extends across the generally annular rear bumper portion 105. The exemplary second reinforcing pillar 116 extends from the outer portion of the rear bumper portion 105 to the rear frame portion 102.
In other arrangements the bumper portions and reinforcing pillars may have different geometries. For example in other exemplary arrangements bumper portions may have different configurations and reinforcing pillars in such portions may have other structures. Also in arrangements where the bumper portions are generally annular, reinforcing pillars may include pillars that extend in different angular configurations or other directions across the annular structures. Further in some exemplary arrangements the reinforcing pillars in the bumper portions may be structures that are assembled independent from the remaining portions of the vehicle floor member. For example in some arrangements reinforcing members may be mounted to respective regions of the front frame portion and/or the outer portion of the front bumper portion 104 or the rear frame portion 102 and the outer portion of the rear bumper portion. Such arrangements are shown for example in the floor members of
In some exemplary arrangements where reinforcing pillars 116 are assembled as a separate member and later connected to the floor member, the reinforcing pillar may include one or more frame components like those described herein which provide desired properties for the reinforcing pillar. In such exemplary arrangements the reinforcing pillar may include frame components of the type described herein as well as one or more fluid connectors which are operative to deliver pressurized fluid into the sealed interior gap of the member.
The exemplary floor member 126 of
In exemplary manufacturing methods for producing vehicle floor member 126 in the step of introducing the pressurized fluid into the sealed interior gap of the floor member preform, the walls of the preform are positioned between pressure plates 113 which may be of the type previously discussed. In exemplary arrangements the pressure plates are configured so that the walls 106, 107 of the preform are in contact with the pressure plates such as is shown in
The exemplary method of manufacturing the floor member 126 including the exemplary frame components may be accomplished using equipment like that shown in
Of course it should be understood that in other arrangements other approaches may be used such as those previously discussed in connection with vehicle floor member 120 shown in
In this exemplary arrangement the vehicle floor member 130 is generally similar to the vehicle floor members 120, 122, 124 and 126 previously discussed, except as otherwise described. Unlike the prior arrangements floor member 130 additionally comprises a frame transverse rib 115. The exemplary frame transverse rib extends between the frame longitudinal ribs 114 that extend adjacent to the side frame portions 103. The exemplary frame transverse rib 115 extends substantially perpendicular to the frame longitudinal ribs 114 in which it is in operative fixed connection. In this exemplary arrangement the frame transverse rib is an integrated structure with the remainder of the vehicle floor member. However it should be understood that in other arrangements the transverse rib 115 may be produced independently from the other structures of the vehicle floor member. In such arrangements the frame transverse rib may be joined in operative connection with the structures of the vehicle floor member through connecting technology such as welding, pressure welding bolting, gluing or other joining methods. Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
Other floor member configurations may include different numbers and configurations of transverse ribs 115. For example
In the exemplary arrangement of the floor member 130, there are two frame components that include inner pockets 110. The pockets 110 of the exemplary arrangement extends partially through the front bumper portion 104, the side frame portion 103 and partially through the rear bumper portion 105. A further frame component of an exemplary arrangement is positioned on the opposite side of the vehicle floor member and is a mirror image of the frame component and pocket.
In exemplary arrangements the frame components used in the vehicle floor member 130 may be utilized to produce different properties and results. In some exemplary arrangements the inner pocket 110 shown on the right in
In the exemplary arrangement the inner pocket 110 shown on the left in
Of course it should be understood that this arrangement is exemplary and in other arrangements the sealed interior gap of the frame component and/or the pockets 110 may be comprised of different materials and/or be filed with different fillers. This is done to provide the desired properties. For example in some arrangements filler materials may provide added strength to the frame components. In other arrangements the configuration of the frame structures and filler materials may provide soundproofing or antivibration properties. Filler materials may be numerous different types of materials including without limitation the materials that have been previously discussed herein.
