US20010000119A1 - Hydroformed space frame and joints therefor - Google Patents
Hydroformed space frame and joints therefor Download PDFInfo
- Publication number
- US20010000119A1 US20010000119A1 US09/729,944 US72994400A US2001000119A1 US 20010000119 A1 US20010000119 A1 US 20010000119A1 US 72994400 A US72994400 A US 72994400A US 2001000119 A1 US2001000119 A1 US 2001000119A1
- Authority
- US
- United States
- Prior art keywords
- end segment
- segment
- wall portions
- wall
- hydroformed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D23/00—Combined superstructure and frame, i.e. monocoque constructions
- B62D23/005—Combined superstructure and frame, i.e. monocoque constructions with integrated chassis in the whole shell, e.g. meshwork, tubes, or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/06—Tubes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49622—Vehicular structural member making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49805—Shaping by direct application of fluent pressure
Definitions
- the present invention is generally related to motor vehicle frames and more particularly to motor vehicle frames constructed of individual hydroformed members and to joints for connecting hydroformed members.
- Space frame architecture is increasingly being used in vehicle manufacturing and represents a relatively new approach to vehicle construction.
- a space frame is an assembly of individual frame components that are connected at joints to form a cage-like structure on which the other vehicle components can be mounted such as the engine, drive train, suspension and the hang-on vehicle body parts.
- the hang-on vehicle body parts may include the floor pan, roof, fenders, doors, body panels, hood and trunk lid.
- Conventional space frames have typically been constructed from numerous stamped or roll-formed parts which are welded or otherwise joined together. In the automotive industry there is always a continuing need to reduce the weight and number of parts in order to produce more cost-effective and fuel efficient vehicles. At the same time, it is important to maintain the structural integrity of the vehicle structure.
- the present invention stems from the recognition that stamped and roll formed vehicle space frame members require numerous assembly steps and joijnts that may result in significant tolerance build-up.
- Tubular hydroforming offers many advantages in space frame construction because it can enable manufacturers to better control frame stiffness, dimensional stability, fatigue life, and crashworthiness over prior vehicle designs while reducing frame mass and cost.
- Hydroforming is a metal-forming process in which high pressure fluid is used to outwardly expand a tubular blank into conformity with surfaces of a die cavity of a die assembly to form an irregularly shaped tubular part.
- Hydroformed members can be provided with a wider range of geometries in comparison with stamped or roll formed parts.
- Each frame member can have a cross-sectional configuration that varies continuously along its length, to the configuration desired.
- Hydroformed parts are also advantageous because they have a higher strength than stamped parts, primarily because of the plastic deformation of the wall of the blank during the hydroforming process. More particularly, the outward expansion of the wall of the blank during hydroforming caused by the fluid pressure creates a work-hardening effect which uniformly hardens the metal material of the blank. Hydroforming also produces less waste metal material than stamping.
- tubular hydroforming has many advantages over more conventional stamping and welding technologies.
- the individual hydroformed members that make up the space frame must be able to be quickly and accurately assembled into space frames for mass production. This requires that joints between individual hydroformed members be quickly and easily formed.
- Typical space frame designs utilize separate joint forming structures, sometimes called “nodes”, to connect two or more elongated hydroformed members.
- An example of a conventional node having several short discrete projections extending outwardly at predetermined angles and of the use of nodal architecture in space frame construction is shown in WO 97/00595.
- Nodal architecture of the type shown in WO 97/00595 requires the elongated hydroformed frame members to be assembled together in a fixed, predetermined angular and spatial arrangement.
- Each outward projection on a '595 node is telescopically interengaged with and then affixed to an opening in one of the elongated tubular hydroformed members to be joined.
- the end of the each hydroformed member is usually affixed to the node by welding.
- Nodal space frame architecture presents manufacturing difficulties that limit the commercial feasibility of the space frames constructed using this design concept.
- the nodes themselves are difficult to manufacture. It may not be easy to form nodes by hydroforming a tubular blank (depending on the node size, geometry and so on). For this reason, nodes are sometimes formed by methods other than hydroforming such as by casting.
- the use of nodes in space frame construction also requires a relatively large number of welds to form a single joint. For example, if three elongated hydroformed members are to be joined with one node, three welds are required. Such connections add to the tolerance stack-up and detract from the dimensional reproduceability from frame to frame.
- use of nodes adds to the total number of parts required to assemble the space frame, thus also adding to the total weight and cost of the frame.
- An object of the present invention is to meet the needs identified above by providing a variety of different types of joints for joining hydroformed members and joint forming methods therefor in constructing the space frame.
- One vehicle space frame joint for example, includes a first space frame structure in the form of a tubular elongated first member and a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member.
- the first member includes an end segment having a predetermined length, a terminal end portion and an exterior surface that defines an exterior configuration of the end segment.
- the second member is defined by an outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration and includes a hydroformed intermediate segment having a cross section that defines a pair of opposing first and second wall portions spaced apart a distance approximately equal to the predetermined length of the end segment.
- the first and second wall portions of the intermediate segment include generally aligned first and second openings formed within the first and second wall portions, respectively, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member.
- the end segment extends through the first opening with the terminal end portion thereof disposed within the second opening, and welding material is disposed on the segments to fixedly secure the first and second segments together.
- the welding material that is constructed and arranged to fixedly secure the first and second segments together is applied in the areas of the juncture between the exterior surface of the end segment and a periphery of the first opening and in the area of juncture between an exterior surface portion of the terminal end portion of the end segment and a periphery of the second opening.
- a method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member; (4) placing the end segment of the first member through the first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of the openings; and (5) welding the intermediate segment and the end
- FIG. 1 is a perspective view of a space frame constructed according to the principles of present invention
- FIGS. 2 - 19 are illustrations of various views of joints used in the space frame of FIG. 1;
- FIG. 20 is a schematic view of a hydroforming die assembly and a tubular blank therein.
- FIG. 1 is a perspective view of a vehicle space frame 10 constructed in accordance with the principles of the present invention.
- the space frame 10 generally includes a forward frame portion 12 , a middle frame portion 16 and a rearward frame portion 18 .
- a pair of laterally spaced, longitudinally extending lower side rail structures 22 are disposed on each side of the space frame 10 and extend the length thereof.
- the lower side rail structures 22 are preferably constructed of three tubular hydroformed members fixed together at joints. Specifically, each side rail structure 22 includes a hydroformed forward lower side rail member 26 , 28 , respectively, a hydroformed intermediate lower side rail member 30 , 32 , respectively, and a hydroformed rearward lower side rail member 34 , 36 , respectively.
- the pairs of hydroformed members 26 , 28 ; 30 , 32 and 34 , 36 are of mirror image construction. Only one member 26 , 30 , and 34 of each pair will be discussed in detail, but the discussion applies to both pair members.
- Each forward lower side rail member 26 is connected to the associated intermediate lower side rail member 30 at a joint 38 .
- each intermediate lower side rail member 30 is connected to the associated rear lower side rail member 34 at a joint 42 .
- a forward end portion of the intermediate lower side rail member 30 is constructed and arranged to be telescopically received within a rearward end portion of the forward lower side rail member 26 and is welded in place to form the joint 38 .
- Joint 42 is of similar construction. That is, a forward end portion of the rearward lower side rail member 34 is constructed and arranged to be telescopically received within a rearward end portion of the intermediate lower side rail member 30 and is welded in place to form the joint 42 .
