GB2557687A

GB2557687A - Mounting member for a vehicle body

Info

Publication number: GB2557687A
Application number: GB1621401.7A
Authority: GB
Inventors: Stephen Rowley Mark
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2016-12-15
Filing date: 2016-12-15
Publication date: 2018-06-27
Anticipated expiration: 2036-12-15
Also published as: GB201621401D0; GB2557687B

Abstract

A mounting member 30 is provided for mounting a subframe (24, Figure 2) to a vehicle body, for example rails 11, 12. The mounting member comprises a preferably threaded bore (31, Figure 5b) extending on an axis (A, Figure 5b) for receiving a mounting pin, and is formed of forged aluminium, preferably drop-forged aluminium, which may provide a mounting member with high stiffness and low corrosion. Mounting member 30 may be mounted to an aluminium casting, for example an inner surface of a crash box. Mounting member 30 may be formed by forging an extruded component, which may be heat-treated before forming a threaded section of the bore.

Description

(71) Applicant(s):

Jaguar Land Rover Limited (Incorporated in the United Kingdom)

Abbey Road, Whitley, Coventry, Warwickshire, CV3 4LF, United Kingdom (72) Inventor(s):

Mark Stephen Rowley (56) Documents Cited:

GB 2538954 A DE 102013015279 A1 US 20150061272 A1

WO 2015/111437 A1 US 5593001 A (58) Field of Search:

INT CL B60R, B62D, C22F

Other: EPODOC, WPI, Patent Fulltext (74) Agent and/or Address for Service:

Jaguar Land Rover

Patents Department W/1/073, Abbey Road, Whitley, COVENTRY, CV3 4LF, United Kingdom (54) Title of the Invention: Mounting member for a vehicle body

Abstract Title: Forged aluminium mount for subframe to vehicle body (57) A mounting member 30 is provided for mounting a subframe (24, Figure 2) to a vehicle body, for example rails 11, 12. The mounting member comprises a preferably threaded bore (31, Figure 5b) extending on an axis (A, Figure 5b) for receiving a mounting pin, and is formed of forged aluminium, preferably drop-forged aluminium, which may provide a mounting member with high stiffness and low corrosion. Mounting member 30 may be mounted to an aluminium casting, for example an inner surface of a crash box. Mounting member 30 may be formed by forging an extruded component, which may be heat-treated before forming a threaded section of the bore.

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MOUNTING MEMBER FOR A VEHICLE BODY

TECHNICAL FIELD

The present disclosure relates to a mounting member for a vehicle body, particularly, but not exclusively, for mounting a sub-frame to the vehicle body. The present disclosure further relates to a method of manufacturing a mounting member, particularly but not exclusively, a mounting member for mounting a sub-frame to a vehicle body. Another aspect of the invention relates to a vehicle including the mounting member.

BACKGROUND

It is generally known that joints of a vehicle structure are required to exhibit high stiffness and rigidity to withstand vibration between heavy parts of the vehicle structure. One position where stiffness is particularly desired is at the connection between the vehicle body (or body in white) and a sub-frame. A sub-frame is a structural component of a vehicle that uses a separate structure to carry certain components, such as the engine, drive train, or suspension and is bolted and/or welded to the vehicle body. Insufficient stiffness in this joint can have significant consequences. As such, mounting members with reinforcement tubes have been fitted inside the vehicle body to facilitate a stiffened rigid connection between the body and its sub-frames.

Conventionally, the reinforcement tubes are constructed as a steel nut, which is attached to the vehicle body and configured to resist high torques and clamping loads introduced by the sub-frame, for example. It has been found that the use of steel mounts as reinforcement tubes may result in early failure of the thread used to receive a mounting bolt, due to corrosion of the steel nut. This is particularly true for steel nuts connected to aluminium parts of the vehicle body, due to a known difference in potential between aluminium and steel. Previous attempts to manufacture the reinforcement tubes from aluminium have been unsuccessful, due to the insufficient structural integrity of aluminium threads.

In view of the above, it is an object of the present invention to provide a mounting member, which is able to withstand high torque and clamping loads while reducing or eliminating corrosion when in use.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a mounting member for mounting a subframe or similar components that require structural integrity to a vehicle body, a vehicle comprising the mounting member and the method of manufacturing the mounting member as set out in the appended claims.

According to an aspect of the invention, there is disclosed a mounting member for mounting a sub-frame or similar component to a vehicle body, the mounting member defining a bore for receiving a mounting pin. The mounting member is formed of forged aluminium.