In this exemplary arrangement each of the side plates 117 includes at least one frame component of the types previously described which provide increased strength and/or other desirable properties for the vehicle frame structure. In the exemplary arrangement the exemplary frame components include first and second side walls which bound a hermetically sealed interior gap in a manner like that previously discussed. Further in exemplary arrangements the side plates may further include frame components including internal pockets within the sealed interior gap. In such exemplary arrangements pressurized fluid is introduced into the sealed interior gap through fluid connectors 108 and through one of the first and second walls. Such delivered pressurized fluid may be operative to provide desired permanent deformation of frame component structures and/or the delivered fluid may have desirable properties for purposes of providing a vehicle frame of the type desired.
As can be appreciated the exemplary vehicle frame system 136 may be attached to other structures such as a suspension arrangement as shown in
Certain vehicle floor members of the exemplary arrangements were subjected to comparative tests with vehicle floor members manufactured using prior art technologies.
In the case of twisting all the floor members were secured in the rear portion (that is in the center of the rear bumper portion 105). The front of the floor member was twisted by an angle equal to 1°. In the case of bending, all frames were supported in two points (in the center of the front bumper portion 104 and the rear bumper portion 105). A force corresponding to a mass of 100 N was applied in the central portion in the center of the side frame portion 103. In the stress distribution maps the legend for the corresponding load cases (twisting/bending) is presented in an identical scale. The values of rotation of twisting, expressed in degrees, correspond to the loading with the twisting moment M=100 Nm. The material used in the simulations was steel, having a Young's modulus E=206.94 GPa, and a Poisson's ratio of v=0.288 and a density p=7829 kg/m3.
The calculated strength parameters are presented in Table 3 below.
As shown in Table 3 the floor member made in accordance with the exemplary arrangements described herein is lighter in weight than the floor member made in a conventional prior art manner from standard profiles. In the exemplary arrangement in which the sheet thickness of the walls of the floor member was 1.0 mm, the compared conventional floor member had the 60×20×1.5 mm rectangular profile. For the exemplary arrangement in which the sheet thickness of the walls of the floor member was 1.2 mm the compared conventional floor member had the 70×20×1.5 mm rectangular profile.
As demonstrated in Table 3 the floor members of the exemplary arrangements described herein generally provide greater strength and lighter weight. Of course it should be understood that these results are exemplary and in other arrangements even more favorable comparisons may be achieved by using different materials, transverse wall thicknesses, wall configurations and/or fluids within the sealed interior gaps of the frame components.
Exemplary arrangements of the frame components which strengthen vehicle structures and/or that provide other desirable properties may also be included in other vehicle structures.
In the exemplary arrangement the vehicle frame longitudinal member 214 includes a front portion 201. The front portion 201 is configured to be directed from a central portion 202 toward the front of the vehicle. The exemplary central portion 202 is configured to be positioned in a central area of the vehicle. The exemplary vehicle frame longitudinal member 214 further includes a rear portion. The rear portion is configured to be directed from the central portion toward the rear of the vehicle. In the exemplary arrangement the central portion is configured to be positioned lower than the front portion and the rear portion when it is integrated in the vehicle structure.
In the exemplary arrangement of the vehicle frame longitudinal member 214 a transition region 216 is positioned intermediate of the front portion 201 and the central portion 202. The exemplary transition region includes a portion that is inclined in the bottom direction. In the exemplary arrangement a further transition region 218 is positioned intermediate of the central portion 202 and the rear portion 203. Second transition region 218 has a configuration that is similar to the inclined portion configuration of the transition region 216. The exemplary transition regions include lower protrusions 220. The exemplary lower protrusions 220 provide regions that extend to the lowest point on the vehicle frame longitudinal members when such members are in the operative position. In the exemplary arrangement the lower protrusions 220 serve the function of connecting members for connecting the floor member or other structures of the vehicle to the vehicle frame longitudinal members. Of course it should be understood that this configuration is exemplary and in other arrangements other approaches and configurations may be used.
As shown in the exemplary arrangement of
A fluid connector 208 is operative to enable the delivery of pressurized fluid into the hermetically sealed interior gap 228 of the frame component 222. The exemplary fluid connector enables leakproof fastening of a supply duct to the interior gap from a source of pressurized fluid. Further as discussed previously in connection with other exemplary frame components, the fluid connector may be in operative connection with a valve such as a check valve or pressure relief valve.