- the forward lower side rail member 26 has an inwardly spaced forwardmost portion 50 (where the terms “inwardly” and “outwardly” in the present detailed description refer respectively to the directions toward and away from a longitudinally extending centerline of the space frame 10 ) which transitions into an outwardly angled middle portion 52 which in turn transitions into a rearward portion 54 .
- the intermediate lower side rail member 30 is essentially straight.
- the hydroformed tubular rear lower side rail member 34 includes a short forward portion 56 which transitions into a central upwardly arching portion 58 which transitions into a relatively straight rearward end portion 60 .
- the central portion 58 forms a rear wheel well on the space frame 10 .
- Each upper longitudinal structure 62 is mounted on each side of the space frame 10 .
- Each upper longitudinal structure 62 is formed from a pair of tubular hydroformed members.
- each upper longitudinal structure 62 includes a tubular hydroformed forward upper longitudinal member 66 , 68 , respectively, and a hydroformed tubular rearward upper longitudinal member 70 , 72 , respectively.
- the pairs of forward and rearward upper longitudinal members 66 , 70 and 68 , 72 on each side of the space frame 10 are connected at joints 44 .
- the joint 44 is formed by placing a forward tubular end of the rearward upper longitudinal member 70 telescopically within a rearward end of the forward upper longitudinal member 68 and welding the pair of members 68 , 70 together.
- Each forward upper longitudinal member 66 is an integral hydroformed tubular member that includes an essentially straight pillar-forming portion 78 and an arcuate longitudinally extending portion 82 .
- Each pillar-forming portion 78 is connected to a respective forward lower side rail member 26 at a joint 75 and extends upwardly therefrom so that the pillar-forming portion 78 of each forms a forward-most or “A” pillar structure of the space frame 10 .
- Each rearward upper longitudinal member 70 has an arcuate forward longitudinally extending portion 86 which transitions into a short end portion 90 .
- the longitudinally extending portions 82 of the forward upper longitudinal member 66 form joints 87 with a tubular hydroformed first U-shaped cross member 94 of the space frame 10 ; and the longitudinally extending portions 86 form joints 89 with a tubular hydroformed second U-shaped cross member 96 .
- Each pair of longitudinally extending portions 82 and 86 on each side of the space frame 10 defines a roof rail structure between the associated A pillar-forming portion 78 of the forward upper longitudinal member 66 and the joints 89 with a cross member 96 on respective sides of the space frame 10 .
- the first U-shaped cross member 94 and the second U-shaped cross member 96 extend laterally across the space frame 10 .
- Each cross member 94 , 96 is preferably an integral tubular hydroformed member that includes a cross portion 98 , 100 , respectively, and a pair of integral leg portions 102 , 104 , respectively, extending from junctures 106 , 108 at opposite ends of the associated cross portion 98 , 100 .
- the leg portions 102 , 104 of the first and second U-shaped members 94 , 96 form joints 110 , 112 , respectively, with the lower side rail members 30 , 34 , respectively.
- the leg portions 102 of the U-shaped member 94 are essentially straight and extend upwardly from respective side rail structures 22 to form a pair of laterally spaced intermediate or “B” pillar structures on the space frame 10 that extend between the associated lower side rail structure 22 and the associated roof rail structure.
- the leg portions 104 of the second U-shaped member 96 form a pair of rearward-most or “C” pillar structures on the space frame 10 that extend between the associated lower side rail structure 22 and the associated roof rail structure.
- the cross portions 98 , 100 of the first and second U-shaped members 94 , 96 provide laterally extending cross structures that extend in the cross-car direction between the pair of B pillar structures and between the pair of C pillar structures, respectively, and define a lateral length between the associated pairs through the use of an integral hydroformed structure, thereby minimizing the stacked tolerances between the pairs of B and C pillars as taught and described in detail in commonly assigned U.S.
- a pair of laterally extending tubular hydroformed cross members 126 , 128 provide space frame cross structures interconnecting the forward upper longitudinal members 66 , 68 and provide support structures for a vehicle windshield (not shown) in the assembled vehicle.
- the cross member 126 is connected to the upper longitudinal members 66 , 68 at joints 129 .
- Each end of the cross member 126 is welded in a hydroformed recess 133 formed within the forward upper longitudinal member 66 , 68 during the hydroforming process.
- the joints 129 are formed on the longitudinally extending portion 82 of each member 66 , 68 above the transition between the pillar-forming portion 78 and the longitudinally extending portion 82 of each forward upper longitudinal member 66 , 68 .
- the tubular cross member 128 has flattened ends that are placed in overlying, abutting relation with the longitudinally extending portions 82 of the forward upper longitudinal members 66 , 68 and welded in place to form joints 131 .
- a plurality of laterally extending, longitudinally spaced tubular hydroformed cross members 134 , 136 , 138 and 140 provide cross structures that are connected between the lower side rail structures 22 .
- the cross members 134 , 136 and 138 are provided with upwardly extending arched central portions 142 , 144 , 146 to accommodate the drive train (not shown) of the assembled vehicle.
- Each end portion of each hydroformed cross member 134 , 136 , 138 , 140 forms a joint with an associated lower side rail structure 22 .
- the cross member 134 forms joints 150 with the forward lower side rail members 26 , 28 respectively; the cross member 136 forms joints 154 with the intermediate lower side rail members 30 , 32 respectively; the cross member 138 forms joints 158 with the intermediate lower side rail members 30 , 32 , respectively; and the cross member 140 forms joints 162 with the rearward lower side rail members 34 , 36 , respectively.
- These joints are considered in detail below.
- a hydroformed tubular U-shaped member 166 and a hydroformed tubular elongated member 168 extend laterally across the forward-most end of the space frame 10 .
- the U-shaped member 166 includes an essentially straight tubular cross portion 170 which transitions through junctures 171 at opposite ends thereof into outwardly and upwardly extending tubular leg portions 172 .
- the cross portion 170 provides the lower cross structure connected between the lower side rails 22 and the leg portions 172 provide a pair of upright structures at the front end of the space frame 10 .
- the U-shaped member 166 is preferably welded at the junctures 171 thereof to the lower side rail structures 22 to form joints 173 .
- the U-shaped member 166 is placed in abutting contact with the lower side rail structures 22 and welded. Wall portions of each lower side rail structure 22 may be cut out to receive portions of the U-shaped member 166 to form the joints 173 .
- the elongated member 168 includes an essentially straight central portion 176 that transitions angularly downwardly at each end thereof into relatively short downwardly extending end portions 178 .
- the end portions 178 form joints 182 with respective leg portions 172 of the U-shaped member 166 .
- a pair of tubular hydroformed forward upper side rail members 180 , 184 are provided which provide forward upper side rail structures in the front portion 12 of the space frame 10 .
- Each upper side rail member 180 , 184 forms a joint 185 at a forward end thereof with an associated leg portion 172 of the U-shaped member 166 and a joint 186 at a rearward end thereof with an associated forward upper longitudinal member 66 , 68 .
- the upper side rail members 180 , 184 and the forward and intermediate portions 50 , 52 of the associated forward lower side rail member 26 , 28 to define a front wheel well 187 on each side of the front portion 12 of the space frame 10 .
- a tubular hydroformed U-shaped cross member 189 is mounted at the rearward-most end of the space frame 10 .
- the U-shaped member 189 has a tubular cross portion 190 and a pair of leg portions 191 extending from junctures 192 at opposite ends of the cross portion 190 .