It will be appreciated that the use of aluminium will significantly reduce corrosion, when attached to parts of a vehicle body made from aluminium since the two aluminium materials will have the same or at least very similar electric potential. The forging process of the mounting member material increases the mechanical properties compared to traditional cast aluminium components and offers greater flexibility of form. It has been found that the present mounting members exhibit a stiffness that is significantly higher than conventional cast aluminium mounting members.

In another embodiment, the mounting member is formed of drop forged aluminium. In particular, the mounting member may be made from a high strength aluminium extruded material that is subsequently drop forged and heat-treated.

According to another embodiment, the bore comprises an internal threaded section. Accordingly, the mounting member can function as a fastening nut and reinforcement tube at the same time. As will be described in more detail below, the threaded section may be introduced after the mounting member is forged and heat treated.

In another embodiment, the bore comprises an unthreaded section arranged co-linear with the threaded section and adapted for alignment of a fastening member with a bore axis along which the bore extends. In other words, the mounting member may comprise a lead-in feature to guide the fastening member of a sub-frame or similar component towards the threaded section of the mounting member, thereby aiding alignment of the sub-frame with the vehicle body.

In another embodiment, the mounting member comprises a tubular member enclosing the bore. The tubular member may comprise a circular, square or polygonal cross-section and may have a constant thickness around the entire circumference of the bore.

In yet another embodiment, the mounting member comprises a mounting flange, the mounting flange extending in a plane substantially perpendicular to the bore axis and arranged to locate the mounting member within the vehicle body, in a direction of the bore axis. The mounting flange will support the mounting member in a vertical direction and can be used to removably or permanently connect the mounting member to the vehicle body. For example, the mounting flange may comprise one or more apertures for which fastening members can be introduced and connected with parts of the vehicle body. Alternatively, the mounting flanges can be used to weld the mounting member to the vehicle body.

In another embodiment, the tubular member extends in the direction of the bore axis and on opposite sides of the mounting flange. In other words, the mounting flange is positioned between first and second ends of the mounting member. As will be described in more detail below, parts of the tubular member extending beyond the mounting flange can be used as a self-alignment feature for quick installation of the mounting member within the structure of the vehicle body, particularly apertures provided therein.

According to another embodiment, the mounting member comprises a first side flange extending in a plane substantially parallel to the bore axis and arranged to allow the mounting member to be secured against rotation within the vehicle body. In another embodiment, the mounting member may additionally comprise a second side flange extending in a plane substantially parallel to and distanced from the plane of the first side flange, the second side flange being arranged to allow the mounting member to be secured against rotation within the vehicle body. According to this embodiment, the mounting member comprises two side wings, each of which is arranged radially distant from the bore axis and adapted to removably or permanently attach the mounting member to radially distant parts of the vehicle body, with respect to the bore axis.

In another embodiment, the outer surface of the tubular member is connected to the first and/or second side flanges by means of first and/or second radial walls. The tubular member, the radial walls and the side flanges may be formed as a unitary structure. This enables excellent structural integrity.

The first and/or second side flange may define at least one fastening aperture. Accordingly, the side flanges are removably connectable to the surrounding structure of the vehicle body. The side flange portions of the mounting member may thus be connected to the surrounding vehicle body by means of riveting or bolting. However, it is equivalently feasible to construct the side flanges without fastening apertures and weld the side flange portions to the vehicle body.

In another embodiment, the first and second radial walls extend in opposite directions, away from the bore axis. As such, the side flanges may be connected to opposing sides of a vehicle body member and thus provide improved anti-rotational support for the mounting member within the body structure.

In yet another embodiment, the mounting member may be substantially symmetrical about the bore axis. Substantially symmetrical in this embodiment means that the two radial walls have approximately the same dimensions and extend in opposite directions. Certain reinforcement structure of the radial walls may, however, differ slightly. This particular arrangement will provide the mounting member with particularly high stiffness characteristics and simplify installation of the mounting member, as the latter may be inserted in the vehicle body in any direction.

According to another embodiment, the tubular member comprises an inner surface and an outer surface, the inner surface defining the bore extending between a first end and an opposite second end of the tubular member, wherein the mounting flange is located at the first end of the tubular member, at least partly around its outer surface. The mounting flange of this embodiment may be constructed as a parabolic structure surrounding parts of the outer surface of the tubular member. The mounting flange of this embodiment may be used to control how far the mounting member is inserted into a corresponding part of the vehicle body as will be described in more detail below.