In the exemplary arrangement the outer edges of the walls 206, 207 are sealed and joined in hermetically sealed operative engagement by a seal 212. In exemplary arrangements the sealing is performed along the continuous circumferential edges of the walls and is accomplished by sealing methods such as circumferential welds or other joining methods of the types previously discussed. For example sealing may be accomplished by means of pressure welding, soldering, gluing, bending, pressing, wall forming or other joining methods. Further it should be understood that in other exemplary arrangements the walls 206, 207 of the frame component may be joined in operative connection through intermediate structures which are joined together with the walls to bound the hermetically sealed interior gap. It should be appreciated that numerous different structures and arrangements may be utilized to produce suitable frame components of the type described herein.
In exemplary methods of producing the vehicle frame longitudinal members, a source of pressurized fluid is connected to the fluid connector 208. In some exemplary arrangements the pressurized fluid comprises air delivered from a compressor or other suitable source of pneumatic pressure. Further it should be understood that in other exemplary arrangements the pressurized fluid may include fluids of the types previously discussed herein. These may include for example gases such as nitrogen containing gases or inert gases. Also in other exemplary arrangements the pressurized fluid may include water-based liquids, petroleum-based liquids, non-Newtonian fluids, foam, fluid cement, fluid concrete and fluid plastic polymers. Also in other exemplary arrangements the pressurized fluids may include flowable natural materials such as liquid rubber. Other exemplary arrangements may include materials that comprise one, two or three component foams such as a flex 140 type foam material. As previously discussed such pressurized fluid materials may be configured to be of a type that is released from the sealed interior gap after the preform is modified to the final configuration through the production method, or alternatively the fluid may remain within the sealed interior gap at the completion of the manufacturing process to provide desired properties. Further in exemplary arrangements the pressurized fluids may undergo changes in the form of curing or hardening after being delivered into the sealed interior gap to achieve other suitable properties such as those previously discussed.
In exemplary arrangements the delivery of the pressurized fluid into the sealed interior gap provides permanent deformation of the walls 206, 207 of the frame component 222.
In the exemplary vehicle frame longitudinal member 214 the structure has different geometrical dimensions in the front portion 201, the central portion 202 and the rear portion 203. These dimensions and configurations are selectively arranged to provide desired safety parameters in terms of both strength of the structure as well as providing areas for controlled deformation in the event of a collision. The exemplary arrangements also provide dimensions that are suitable for integrating the vehicle frame longitudinal members into the body structures of the particular vehicle.
In exemplary manufacturing methods of the vehicle frame longitudinal members 214 as shown, the manufacturing process is carried out at generally room temperature. However it should be understood that in alternative arrangements other manufacturing environments may be used. In exemplary arrangements the manufacturing processing parameters include processing the initial preform structure at a temperature of approximately 20° C. The fluid pressure that is applied to the sealed interior gap of the frame component is approximately 2 bars. In the exemplary arrangement the deformation time of the structure is approximately one minute which is required for pressure to be equalized in the structures of the frame component. The time associated with the delivery of the pressure within the sealed interior gap is 30 seconds and the total hold time during which deformation occurs is 1.5 minutes. Of course it should be understood that the structures of the vehicle frame longitudinal members and these production parameters are exemplary and in other arrangements other approaches may be used.
In exemplary arrangements vehicle frame longitudinal members that include frame components of exemplary arrangements, may also be made of different materials as well as materials having different transverse wall thicknesses.