- the cross portion 190 provides a cross structure connected between the lower side rail structures 22 and the leg portions 191 provide a pair of upright structures on the rearward portion 18 of the space frame 10 .
- Each leg portion 191 of the U-shaped cross member 189 forms a joint 118 with the free end of the associated rearward upper longitudinal member 70 , 72 .
- Each juncture 192 forms a joint 119 with an associated lower side rail structure 22 .
- Each hydroformed member used to construct the space frame 10 is formed from a tubular blank 200 constructed of a suitable metal material.
- Each tubular blank 200 has a closed transverse cross section and open tubular ends.
- Each tubular blank 200 may be constructed by any suitable method.
- the transverse cross section of each tubular blank may be shaped by roll forming a continuous longitudinally extending strip of sheet metal in a roll forming operation. The transverse cross section may be closed subsequently by a seam welding operation.
- each of the hydroformed tubular members of each exemplary space frame 10 has only a single longitudinally extending seam weld that is formed in creating the original tubular blank.
- This is distinct from more conventional tubular frame members, which comprise two C-shaped or “clam-shell” halves welded to one another in facing relation along two seams. The tubular blank is then cut to the length required to make a particular hydroformed member.
- the tubular blank used to make that hydroformed member can be constructed by butt welding two blanks of different diameter.
- the diameters of the two ends to be butt-welded can be equalized either by using a reduction tool to reduce the diameter of one end of the larger diameter tubular blank or, alternately, by using a flaring or expansion tool to expand the diameter of an end portion of the smaller diameter blank, or a combination of both.
- the result of either operation is to equalize the diameters of the two ends to be butt-welded together.
- the butt-welded connection is formed prior to the hydroforming operation, but the butt-welding operation can be performed either before or after any pre-bending operations are performed, which operations are considered immediately below.
- the blank may optionally be “pre-bent”, that is, bent prior to being placed in a hydroforming die assembly, if the geometry of the part is complex or if there are to be any sharp bends in the finished member. For example, if there is a sharp bend (a bend of greater than 30°) in the hydroformed member, preferably the present invention bends the blank according the teachings of Ser. No. 09/299,595, filed Oct.
- the tubular blank 200 is then placed between the die halves 202 , 204 of the die assembly 206 and assembly is closed.
- the tubular blank 200 is preferably immersed in a fluid bath so that it is filled with hydroforming fluid.
- a hydroforming ram assembly 208 , 210 is engaged with each end of the tubular blank 200 such that a ram member 216 , 218 of each assembly 208 , 210 seals an end of a tubular blank 200 .
- the ram members 216 , 218 include hydraulic intensifiers which can intensify the hydroforming fluid, thereby increasing the fluid pressure of the fluid within the blank 200 to irregularly outwardly deformed tubular metallic wall, generally designated 220 , of the tubular blank 200 into conformity with the die surfaces 222 of the die cavity (as disclosed in Ser. No. 60/061,238) to thereby form a hydroformed member having an exterior surface that is fixed into a predetermined irregular configuration.
- the ram members 216 , 218 push axially inwardly on opposite ends of the blank 200 to create metal flow within the blank 200 during outward expansion.
- the fluid pressure and the axial pressure are independently controllable.
- the ends of the tubular blank 200 are pushed axially inwardly during the hydroforming operation to maintain the wall thickness of the fully formed hydroformed member within a predetermined range of the wall thickness of the initial tubular blank 200 . This process is discussed in detail in the aforesaid application Ser. No. 60/061,238.
- the ram members 216 , 218 cooperate to replenish or maintain the wall thickness of the outwardly expanding wall portions of the blank 200 so that the wall thickness of the resulting hydroformed member is within about ⁇ 10% of the original wall thickness of the blank 200 (i.e., to compensate for wall thinning during diametric outward expansion of the tube).
- the tubular blank 200 expands into conformity with the surfaces 222 defining the hydroforming die cavity so as to irregularly outwardly expand the metallic wall 220 of the blank 200 into conformity with the surfaces 222 of the die assembly 206 to provide the metallic wall 220 with a shape corresponding to the desired shape for the member.
- the shape of each die cavity used to form each hydroformed member of the space frame 10 in accordance with the present invention is particularly adapted to the shape of the new and advantageous hydroformed tubular members contemplated herein.
- holes are to be formed in a hydroformed member, the holes may be formed whole the member is still in the die assembly during the hydroforming operation or may be formed after the hydroformed member is removed from the die assembly along with any other required further processing of the member. More particularly, holes may be formed during the hydroforming process in what is known in the art as a hydropiercing operation. A hydropiercing operation is disclosed in U.S. Pat. No. 5,460,026 which is hereby incorporated by reference in its entirety into the present application. Alternatively, holes or notches may be cut in a hydroformed member after the hydroforming operation is completed, such as by laser cutting. A net pad can be used to form a recess in a hydroformed member (such as recess 133 ).
- transverse cross section of many of the hydroformed members varies along the length of the particular hydroformed member.
- the transverse cross sections of the leg portions 102 and the cross portion 98 of the tubular hydroformed cross member 94 vary long the longitudinal length thereof.
- the cross portion 98 has a relatively small substantially rectangular cross-section and the leg portions 102 have relatively large substantially rectangular cross-section near the free ends thereof and an irregular transverse cross section in the middle portions thereof. It can be understood that altering the cross-sectional configuration of this tubular hydroformed member or of any other tubular hydroformed member disclosed herein can be accomplished without departing from the principles of the present invention.
- each hydroformed member used to construct the space frame 10 is of generally of tubular construction. Forming a space frame of individual tubular hydroformed members offers may advantages, but Joining these tubular hydroformed members together to form the space frame 10 is a critical part of space frame construction. Several representative types of joints formed between tubular hydroformed members are described below and illustrated in the drawings. A preferred welding method is considered thereafter.
- FIGS. 2 - 19 show enlarged fragmentary views of joints 150 , 154 , 158 and 162 of FIG. 1. Because these joints are of similar construction, only joint 162 is considered in detail, but the construction of joints 150 , 154 and 158 can be understood from the perspective view of joint 162 in FIG. 4 and the cross sectional views of joint 162 in FIGS. 5 and 6 .
- joint 162 is the connection between the hydroformed cross member 140 and the hydroformed rearward lower side rail member 34 in the space frame 10
- the members 34 , 140 should be viewed as representing two generic space frame members, and is not restricted to being formed between a lower side rail member and a cross member of the space frame, nor to being formed between two hydroformed members.
- joint 162 can be broadly understood to be a vehicle space frame joint comprising a first space frame structure in the form of a tubular elongated first member 140 and a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member 34 .
- the first member 140 includes an end segment 315 that has a predetermined length and an exterior surface 316 that defines an exterior configuration of the end segment 315 .
- the hydroformed second member 34 is defined by an outwardly deformed tubular metallic wall 314 fixed into a predetermined exterior surface configuration.
- the hydroformed second member 34 has an intermediate segment 318 that includes a pair of opposing first and second wall portions 320 , 322 .
- the first and second wall portions 320 , 322 of the intermediate segment 318 include generally aligned first and second openings 324 , 326 formed within the first and second wall portions 320 , 322 , respectively.
- the first and second openings 324 , 326 are of complimentary configuration to portions of the exterior surface 316 of the end segment 315 of the first member 140 , and are preferably formed by laser cutting.