In another embodiment, the inner surface of the tubular member comprises an oval crosssection, at least at the first end of the tubular member. This oval cross-section can be used as an alignment feature for an installation tool used to locate the mounting member within the corresponding part of the vehicle body. The oval cross-section of the inner surface will ensure that the mounting member is inserted into the vehicle body in a suitable orientation. Although an oval cross-section provides a simple arrangement to facilitate tool alignment of course, the inner surface may comprise any other cross-sectional shape which would facilitate said tool alignment. The skilled person will appreciate that essentially any nonsymmetrical shape (relative to the bore axis) of the inner surface would provide said tool alignment characteristic.

According to another embodiment, the tubular member comprises at least one spline located on the outer surface of the tubular member and extending in the direction of the bore axis. The tubular member may also comprise several splines distributed equidistantly around the circumference of the tubular mounting member. When inserting the mounting member into the corresponding part of the vehicle body, the splines are adapted to deform and provide an interference fit between the mounting member and the corresponding structure of the vehicle body. Deformation of the splines during insertion stops the mounting member from inadvertent movement along the bore axis.

In another embodiment, the tubular member comprises an anti-rotation member protruding from the outer surface.

In another embodiment, the anti-rotation member is a nose portion located in the vicinity of the first end. This arrangement is particularly advantageous if the first end is the end of the mounting member, which is inserted into the vehicle body last, i.e. after the second end, as rotation of the mounting member with respect to the vehicle body may still be possible for alignment purposes until the first end of the mounting member is completed inserted.

In another embodiment, the nose portion is in direct contact with the mounting flange. In particular, the nose portion may be provided directly underneath the mounting flange, that is, extending from the mounting flange towards the second end of the mounting member.

According to another aspect of the present invention, a vehicle is provided comprising a vehicle body and a sub-frame attached thereto. The sub-frame may be, but not necessarily, removably attached to the vehicle body. The vehicle further comprises a mounting member as described hereinbefore and a fastening member connecting the vehicle sub-frame with the vehicle body, the fastening member being received within the bore of the mounting member.

In another embodiment, the sub-frame or similar structural components are attached to an aluminium part of the vehicle body. Accordingly, the mounting member facilitating the connection between the sub-frame and the vehicle body is attached to an aluminium part of the vehicle body. As mentioned previously, the similar electric potential of the aluminium part and the forged aluminium mounting member will significantly reduce corrosion of the mounting member.

According to another embodiment, the aluminium part is a crash box of the vehicle body. The crash box may be made of two sheet metal panels joined to form a substantially rectangular crash box. The mounting member may be inserted into the crash box before the two sheet metal panels are joined.

According to another embodiment, the mounting member is attached to an inner surface of the crash box by means of fastening members. As such, the mounting member is advantageously removable from the crash box, in contrast to known mounting connections.

In another embodiment, the aluminium part is an aluminium casting of the vehicle body. The aluminium casting may comprise a cylindrical opening adapted to receive the mounting member and a plurality of reinforcement member is extending radially from and supporting the structure of the circular opening.

In another embodiment, the mounting member is attached to the aluminium casting by means of an interference fit. Accordingly, the mounting member may be attached to an assembly tool in a predetermined orientation with respect to the aluminium casting of the vehicle body and pressed into the opening of the casting. This particular arrangement provides for a simple and repeatable way of arranging the mounting member within the aluminium casting.

In another aspect of the invention, a method of manufacturing a mounting member is provided. The method comprises forging an aluminium mounting member with a bore adapted to receive a mounting pin and forming a threaded section inside the bore.

According to another embodiment, the aluminium material of the mounting member is extruded and forged into its final shape. The extruded aluminium material may be drop forged.

In another embodiment, the forged mounting member is heat treated before forming the threaded section inside the bore. As will be appreciated, the enclosed section inside the bore according to this embodiment will inhibit a significantly higher tensile strength than threads within traditionally cast aluminium members. As a consequence, the threaded section inside the bore of the aluminium mounting member will withstand even the highest torque and clamp loads subject thereto.

Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a perspective view of a vehicle according to an embodiment of the present invention;

Figure 2 shows a perspective rear view of a vehicle according to an embodiment of the present invention;

Figure 3 shows a perspective view of a vehicle body comprising mounting members according to embodiments of the present invention;

Figure 4 shows a perspective view of a mounting member according to an embodiment of the present invention;

Figure 5a shows a perspective view of the mounting member shown in Figure 4 arranged on a vehicle body;

Figure 5b shows a cross-section along line A-A in Figure 5a;

Figure 6a shows a perspective bottom side view of a mounting member according to a further embodiment of the present invention;

Figure 6b shows a perspective top side view of the mounting member shown in Figure 6a; Figure 6c shows a cross-section of the mounting member shown in Figure 6a;

Figure 7a shows an embodiment in which the mounting member of Figure 6a is installed within a vehicle body;

Figure 7b is an arched cross-section of parts of the arrangement shown in Figure 7a;

Figure 8a shows a perspective view of the mounting member shown in Figures 6a to 6c arranged within a part of the vehicle body; and

Figure 8b is a cross-section along line B-B in Figure 8a.

Figure 9 shows a vehicle according to an embodiment of the present invention.

DETAILED DESCRIPTION

Figure 1 shows a perspective view of a vehicle body, which may also be known as a body in white. The vehicle body 1 comprises conventionally known parts such as an A-pillar 2, a Bpillar 3 and a C-pillar 4 as well as a floor section 5 forming a passenger compartment 6 therebetween. The vehicle body further comprises a front section 10 with two front rails 11,

12. The front rails comprise a first front rail 11 arranged on the left side of the vehicle body and a second front rail 12 arranged on the right side of the vehicle body 1. Both front rails 11 and 12 of this embodiment are constructed as crash boxes, having a rectangular crosssection.

The front rails 11 and 12 are produced from two metal sheet plates, which are attached to each other at upper and lower ends of the front rails 11, 12 as can be derived from Figure 1. A first sub-frame 14 for the vehicle's suspension is attached to the front rails 11, 12 via fastening members. In the illustrated embodiment, two fastening members 16, 17, such as threaded bolts extend in a substantially vertical direction through parts of the sub-frame 14 into the rectangular front rail 11. As will be described in more detail below, two mounting members, such as the mounting member shown in Figure 4, are received within the rectangular shaped cavity of the front rails 11, 12 in order to receive the fastening members 16, 17.

A perspective view of the rear part of the vehicle body 1 is illustrated in Figure 2. The rear part 20 comprises first and second rear rails 21, 22, which are produced from cast aluminium. A sub-frame 24 is attached to the first and second rear rails 21, 22 via fastening members 26, 27, 28 and 29. The fastening members 26, 27, 28 and 29 extend in a substantially vertical direction through corresponding bushings of the sub-frame 24 to connect the latter with the rear rails 21 and 22. Similar to the front part 10 of the vehicle body 1, the rear part 20 comprises four aluminium mounting members, which are received within the rear rails 21 and 22 and aligned with the fastening members 26, 27, 28 and 29 to receive the latter and carry the load of the sub-frame 24.

Figure 3 shows a perspective view of the vehicle body 1 without sub-frames. The vehicle body 1 is shown in a slightly transparent manner to show the position of mounting members 30 within the first and second front rails 11, 12, as well as the position of mounting members 90 arranged within the first and second rear rails 21, 22. It will be understood that the mounting members 30, 90 are located in positions of the front/rear part 10, 20 that align with the sub-frames described with reference to Figures 1 and 2.

Figure 4 shows a perspective view of an embodiment of a mounting member 30 according to the present invention. The mounting member 30 comprises a bore 31 extending along a bore axis A. The bore 31 is a symmetrical bore adapted to receive the fastening members 16, 17 shown in Figure 1. A tubular member, such as a cylindrical tube 33 extends around and encloses the circular bore 31. The mounting member 30 is made as a single piece of drop forged aluminium.

The mounting member 30 comprises two mounting flanges 34, which extend away from the bore 31 in a plane substantially perpendicular to the bore axis A. Of course the mounting member 30 may have only one such mounting flange. In the embodiment of Figure 4, the mounting flange 34 has a generally parabolic shape and a mounting hole 35 extending through the mounting flange 34 in a direction parallel to the bore axis A.

The tubular member 33 comprises a first part 33a extending away from the mounting flange 34 in a first direction along bore axis A. A second part 33b . of the tubular member 33 extends away from the mounting flange 34 in a second direction opposite to the first direction along the bore axis A. The second part 33b has a tapered end section 33c, which gradually reduces in diameter towards the second (lower) end of the tubular member 33.