Vehicle frame longitudinal member 224 includes frame components that are manufactured of walls including metal sheets. However in this exemplary arrangement the metal sheets have different transverse cross-sectional thicknesses in different regions of the structure. The different transverse cross-sectional thicknesses in different regions form a patchwork type structure. As shown in
In this exemplary arrangement the inner wall 206 and the outer wall 207 are comprised of metal sheets which have varying thicknesses between the individual regions of the vehicle frame longitudinal member 224. As a result of the patchwork type structure the vehicle frame member produced through the exemplary manufacturing methods achieved as a result of the frame components integrated therewith desired functional characteristics of increased strength and rigidity in the regions having the increased sheet thickness. In the exemplary arrangement the structure of the first wall 206 and the second wall 207 is an integrated structure including regions of smaller and greater thicknesses of the respective sheets which comprise the walls. In exemplary arrangements the different thicknesses of the walls in the different respective regions is achieved through wall formation processes which provide different thicknesses such as press forming, rolling, joining of multiple overlying sheets having different thicknesses, and other processes for providing varied transverse wall thicknesses.
Further the exemplary vehicle frame longitudinal member 224 includes an annular structure 204. The exemplary annular structure 204 provides thereon connecting surfaces for connecting to other members of the vehicle. Further the exemplary annular structure 204 provides increased strength and stability in the region in which the annular structure is located. In the exemplary arrangement the annular structure helps to withstand deformations resulting from impacts at the front of the vehicle. However it should be understood that this arrangement is exemplary and in other arrangements other structures similar to annular structures 204 may be provided without an opening to provide increased strength and rigidity. In exemplary arrangements annular structures may be provided for purposes of achieving reduced weight or other properties in the area of the front portion 201 in which the annular structure 204 is located.
Further in the exemplary arrangement the vehicle frame longitudinal member 224 further includes an annular transition structure 205. In this exemplary arrangement the annular transition structure is positioned between the front portion 201 and the central portion 202. The exemplary annular transition structure 205 serves to provide connection surfaces for connecting vehicle floor members. Further in exemplary arrangements the transition structure 205 may serve to provide increased strength and stability of the vehicle frame longitudinal member. Further in some arrangements the annular transition structure may provide reduced mass of the longitudinal member. Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
Vehicle frame longitudinal member 226 includes a central portion 202 that includes a central annular structure 209. In the exemplary arrangement the central annular structure 209 includes a pair of longitudinally disposed reinforcing ribs 210. The exemplary ribs 210 extend in an opening defined by the central annular structure and serve to operatively connect the opposed longitudinal regions of the exemplary central annular structure.
The exemplary configuration of the vehicle frame longitudinal member 226 and particularly the number and configuration of the central annular structure 209 and reinforcing ribs 210 may have various configurations in different arrangements. Further it should be understood that the reinforcing ribs in some arrangements may be initially manufactured as independent structures that are joined in operative fixed connection with the vehicle frame longitudinal members. Numerous different connecting methods may be utilized for operatively connecting the reinforcing ribs 210 within the central annular structure 209. As can be appreciated joining methods such as welding, bolting, crimping, gluing or other fastening methods may be utilized for joining the reinforcing ribs and the longitudinal member structures.
Further it should be understood that in exemplary arrangements where the reinforcing ribs are initially produced as separate structures that are joined in fixed connection with the vehicle frame longitudinal member central portion 209, one or more of the respective reinforcing ribs, may include frame components of the exemplary arrangements which provide increased strength thereof. In such arrangements the ribs may include a first wall and a second wall that bound a sealed interior gap into which pressurized fluid is introduced through a fluid connector in a manner like that previously discussed. Of course it should be understood that these approaches are exemplary and in other arrangements other approaches may be used.
As shown in
As represented in
A cross-sectional view of the central portion taken along lines 52-52 in
Because in this exemplary arrangement the walls 206, 207 are comprised of metal sheets of varying materials the exemplary vehicle frame longitudinal member is provided with desirable functional characteristics. These include increased strength in the form of higher rigidity in the regions in which the walls of the frame components are comprised of materials which have such properties. As can be appreciated in the exemplary arrangements the different materials of the different regions are joined in permanently engaged connection through suitable joining methods of the types previously discussed. Further in exemplary arrangements in which the pressurized fluid that is introduced into the sealed interior gap remains within the frame component after manufacture is completed, additional advantageous properties may be achieved for the vehicle frame longitudinal members. Suitable pressurized fluids for achieving different properties may also be of the types that have been previously discussed herein in connection with other vehicle structures.