- the joint 162 is formed by placing the end segment 315 of the first member 140 through the first and second openings 324 , 326 such that portions of the exterior surface 325 thereof are in abutting engagement with edge portions of the openings 324 , 326 . More specifically, the joint 162 is formed by positioning the end segment 315 so that it extends through the first opening 324 with a terminal end portion 328 thereof disposed within (and preferably slightly beyond) the second opening 326 .
- the joint 162 further includes welding material 330 that is constructed and arranged to fixedly secure the intermediate and end segments 318 , 315 together, the welding material 330 being applied in the areas of the juncture between the exterior surface 325 of the end segment 315 and the edge portions of the openings 324 , 326 . More specifically, the welding material 330 is applied in the areas of the juncture between the exterior surface 325 of the end segment 315 and a periphery 327 of the first opening 324 and in the area of juncture between an exterior surface portion 332 of the terminal end portion 328 of the end segment 315 and a periphery 329 of the second opening 326 .
- the end segment 315 of the first member has a generally uniform cross section along its length and preferably the first and second openings 324 , 326 in the intermediate segment 318 of the hydroformed second member 34 are of approximately equal size and shape as shown, for example, in FIGS. 5 and 6 . It can be understood, however, that this is exemplary only and not intended to be limiting.
- the exterior surface of the end segment 315 (and, therefore, the cross section of the end segment) will vary (i.e., be nonuniform) along the length of the end segment and that, consequently, the openings 324 , 326 will be of different size and shape from one another so that they will be in abutting engagement with portions of the end segment adjacent thereto when the end segment is disposed within the openings to allow welding material to be placed in bonding relation therebetween.
- the cross section of the first member 140 will be uniform along its entire length in some embodiments of the space frame 10 and of the joint 162 .
- the cross section of the first member 140 can be nonuniform along its length in other joint 162 or space frame 10 embodiments.
- the first member 140 may be formed by any known metal forming process such as by roll forming, or by hydroforming.
- the forming of the first member 140 is accomplished by a roll forming operation.
- An embodiment of the joint 162 is contemplated, for example, in which the first member 140 is roll formed into a quadrilateral configuration.
- the first member 140 is formed by hydroforming a tubular blank having a tubular metallic wall so that the first member 140 is defined by an outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration. It will be understood that when the first member 140 (and the end segment 315 thereof) is formed by hydroforming, it can be constructed to have a uniform cross section in some embodiments of the joint 162 and to have a nonuniform cross section in other embodiments of the joint 162 .
- the members 140 , 34 when they are hydroformed, they can be constructed to have cross sections that are uniform or non uniform. It is contemplated, for example, that the cross section of the intermediate segment 318 can have a wide range of constructions and it can be understood that the embodiment of the hydroformed second member 34 is exemplary only and not intended to limit the scope of the invention.
- the opposing first and second wall portions 320 , 322 of the hydroformed second member 34 are essentially planar and parallel, but, although this is one preferred embodiment of the joint 162 , this planar and parallel configuration of the wall portions 320 , 322 of the intermediate segment 318 is not a requirement.
- the opposing wall portions 320 , 322 can in other preferred embodiments, for example, be arcuate, can consist of a plurality of straight portions (as viewed from the cross sectional view of FIG. 6, for example), or can be planar and nonparallel. Planar, parallel opposing walls 320 , 322 present straight, easily accessible and easily tracked seams for welding. Furthermore, it is contemplated that the intermediate segment 318 of the hydroformed second member 34 can have a generally uniform cross section along its length or, alternatively, a nonuniform cross section along its length.
- the present invention contemplates a method of forming a vehicle space frame joint 162 comprising (a) forming a tubular elongated first member 140 constructed of a metallic material that includes an end segment 315 .
- the end segment 315 has a predetermined length and an exterior surface 325 that defines an exterior configuration of the end segment 315 ; (b) forming an elongated tubular hydroformed second member 34 by hydroforming a tubular blank having a tubular metallic wall so as to irregularly outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member 34 having an intermediate segment 318 that includes first and second spaced apart wall portions 320 , 322 ; (c) forming generally aligned first and second openings 324 , 326 within the first and second wall portions 320 , 322 , respectively, of the intermediate segment 318 of the second member 34 , the first and second openings 324 , 3
- the welding material is applied in an area of juncture between exterior surface portions 325 of the end segment 315 and the surfaces adjacent the periphery 327 of the first opening 324 and in an area of juncture between an exterior surface portion of the terminal end portion 328 of the end segment 315 and surfaces adjacent the periphery of the second opening 326 .
- the forming of the first member 140 is accomplished by roll forming, and in one preferred example of roll forming, the first member is roll formed to have a quadrilateral configuration, although it can be understood that the first member 140 can be roll formed to have a wide range of cross-sectional configurations.
- the first member is of tubular hydroformed construction.
- the forming of the first member 140 is accomplished by hydroforming a second tubular blank having a tubular metallic wall so as to outwardly deform the second tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a second die assembly. More preferably, the second tubular blank is irregularly outwardly deformed during the hydroforming process for hydroforming the first member so that the first member 140 has a nonuniform cross section along its length.
- FIGS. 7 - 9 show an enlarged view of the joint 182 (see FIG. 1).
- joint 182 is the connection between the U-shaped cross member 166 and the cross member 168
- the joint 182 can be broadly understood to be a vehicle space frame joint comprising a first space frame structure in the form of a first elongated tubular hydroformed member 166 defined by an outwardly deformed first tubular metallic wall 360 fixed into a predetermined irregular exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated tubular hydroformed member 168 defined by an outwardly deformed second tubular metallic wall 342 fixed into a predetermined exterior surface configuration.
- the first member 166 includes a tubular first segment 344 that includes a pair of spaced first and second wall portions 346 , 348 which provide first and second exterior surfaces 354 , 356 , respectively.
- the second member 168 includes an end segment 358 having a pair of spaced cantilevered first and second wall portions 360 , 362 .
- the first and second wall portions 360 , 362 define spaced generally opposing interior wall surfaces 368 , 370 , respectively.
- the first segment 344 is positioned between the cantilevered first and second wall portions 360 , 362 of the end segment 358 such that the interior surfaces 368 , 370 of the first and second wall portions 360 , 362 of the end segment 358 and the exterior surfaces 354 , 356 of the first and second wall portions 346 , 348 of the first segment 344 are in abutting relation.
- Welding material 380 is disposed in bond forming relation between the interior surfaces 368 , 370 of the first and second wall portions 360 , 362 of the end segment 358 and the abutting exterior surfaces 354 , 356 of the first segment 344 .
- the end segment 358 has a pair of connecting wall portions 364 , 366 that extend between the first and second wall portions 360 , 362 .
- Each connecting wall portion 364 , 366 of the end segment 358 has a notch 372 cut therein (by laser cutting or by any other appropriate means) to form the cantilevered wall portions 360 , 362 and to allow the first segment 344 to be received between the first and second wall portions 360 , 362 of the end segment 358 in abutting relation therewith.
- the respective metallic walls 340 , 342 of the hydroformed members 166 , 168 can be shaped during the hydroforming process to have either uniform cross sections (by regularly outwardly deforming the same during hydroforming) or varying cross sections (by irregularly outwardly deforming the same during hydroforming).
- the metallic wall 342 of the second blank is irregularly outwardly deformed during the hydroforming procedure so that the second hydroformed member 168 has an irregularly outwardly deformed tubular metallic wall 342 .
- the first segment 344 of the first member 166 can be constructed to have a generally uniform cross section, or, alternatively, the cross section of the first segment 344 can vary along its length.