The mounting member 30 comprises a first side flange 50 extending in a plane parallel to and distant from the bore axis A. In particular, the side flange 50 is distanced from the bore axis A in a radial direction of the tubular member 33. As such, the first side flange 50 and the tubular member 33 are connected via a first radial wall 51. The first radial wall 51 connects one side of the first side flange 50 to the outer diameter of the tubular member 33, and thus facilitates a transmission of radial forces (introduced into the tubular member 33 by the fastening members) to be transmitted to the side flange 50. The side flanges, therefore, can act as an anti-rotation lock as will be described in more detail below.

The mounting member 30 further comprises a second side flange 60 extending in a plane parallel to and distant from the bore axis A. The second side flange 60 is arranged on an opposite side of the tubular member 33 relative to the first side flange 50 and is connected to the tubular member 33 via a second radial wall 61. Similar to the first radial wall 51, the second radial wall 61 extends in a radial direction of the tubular member 33 to connect the latter with one end of the second side flange 60. The first and second radial walls 51 and 61 extend in substantially opposite directions away from the tubular member 33. The mounting member 30 is substantially symmetrical about the bore axis A, that is, the first side flange and the first radial wall 51 are mirror images of the second side flange 60 and the second radial wall 61.

The first and second side flanges 50, 60 each comprise two mounting holes 53, 54, 63, 64. The mounting holes 53, 54, 63, 64 extend in a direction substantially perpendicular to the direction of the bore axis A. As will be described in more detail below, the mounting holes 53, 54, 63, 64 can be used to receive fasteners for example rivets or bolts, for removably attaching the mounting member 30 to the vehicle body 1.

Figures 5a and 5b show the mounting member 30 of Figure 4 inserted in one of the front rails 11, 12. Figure 5a shows that the first and second side flanges 50, 60 are raised against side surfaces of the front rails 11, 12. The apertures 53, 54 of the first side flange 50 are aligned with openings 73, 74 of a first side wall 70 of the front rail 11, 12. The apertures 63, of the second side flange 60 are aligned with corresponding openings (not shown) of the second side wall 71.

A cross-section along axis A-A shown in Figure 5a is illustrated by Figure 5b. As depicted, the first section 33a of the tubular member 33 is located within a cavity 75 defined by the rail members 11 or 12. The mounting flanges 34 rest on a bottom surface of the rail members 11,12 and secure the mounting member 30 in a vertical direction, that is along bore axis A.

The rail members 11, 12 are manufactured from two separate metal sheets, which are attached at upper and lower ends 74a, 74b of the rail members 11, 12. An opening 76 is formed along the bottom of the rail members 11, 12. The second part 33b of the tubular member 33 is configured to fit through opening 76 and protrudes from the rail members 11, 12 below their bottom surface. The bore 31 of the mounting member 30 has a threaded section 37. In this embodiment, the threaded section 37 is located in the first part 33a of the tubular member 33. The bore 31 further comprises an unthreaded section 38, which is located in the second part 33b of the tubular member 33 in the embodiment of Figure 5b. The unthreaded section is arranged collinearly with the threaded section 37 and extends from the second end 30b towards the threaded section 37. The threaded section 37 extends from the first end 30a towards the unthreaded section 38. Accordingly, the unthreaded section 38 can be used as a lead-in means for the fastening member of the sub-frame. Similar to the first embodiment of Figure 4, the mounting member 90 of Figures 6a to 6c is a single piece, drop forged aluminium structure.

Another embodiment of a mounting member according to the present invention is shown in Figures 6a to 6c. The mounting member 90 of this embodiment is constructed as an insert. The mounting member 90 comprises a bore 91 extending along a bore axis B between a first end 90a and a second end 90b of the mounting member 90. The mounting member 90 comprises a threaded section 97 which is arranged collinearly with an unthreaded section 98. The unthreaded section 98 extends from the second end 90b of the mounting member 90 towards the threaded section 97, and thus provides a lead-in feature for the fastening member of the sub-frame.