A further exemplary vehicle frame longitudinal member 228 is shown in
Vehicle frame longitudinal member 228 includes a central portion 202, a front portion 201 and a rear portion 203. A front end annular structure 204 is located in the front portion 201. A rear end annular structure 204 is positioned in the rear portion 203. In the exemplary arrangement a purpose of the end annular structures 204 is to provide connection surfaces for connecting to members of the vehicle as well as for providing increased strength and stability. Further in exemplary arrangements the annular structures with the openings therein provide reduced weight compared to exemplary arrangements which may use solid end structures.
In the exemplary arrangement frame longitudinal member 228 has flattened regions 211 on the inner wall 206 and the outer wall 207 of the frame component that is integrated in the respective member. In the exemplary arrangements the flattened regions have a substantially flat surface. The flattened regions enable adjustment of the technical parameters and properties of the frame longitudinal members. The flattened regions also provide mounting regions for equipment of the vehicle. The exemplary arrangement of the vehicle frame longitudinal member 228 is configured particularly to reduce the width dimension of the member compared to conventional structures while providing improved properties.
The exemplary flattened regions 211 are formed using methods like those previously discussed. This includes placing the vehicle frame longitudinal member preform within an area bounded by pressure plates 213 (such as is shown in
The exemplary manufacturing method which is utilized in producing the structure illustrated in
Of course it should be understood that these configurations are exemplary and in other arrangements other approaches may be used.
The vehicle frame longitudinal members manufactured using the exemplary methods and produced in accordance with the exemplary arrangements described herein were subjected to comparative tests based with a vehicle frame longitudinal member manufactured using known prior art technology. For the purpose of performing the comparative tests, a frame structure comprising frame longitudinal members of a Chevrolet® Silverado® 1500 (2014 model year) was selected. A model of the vehicle frame based on the Chevrolet Silverado 1500 frame longitudinal members manufactured in accordance with prior art technology is shown in
The calculated strength parameters are presented in Table 4 below.
As shown in Table 4 the frame made in accordance with the exemplary arrangements discussed herein is lighter in weight than the conventional frame while showing more favorable torsional rigidity. In the case of the prior art technology the frame was constructed from 62 component members, while the frame made from the exemplary arrangements discussed herein was constructed from 74 component members, 58 of which were members manufactured produced by introducing fluid under pressure into the sealed interior gap between the walls comprised of sheet metal to achieve permanent deformation to produce the final wall configurations.
The Light Weight Index (LWI) parameter shown in Table 4 is a parameter known to persons of skill in the art for comparison purposes and defines the structural efficiency of a structure. Its lower value indicates that a more favorable structural efficiency was obtained. The LWI parameter referred to herein was defined for example in the publication of Singh, Harry dated August 2012 entitled Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025 (Report No. DOT HS 811 666).
Thus the exemplary arrangements achieve improved capabilities, have desirable properties and eliminate difficulties encountered in the use of prior vehicle frame arrangements and attain the useful results described herein.
In the foregoing description, certain terms have been used for brevity, clarity and understanding. However, no unnecessary limitations are to be implied therefrom because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover the descriptions and illustrations herein are by way of examples and the new and useful features and methods are not limited to the exact features and methods shown and described.
It should further be understood that the features and/or relationships associated with one exemplary arrangement can be combined with features and/or relationships from another exemplary arrangement. That is, various features and/or relationships from various arrangements can be combined together to form further arrangements. The new and useful scope of the disclosure is not limited only to the exemplary arrangements that have been shown and described.
Having described features, discoveries and principles of the exemplary arrangements, the manner in which they are constructed, produced and operated, and the advantages and useful results attained, the new and useful features, devices, elements, arrangements, parts, combinations, systems, equipment, operations, methods, processes and relationships are set forth in the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| P.435561 | Oct 2020 | PL | national |
| P.436548 | Dec 2020 | PL | national |
| P.438785 | Aug 2021 | PL | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/IB2021/059033 | Oct 2021 | US |
| Child | 18127392 | US |