- the end segment 358 of the second member 168 can have a generally uniform cross section as shown in the exemplary embodiment of FIGS. 7 - 9 , or the cross section can vary (i.e., be nonuniform).
- first and second wall portions 346 , 348 and 360 , 362 of the first segment 344 and of the end segment 358 are essentially planar and parallel in some preferred embodiments of the joint 182 (as shown in FIGS. 7 - 9 ), but in other preferred embodiments of the joint 182 can be constructed to be, for example, arcuate or, alternatively, to be planar and nonparallel and so on.
- the wall portions 346 , 348 and 360 , 362 can be constructed to have a wide range of configurations, and can be of any configuration that allows sufficient abutting engagement therebetween to allow them to be welded together.
- the wall portions 346 , 348 and 360 , 362 of the members 166 and 168 can all be essentially parallel (as shown) or, alternatively, the walls 346 and 348 (and therefore walls 360 and 362 ) can be nonparallel.
- a method of forming a space frame joint 182 can be understood from FIGS. 7 - 9 , the method comprising (a) hydroforming a first blank having a first tubular metallic wall 340 so as to irregularly outwardly deform the first wall 340 into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubular hydroformed member 166 .
- the first elongated tubular hydroformed member 166 includes a tubular first segment 344 that includes a pair of spaced, generally opposing first and second wall portions 346 , 348 , the first and second wall portions 346 , 348 having exterior surfaces 354 , 356 ; (b) hydroforming a second blank having a second tubular metallic wall 342 so as to outwardly deform the second wall 342 into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second tubular hydroformed member 168 .
- the second tubular hydroformed member 168 includes a tubular end segment 358 that includes a pair of spaced, generally opposing first and second wall portions 360 , 362 and first and second connecting wall portions 364 , 366 extending therebetween.
- the first and second wall portions 360 , 362 having interior wall surfaces 368 , 370 ;
- the joints 75 , 110 and 112 are essentially identical.
- the joint 75 is shown in isolation in FIGS. 10 - 12 and is considered in detail immediately below.
- the joints 110 and 112 can be understood from this discussion.
- the joint 75 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of a first elongated tubular hydroformed member 26 (the essentially straight portion 54 thereof) defined by a first outwardly deformed tubular metallic wall 390 fixed into a predetermined exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated tubular hydroformed member 66 (i.e., the pillar-forming portion 78 of the forward upper longitudinal member 66 ) defined by a second outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration.
- the first member 26 includes an intermediate segment 394 having generally opposing first and second wall portions 396 , 398 , a connecting wall portion 400 extending between the first and second wall portions 396 , 398 , and an opening into the first member 418 .
- the first and second wall portions 396 , 398 of the intermediate segment 394 provide a pair of generally opposing interior surfaces 404 , 406 .
- the first wall portion 396 has a weld opening 424 formed therein.
- the second member 66 has an end segment 408 that has generally opposing first and second wall portions 410 , 412 providing a pair of generally opposing exterior surfaces 414 , 416 .
- the first and end segments 394 , 408 are constructed and arranged such that when the end segment 408 is positioned between the first and second wall portions 396 , 398 of the intermediate segment 394 , the pair of interior surfaces 404 , 406 is in abutting relation with the pair of exterior surfaces 414 , 416 .
- a section of at least one connecting wall portion 400 or 402 of the intermediate segment 394 is cut out and removed to form at least one opening 418 to allow the end segment 408 to be positioned in abutting relation with the intermediate segment 394 as aforesaid (and as shown in FIGS. 11 and 12 ).
- the end segment 408 is positioned within the opening 418 so that the opposing exterior surfaces 414 , 416 of the end segment 408 are disposed adjacent to the opposing interior surfaces 404 , 406 of the intermediate segment 390 and to the welding opening 424 .
- a section of the first wall portion 396 of the intermediate segment 394 is cut out and removed to form a weld opening 424 therein constructed and arranged such that when the end segment 408 is in abutting relation with the intermediate segment 394 , an exterior surface 414 of the end segment 408 is adjacent the weld opening 424 .
- Welding material 428 is disposed in bond forming relation between a peripheral edge portion 431 of the weld opening 424 and the adjacent exterior surface 414 of the end segment 408 , thus fixing the first and second members 394 , 408 together. More particularly, preferably there is a puddle weld 427 formed within the opening 424 and a mig weld 429 formed along the upper edge 430 . As stated, there can optionally be a second weld opening on the opposite side of the segment 394 for a second puddle weld. The mig weld 429 can be applied to the upper edge 430 of the opening 418 on one longitudinally extending side of the segment 394 or on both sides as shown (see FIG. 12).
- the joint 75 is exemplary only and not intended to limit the scope of the invention.
- the second member 66 is a tubular hydroformed member, but it is within the scope of the invention to form the second member by roll forming (particularly roll forming a quadrilateral configuration) or using any other suitable construction.
- the tubular metallic walls for 390 , 392 can be outwardly expanded during the hydroforming operation to have uniform cross sections or can be hydroformed to have irregularly outwardly deformed exterior surfaces to provide each member with non-uniform (i.e., varying) cross sections.
- first and second wall portions 396 , 398 of the intermediate segment 394 and the first and second wall portions 410 , 412 of the end segment 408 are generally planar and parallel. It is within the scope of the invention however, to provide embodiments of the joint 75 in which the surfaces 404 , 406 and 414 , 416 are planar and nonparallel or, alternatively, are arcuate, or of any other suitable configuration that provides pairs of interior and exterior surfaces on the intermediate and end segments that can be placed in adjacent relation when the end segment is positioned in the intermediate segment.
- the intermediate segment 394 has a pair of generally opposing connecting wall portions 400 , 402 .
- An embodiment of the joint 75 is contemplated in which a wall section can be cut out and removed from both the first and second connecting wall portions 400 , 402 of the intermediate segment 394 to form a pair of generally aligned first and second openings (only one 418 is formed in the intermediate segment 394 in the exemplary joint shown in FIGS. 10 - 12 ).
- the second member 66 is positioned such that it extends through two aligned openings (one opening being in each connecting wall portion 400 , 402 ) in the first member so that the second member extends outwardly from the first member on two sides thereof.
- the weld opening or openings 424 provides welding access to the second member at a location at or near the free end of the end segment of the second member (when the end segment 408 is in the position, for example, shown in FIG. 11) without the necessity of forming a large opening in the wall portion 402 to expose a portion of the end segment 408 .
- the joint 75 can be constructed utilizing a method of forming a vehicle space frame joint 75 comprising (a) hydroforming a first blank having a first tubular metallic wall 390 to outwardly deform the first wall into an exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubular hydroformed member 26 .
- the first member 26 includes a intermediate segment 394 having generally opposing first and second wall portions 396 , 398 and generally opposing first and second connecting wall portions 400 , 402 extending therebetween.
- the first and second wall portions 396 , 398 provide a pair of generally opposing interior surfaces 404 , 406 ; (b) hydroforming a second blank having a second tubular metallic wall 392 to outwardly deform the second wall into an exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubular hydroformed member that includes a end segment 408 having generally opposing first and second wall portions 410 , 412 providing a pair of generally opposing exterior surfaces 414 , 416 ; (c) cutting and removing a section of one of said connecting wall portions 400 , 402 of the intermediate segment 394 to form an opening of sufficient dimension to receive the end segment of the second member and cutting a section of the first wall portion 396 of the intermediate segment 394 to form a weld opening 424 therein; (d) positioning the end segment 408 into said opening 418 and between the first and second wall portions 396 , 398 of the intermediate segment 394 so that the exterior surface of the first wall portion
- the joints 185 (see FIGS. 1 and 7 ) and 186 (see FIGS. 1 and 13 - 15 ) are identical. Joint 186 will be considered in detail. Joint 186 is shown in isolation in FIGS. 13 - 15 .