The mounting member 90 of the embodiment shown in Figures 6a to 6c is constructed as a tubular member 93, particularly a circular cylinder, extending along the bore axis B. The tubular member 93 comprises three sections 93a, 93b and 93c. A first section 93a extends from the first end 90a of the mounting member 90 towards the second end 20b. A third section 93c extends from the second end 90b towards the first end 90a. A second section 93b extends between the first section 93a and a third section 93c. The second section 93b comprises the threaded section 97 of the bore 91, while the third section 93c comprises the unthreaded section 98. A recess 96 is formed within the bore 91 along the first section 93a. As shown in Figure 6b and 6c, the recess 96 results in a larger bore diameter in the vicinity of the first end 90a of the mounting member 90. This recess 96 provides the bore opening 92 at the first end 90a of the mounting member 90 with an oval or eccentric cross-sectional shape. This oval or eccentric cross-sectional shape can be used to attach the mounting member 90 to a corresponding insertion tool, thereby aligning the mounting member 90 correctly with respect to the insertion tool.

The tubular member 93 of the mounting member 90 comprises an anti-rotation member 95 protruding from the outer surface of the tubular member 93, as is best shown in Figure 6a. The protruding anti-rotation member 95 of this embodiment is constructed as a nose portion arranged along the first section 93a, that is, in the vicinity of the first end 90a of mounting member 90. The anti-rotation member 95 is positioned at the same circumferential position as the recess 96, illustrated by Figure 6c.

The tubular member 93 of the mounting member 90 comprises a plurality of splines 99a, 99b, and 99c. The splines extend along the outer surface of the tubular member 93 in a direction parallel with the bore axis B. The splines 99a, 99b, 99c extend from the first end 90a of the mounting member 90 across about a third of the length of the tubular member 93. Of course, it is also feasible to provide the splines 99a, 99b, and 99c across the entire length of the tubular member 93, for example. The splines 99a, 99b, 99c are spaced equidistantly around the circumference of the tubular member 93 and are used to provide an interference fit between the mounting member and a corresponding receptacle of the vehicle body.

A mounting flange 94 is arranged at the first end 90a of the mounting member 90. The mounting flange 94 is constructed as a boss to retain the mounting member 90 within a respective wall of the vehicle body, as will be described in more detail below. The mounting flange 94 extends around the entire circumference of the mounting member 90.

Figures 7a and 7b shows cross-sectional views of a rear part rail 21, 22 as described with reference to Figure 2. The rear part rails 21 or 22 shown in Figures 7a and 7b are constructed from a cast aluminium structure 101, which comprises a receptacle 103 adapted to receive the mounting member 90 described with reference to Figures 6a to 6c. An enlarged view of the illustration in Figure 7a is depicted by Figure 7b. The receptacle 103 has a generally circular bore 104 to receive the circular cylinder of the mounting member 90. The receptacle 103 comprises a recess 106 at a first, top end of the bore 104. As such, the first, top end of the bore 104 also has an elliptical or eccentric shape, similar to the first end 90a of the mounting member 90. The mounting member 90 is arranged inside the bore 104 of the receptacle 103 in such a way that the nose portion 95 is aligned with and received within the recess 106. Accordingly, the mounting member 90 interlocks with the receptacle 103 such that the nose portion 95 prevents the mounting member 90 from rotating within the receptacle 103 during assembly of the sub-frame to the vehicle body.

Figure 7b further shows that the mounting flange 94 sits on a first top end 103a of the receptacle 103 and prevents the mounting member 90 from being pulled downwards through the bore 104 of receptacle 103. The mounting member 90 is constructed such that the second end 90b never protrudes from the second end 103b of the receptacle 103. In other words, the distance between the mounting flange 94 and the second end 90b of the mounting member 90 is shorter than the longitudinal length of the receptacle 103 between its first end 103a and its second end 103b.

Figures 8a and 8b show another embodiment of an aluminium casting 201, which comprises a receptacle 203. The receptacle 203 is reinforced by a plurality of vanes 205a, 205c, 205d, 205e, 205f, 205g, and 205h. The mounting member 90 is received within the receptacle 203 in substantially the same manner as described with reference to Figures 7a and 7b above. The illustration in Figure 8b shows a cross-section of the mounting member 90 along line BB in Figure 8a, that is, a cross-section that does not run through the recess 96 of the bore 91.

Figure 9 shows a right-hand side view of a vehicle 300 according to an embodiment of the invention, which comprises a first sub-frame 14 releasably connected to the front section 10 of a vehicle body 1 using fasteners 16, 17 received within the bores 31 of mounting members 30 which are located in the second front rail 12. This vehicle 300 further comprises another sub-frame 24 releasably connected to the rear part 20 of a vehicle body 1 using fasteners 28, 29 received within the bores 91 of mounting members 90 which are located in the second rear rail 22.

Claims

1. A mounting member for mounting a sub-frame to a vehicle body, the mounting member defining a bore for receiving a mounting pin, wherein the mounting member is formed of forged aluminium.

2. The mounting member of claim 1, wherein the mounting member is formed of drop forged aluminium.

3. The mounting member of claim 1 or 2, wherein the bore comprises an internal threaded section.

4. The mounting member of any of claims 1 to 3, wherein the bore comprises an unthreaded section arranged collinearly with the threaded section and adapted for alignment of a fastening member with a bore axis of the bore.

5. The mounting member of any of claims 1 to 4, wherein the mounting member comprises a tubular member enclosing the bore.

6. The mounting member of any of claims 1 to 5, wherein the bore extends along a bore axis, wherein the mounting member comprises a mounting flange, the mounting flange extending in a plane substantially perpendicular to the bore axis and arranged to locate the mounting member within the vehicle body, in a direction of the bore axis.

7. The mounting member according to a combination of claims 5 and 6, wherein the tubular member extends in the direction of the bore axis on opposite sides of the mounting flange.

8. The mounting member of any of claims 1 to 7, wherein the mounting member comprises a first side flange extending in a plane substantially parallel to a bore axis of the bore and arranged to allow the mounting member to be secured against rotation within the vehicle body.

9. The mounting member according to a combination of claims 5 and 8, wherein an outer surface of the tubular member is connected to the first side flange by means of a first radial wall.

10. The mounting member of claim 8 or claim 9, wherein the first side flange defines at least one fastening aperture.

11. The mounting member of claim 8, claim 9, or claim 10, wherein the mounting member comprises a second side flange extending in a plane substantially parallel to and distanced from the plane of the first side flange, the second side flange being arranged to allow the mounting member to be secured against rotation within the vehicle body.

12. The mounting member according to a combination of claims 5 and 11, wherein an outer surface of the tubular member is connected to the second side flange by means of a second radial wall.

13. The mounting member of claim 11 or claim 12, wherein the second side flange defines at least one fastening aperture.

14. The mounting member of claim 12, wherein the first and second radial walls extend in opposite directions, away from the bore axis.

15. The mounting member of any of claims 1 to 14, wherein the mounting member is substantially symmetrical about the bore axis.

16. The mounting member of claims 5 and 6, wherein the tubular member comprises an inner surface and an outer surface, the inner surface defining the bore extending between a first end and an opposite second end of the tubular member, and wherein the mounting flange is located at the first end of the tubular member, at least partly around its outer surface.

17. The mounting member of claim 16, wherein the inner surface of the bore comprises an oval cross-section, at least at the first end of the tubular member.

18. The mounting member of claim 16 or 17, wherein the tubular member comprises at least one spline, extending in the direction of the bore axis.

19. The mounting member of any of claims 16 to 18, wherein the tubular member comprises an anti-rotation member protruding from the outer surface.

20. The mounting member of claim 19, wherein the anti-rotation member is a nose portion located in the vicinity of the first end.

21. The mounting member of claim 20, wherein the nose portion is in direct contact with the mounting flange.

22. A vehicle, comprising:

a vehicle body and a sub-frame attached thereto; a mounting member according to any one of claims 1 to 21; and a fastening member connecting the vehicle sub-frame with the vehicle body, the fastening member being received within the bore of the mounting member.

23. The vehicle of claim 22, wherein the sub-frame is attached to an aluminium part of the vehicle body.

24. The vehicle of claim 23, wherein the aluminium part is a crash box of the vehicle body.

25. The vehicle of claim 24, wherein the mounting member is attached to an inner surface of the crash box by means of fastening members.

26. The vehicle of claim 23, wherein the aluminium part is an aluminium casting of the vehicle body.

27. The vehicle of claim 26, wherein the mounting member is attached to the aluminium casting by means of an interference fit.

28. A method of manufacturing a mounting member for mounting a sub-frame to a vehicle body, the method comprising:

forging an aluminium mounting member with a bore adapted to receive a mounting pin; and forming a threaded section inside the bore.

29. The method of claim 28, wherein the aluminium material of the mounting member is extruded before forging into its final shape.

30. The method of claim 28 or 29, wherein the forged aluminium mounting member is 5 heat treated before forming the threaded section inside the bore.

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Intellectual

Property

Office

Application No: GB1621401.7 Examiner: Simon Rose