- the joint 186 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of an elongated tubular hydroformed first member 66 (specifically, the pillar-forming portion 78 thereof) defined by a first outwardly deformed tubular metallic wall 432 fixed into a predetermined exterior surface configuration and an intersecting space frame structure in the form of an elongated tubular hydroformed second member 184 defined by a second outwardly deformed tubular metallic wall fixed 434 into a predetermined exterior surface configuration.
- the first member 66 includes a tubular hydroformed first end segment 436 that includes a pair of spaced generally opposing first and second wall portions 438 , 440 and a connecting wall portion 441 extending therebetween.
- the first and second wall portions 438 , 440 provide a pair of spaced generally opposing exterior surfaces 446 , 448 .
- the second member 184 includes a tubular hydroformed end segment 450 that includes a pair of spaced generally opposing first and second wall portions 452 , 454 and first and second connecting wall portions 455 , 457 extending therebetween.
- the first and second wall portions 452 , 454 define spaced generally opposing interior wall surfaces 458 , 460 .
- the opposing first and second wall portions 438 , 440 of the first segment 436 and the opposing first and second wall portions 452 , 454 of the end segment 450 are constructed and arranged such that when the first segment 436 is received between the first and second wall portions 452 , 454 of the end segment 450 , the interior surfaces 458 , 460 of the end segment 450 and the exterior surfaces 446 , 448 of the first segment 436 are in abutting relation;
- Each connecting wall portion 455 , 457 of the end segment 450 has a notch 456 sufficient to allow the first segment 436 to be received between the first and second wall portions 452 , 454 of the end segment 450 in abutting relation therewith as aforesaid.
- the first segment 436 is positioned in the notches 456 between the first and second wall portions 452 , 454 of the end segment 450 in abutting relation therewith.
- Welding material 464 is disposed in bond forming relation between adjacent portions of the first and second wall portions 452 , 454 of the end segment 450 and adjacent exterior surfaces of the first segment 436 .
- the metallic wall 434 of the second members 184 is shaped during the hydroforming process to provide the end segment 450 with a somewhat enlarged cross section relative to an elongated central portion 461 of the member 184 .
- a hydroformed transition portion 463 is provided between the central portion 461 and the end segment 450 .
- the metallic wall 432 of the first member 66 can be shaped during the hydroforming process to have either a uniform cross section (as shown in the fragmentary view of FIGS. 13 - 15 ) or can be shaped to have a varying cross section.
- the first segment 436 of the first member 66 can be constructed to have a generally uniform cross section, or, alternatively, the cross section of the first segment 436 can vary along its length.
- the end segment 450 of the second member 184 can have a generally uniform cross section as shown in the exemplary embodiment of FIGS. 13 - 15 , or the cross section can vary (i.e., be nonuniform).
- first and second wall portions 438 , 440 and 452 , 454 of the first and second members 66 and 184 and the exterior and interior surfaces 446 , 448 and 458 , 460 , respectively, defined thereby can be essentially planar (as shown in FIGS. 13 - 15 ), can be arcuate, or can be of any configuration that allows sufficient abutting engagement therebetween.
- first second wall portions 438 , 440 and 452 , 454 of the members 66 and 184 are planar, the wall portions 438 , 440 and 452 , 454 can all be essentially parallel (as shown) or, alternatively, the walls 438 and 440 (and therefore walls 452 and 454 ) can be nonparallel.
- the joint 118 is shown in FIGS. 16 and 17 .
- the joint 118 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of an elongated tubular hydroformed first member 189 (that is, the upwardly extending leg portion 191 thereof) defined by a first irregularly outwardly deformed metallic wall 470 fixed into a predetermined irregular exterior surface configuration and a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member 62 (that is, the end portion 90 thereof) defined by a second irregularly outwardly deformed metallic wall 472 fixed into a predetermined irregular exterior surface configuration.
- the first member 189 includes a first end segment 474 having spaced generally opposing first and second wall portions 473 (FIG. 17), 475 (FIG. 18) and a connecting wall portion 476 extending therebetween.
- the first and second wall portions 473 , 475 provide spaced generally opposing interior surfaces 469 (only one of which is visible, see FIG. 17) along the first end segment 474 .
- the first end segment 474 has an opening 498 (formed by a notch cut into a first connecting wall portion 477 ) opposite the connecting wall 476 .
- the second member 62 includes a second end segment 484 having spaced generally opposing first and second wall portions 486 (see FIG. 17), 488 (see FIG. 18) and first and second connecting wall portions 490 , 492 extending therebetween.
- the first and second wall portions 486 , 488 of the second end segment 484 provide spaced generally opposing exterior surfaces 489 (only one of which is visible, see FIG. 16).
- the second end segment 484 has a terminal opening 494 defined by a terminal edge surface 496 .
- the first and second wall portions 473 , 475 and 486 , 488 , respectively, of each of the first and second end segments 474 , 484 are constructed and arranged such that when the second end segment 484 is received through the opening 498 and is disposed between the first and second wall portions 473 , 475 of the first end segment 474 , the first end segment interior surfaces 469 and the second end segment exterior surfaces 489 are in adjacent relation.
- a section of the first connecting wall portion 477 of the first end segment 474 is cut out and removed to form a notch or opening 498 at the terminal end portion thereof, and the first and second members are positioned such that the second end segment 484 extends generally through the notch 498 so that the interior and exterior surfaces 469 and 489 are in adjacent relation.
- Welding material 481 is disposed in bond forming relation between the first and second wall portions 486 , 488 of the second end segment 484 and the first and second wall portions 473 , 475 of the first end segment 474 .
- the first connecting wall portion 490 of the second end segment 484 is welded to an edge 479 on the first connecting wall portion 477 of the first end segment 474 formed by the cutting to form the notch 498 .
- the embodiment of the joint 118 shown in FIGS. 16 - 17 is exemplary and is not intended to limit the scope of the invention.
- the cross sections of the member 189 is exemplary only.
- the first and second wall portions 473 , 475 of the first end segment 189 (and thus the interior surfaces 469 defined thereby) and the first and second wall portions 486 , 488 of the second end segment 484 (and thus the exterior surfaces 489 defined thereby) are preferably generally planar and parallel, this is exemplary only.
- the walls 473 , 475 and 486 , 488 can be planar and nonparallel, or arcuate, for example.
- first and second connecting wall portions 476 , 477 of the first end segment 474 and the first and second connecting wall portions 490 , 492 of the second end segment 484 are generally planar and parallel, this is exemplary only and not intended to be limiting. It can be understood that the connecting wall portions 476 , 477 , 490 , 492 can have a wide range of configurations.
- Embodiments of the joint 118 are contemplated in which either member is regularly (i.e., uniformly) or irregularly (i.e., nonuniformly) outwardly deformed into a fixed configuration during the hydroforming thereof and embodiments are contemplated in which one or the other member 189 , 62 is formed by roll forming.
- the present invention contemplates a method of forming a vehicle space frame joint 118 , comprising (a) hydroforming a first blank having a first tubular metallic wall 470 so as to outwardly deform the first wall into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first tubular hydroformed member 189 .
- the first tubular member includes a first end segment 474 having spaced generally opposing first and second wall portions 473 , 475 and first and second connecting wall portions 476 , 477 extending therebetween.
- the first and second wall portions 473 , 475 provide spaced generally opposing interior surfaces 469 along the first end segment 474 ; (b) hydroforming a second blank having a second tubular metallic wall 472 so as to outwardly deform the second wall into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubular hydroformed member 62 .
- the second tubular member 62 includes a second end segment 484 having spaced generally opposing first and second wall portions 486 , 488 and first and second connecting wall portions 490 , 492 extending therebetween.
- the first and second wall portions 486 , 488 of the second end segment 484 provide spaced generally opposing exterior surfaces 489 .
- the second end segment 484 has a terminal edge surface 496 ; (c) cutting and removing a section of the first connecting wall portion 476 of the first end segment 474 to form a notch 498 in the first end segment; (d) positioning the first and second members 189 , 62 such that the second end segment 484 extends through the notch 498 in the first end segment so that the interior surfaces 469 of the first end segment 474 are adjacent to the exterior surfaces 489 of the second end segment 484 and so that the terminal edge surface 496 of the second end segment 484 engages the second connecting wall portion 476 of the first end segment 474 ; and (e) welding the first and second wall portions 486 , 488 of the second end segment 484 to the first and second wall portions 473 , 475 of the first end segment 474 .
- the first connecting wall portion 490 of the second end segment is welded to an edge 479 on the first connecting wall portion 477 formed by the cutting and preferably the terminal edge surface 497 of the second end segment 484 is welded to the second connecting wall portion 476 of the first end segment 474 .
- FIGS. 18 and 19 show joint 87 in isolation.
- the joint 87 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of a first elongated hydroformed tubular member 94 defined by a first outwardly deformed tubular metallic wall 506 fixed into a predetermined exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated hydroformed tubular member 66 defined by a second outwardly deformed tubular metallic wall 508 fixed into a predetermined exterior surface configuration.
- the joint 87 is formed at a juncture or transition 106 between the tubular cross portion 98 and the leg portion 102 of the cross member 94 .
- the first member 94 includes a first segment 512 having a cross section that defines an exterior surface portion 514 therealong.
- the second member 66 includes a second segment 516 having a cross section that defines an exterior surface portion 518 therealong. It can be appreciated from FIG. 1 that the second hydroformed segment 516 of the second hydroformed member 66 is part of the longitudinally extending portion 82 of the forward upper longitudinal member 66 .
- the first and second members 94 , 66 are positioned such that the engaging surface portions 514 , 518 thereof are in abutting relation.
- Welding material 520 is disposed in bonding relation between the surfaces 514 , 518 to fixedly secure the first and second segments 512 , 516 together.
- a space frame 10 for a motor vehicle comprising a pair of tubular hydroformed upper longitudinal members 66 , 68 (that is, the forward upper longitudinal members), each being defined by an outwardly deformed metallic wall fixed into a predetermined exterior surface configuration and each having a pillar forming portion 78 and a longitudinally extending portion 82 .
- the space frame farther includes a tubular hydroformed cross member 94 defined by an outwardly deformed metallic wall fixed into a predetermined exterior surface configuration and having a cross portion 98 and a pair of leg portions 102 extending from junctures 106 at each end of the cross portion.
- each upper longitudinal member 66 , 68 and each juncture 106 of the cross member 98 each include a segment 516 , 514 , respectively, that defines an exterior surface portion 518 , 514 , respectively, on each segment.
- a pair of longitudinally extending, laterally spaced side rail structures 22 are included in the space frame 10 and the side rail structures 22 and the hydroformed members 66 , 68 , 94 are assembled such that: (a) the pillar forming portion 78 of each upper longitudinal member 66 is connected to and forms a pillar on a respective side rail structure 22 , (b) the leg portions 102 of the cross member 94 are each connected to a respective side rail structure 22 and extend upwardly therefrom to provide one of a pair of intermediate pillars 102 and (c) the cross portion 98 of the cross member 94 connects the pair of side rail structures 22 in laterally spaced relation.
- the upper longitudinal members 66 , 68 and the cross member 94 are assembled together such that the exterior surface portion 518 of each upper longitudinal member 66 , 68 and the exterior surface portion 514 of the associated juncture 106 are in abutting relation.
- Welding material is disposed in bonding relation between each pair of abutting surface portions 518 , 514 to fixedly secure the longitudinally extending portion 82 of each upper longitudinal member 66 , 68 to the associated juncture 106 of the cross member 94 .
- the pillar forming portions 78 of the upper longitudinal members 66 , 68 define the A pillars on the side rail structures 22 .
- the joint 87 and of the space frame 10 are exemplary only and not intended to limit a scope of invention.
- the joint 87 can also be constructed to secure the longitudinally extending portion of an upper longitudinal member that is in underlying relation to the associated juncture of the U-shaped cross member of the space frame.
- the longitudinally extending portion of each upper longitudinal member be in overlying relation with the associated juncture of the cross member in some space frame embodiments (as shown, for example, in FIG.
- the engaging surface is 514 , 518 to planar surfaces.
- the surfaces 514 , 518 can be of any commentary configuration that allows sufficient abutting engagement between the tubular hydroformed members to the joined.
- a method of forming a space frame for a motor vehicle comprising: (1) forming a pair of upper longitudinal members 66 , 68 and a U-shaped cross member 94 by hydroforming wherein an angularly shaped tubular metallic blank is placed into a die assembly having die surfaces defining a die cavity, and pressurized fluid is provided into an interior of the blank so as to expand the blank into conformity with the die surfaces.
- Each upper longitudinal hydroformed member includes a pillar-forming portion 78 and a longitudinally extending portion 82 .
- the hydroformed cross member 94 includes a cross portion 98 and leg portions 102 extending from junctures 106 at each end of the cross portion.
- the longitudinally extending portion 82 of each upper longitudinal hydroformed member 66 , 68 and each juncture 106 of the cross member 94 each include a segment 516 , 512 , respectively that defines an exterior surface portion 518 , 514 , respectively; (2) providing a pair of side rail structures; and (3) assembling the side rail structures 22 with the hydroformed members 66 , 68 , 94 so that (a) the pillar forming portion 78 of each upper longitudinal hydroformed member 66 , 68 is connected to and forms a pillar on a respective side rail structure 22 , (b) the leg portions 102 of the hydroformed cross member 94 are each connected to a respective side rail structure 22 and extend upwardly therefrom to provide one of a pair of intermediate pillars, and (c) the cross portion 98 of the hydroformed cross member 94 connects the side rail structures 22 in later
- the upper longitudinal hydroformed members and the hydroformed cross member are positioned such that the exterior surface portion 518 of each upper longitudinal member 66 , 68 and the exterior surface portion 514 of the associated juncture 106 are in abutting relation; and welding said abutting surface portions to fixedly secure the longitudinally extending portion of each upper longitudinal member to the associated juncture of the cross member.
- the joint 87 allows two hydroformed members to be joined quickly and easily. Because the tubular hydroformed members are in abutting relation, the joint 87 can accommodate a high degree of stacked tolerance. It can be understood that although it is preferred that both surfaces 514 , 518 be planar, the members 66 , 94 can be constructed so that the surfaces are of any complimentary configuration (such as convex/concave) that provides abutting contact and accommodation for dimensional or stacked tolerances.
- FIG. 19 shows a portion of a body panel 521 in phantom to illustrate that the hydroformed members 66 , 94 when installed in the space frame 10 preferably provide aligned (i.e., co-planar), outwardly facing surfaces 523 , 525 , for example, for attaching body panels. It can also be appreciated from FIGS. 19 and 20 that the members 66 , 94 also provide upwardly facing exterior surfaces 527 , 529 to facilitate attachment of a roof panel to the space frame.
- FIGS. 2 - 19 are intended to be illustrative only and are not limited to members having rectangular cross sections.
- the joints in FIGS. 2 - 19 are intended to teach broad principles for joining hydroformed members and for joining a nonhydroformed member to hydroformed member which principles can be applied to hydroformed members having a wide range of cross sectional geometries.
Abstract
A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member; (4) placing the end segment of the first member through the first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of the openings; and (5) welding the intermediate segment and the end segment together in the area of said abutting engagement between exterior surface portions of the end segment and the edge portions of the openings.
Description
- 1. This application is a continuation-in-part of U.S. patent application Ser. No. 09/173,554, filed Oct. 16, 1998, which is hereby incorporated by reference in its entirety.
- 2. The present invention is generally related to motor vehicle frames and more particularly to motor vehicle frames constructed of individual hydroformed members and to joints for connecting hydroformed members.
- 3. Space frame architecture is increasingly being used in vehicle manufacturing and represents a relatively new approach to vehicle construction. A space frame is an assembly of individual frame components that are connected at joints to form a cage-like structure on which the other vehicle components can be mounted such as the engine, drive train, suspension and the hang-on vehicle body parts. The hang-on vehicle body parts may include the floor pan, roof, fenders, doors, body panels, hood and trunk lid. Conventional space frames have typically been constructed from numerous stamped or roll-formed parts which are welded or otherwise joined together. In the automotive industry there is always a continuing need to reduce the weight and number of parts in order to produce more cost-effective and fuel efficient vehicles. At the same time, it is important to maintain the structural integrity of the vehicle structure.
- 4. The present invention stems from the recognition that stamped and roll formed vehicle space frame members require numerous assembly steps and joijnts that may result in significant tolerance build-up.
- 5. Tubular hydroforming offers many advantages in space frame construction because it can enable manufacturers to better control frame stiffness, dimensional stability, fatigue life, and crashworthiness over prior vehicle designs while reducing frame mass and cost. Hydroforming is a metal-forming process in which high pressure fluid is used to outwardly expand a tubular blank into conformity with surfaces of a die cavity of a die assembly to form an irregularly shaped tubular part. Hydroformed members can be provided with a wider range of geometries in comparison with stamped or roll formed parts. Each frame member can have a cross-sectional configuration that varies continuously along its length, to the configuration desired.
- 6. As a result a single hydroformed part can often replace a plurality of stamped (or roll formed) and welded parts, thereby reducing the number of parts necessary to complete frame construction. Consequently, vehicle weight and assembly cost are reduced.
- 7. Hydroformed parts are also advantageous because they have a higher strength than stamped parts, primarily because of the plastic deformation of the wall of the blank during the hydroforming process. More particularly, the outward expansion of the wall of the blank during hydroforming caused by the fluid pressure creates a work-hardening effect which uniformly hardens the metal material of the blank. Hydroforming also produces less waste metal material than stamping.
- 8. Thus, tubular hydroforming has many advantages over more conventional stamping and welding technologies. For the promise of hydroforming technology to be fully realized in the creation of vehicle space frames, the individual hydroformed members that make up the space frame must be able to be quickly and accurately assembled into space frames for mass production. This requires that joints between individual hydroformed members be quickly and easily formed. Typical space frame designs utilize separate joint forming structures, sometimes called “nodes”, to connect two or more elongated hydroformed members. An example of a conventional node having several short discrete projections extending outwardly at predetermined angles and of the use of nodal architecture in space frame construction is shown in WO 97/00595.
- 9. Nodal architecture of the type shown in WO 97/00595 requires the elongated hydroformed frame members to be assembled together in a fixed, predetermined angular and spatial arrangement. Each outward projection on a '595 node is telescopically interengaged with and then affixed to an opening in one of the elongated tubular hydroformed members to be joined. The end of the each hydroformed member is usually affixed to the node by welding.
- 10. Nodal space frame architecture presents manufacturing difficulties that limit the commercial feasibility of the space frames constructed using this design concept. The nodes themselves are difficult to manufacture. It may not be easy to form nodes by hydroforming a tubular blank (depending on the node size, geometry and so on). For this reason, nodes are sometimes formed by methods other than hydroforming such as by casting. The use of nodes in space frame construction also requires a relatively large number of welds to form a single joint. For example, if three elongated hydroformed members are to be joined with one node, three welds are required. Such connections add to the tolerance stack-up and detract from the dimensional reproduceability from frame to frame. In addition, use of nodes adds to the total number of parts required to assemble the space frame, thus also adding to the total weight and cost of the frame.
- 11. For manufacturers to be able to mass produce hydroformed space frames in a time and cost effective manner, there is a need for the joints between the individual members to be quickly and accurately formed with a minimum number of parts and a minimum number of welds. Consequently, there is a need for a method of joining hydroformed members together directly without the use of separate nodes to reduce the number of parts and welds.
- 12. An object of the present invention is to meet the needs identified above by providing a variety of different types of joints for joining hydroformed members and joint forming methods therefor in constructing the space frame.
- 13. One vehicle space frame joint, for example, includes a first space frame structure in the form of a tubular elongated first member and a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member. The first member includes an end segment having a predetermined length, a terminal end portion and an exterior surface that defines an exterior configuration of the end segment. The second member is defined by an outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration and includes a hydroformed intermediate segment having a cross section that defines a pair of opposing first and second wall portions spaced apart a distance approximately equal to the predetermined length of the end segment. The first and second wall portions of the intermediate segment include generally aligned first and second openings formed within the first and second wall portions, respectively, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member. The end segment extends through the first opening with the terminal end portion thereof disposed within the second opening, and welding material is disposed on the segments to fixedly secure the first and second segments together. The welding material that is constructed and arranged to fixedly secure the first and second segments together is applied in the areas of the juncture between the exterior surface of the end segment and a periphery of the first opening and in the area of juncture between an exterior surface portion of the terminal end portion of the end segment and a periphery of the second opening.
- 14. A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member; (4) placing the end segment of the first member through the first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of the openings; and (5) welding the intermediate segment and the end segment together in the area of said abutting engagement between exterior surface portions of the end segment and the edge portions of the openings.
- 15. Other objects, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
- 16.FIG. 1 is a perspective view of a space frame constructed according to the principles of present invention;
- 17. FIGS. 2-19 are illustrations of various views of joints used in the space frame of FIG. 1; and
- 18.FIG. 20 is a schematic view of a hydroforming die assembly and a tubular blank therein.
- 19.FIG. 1 is a perspective view of a
vehicle space frame 10 constructed in accordance with the principles of the present invention. Thespace frame 10 generally includes aforward frame portion 12, amiddle frame portion 16 and arearward frame portion 18. A pair of laterally spaced, longitudinally extending lowerside rail structures 22 are disposed on each side of thespace frame 10 and extend the length thereof. - 20. The lower
side rail structures 22 are preferably constructed of three tubular hydroformed members fixed together at joints. Specifically, eachside rail structure 22 includes a hydroformed forward lowerside rail member 26, 28, respectively, a hydroformed intermediate lowerside rail member side rail member hydroformed members 26, 28; 30, 32 and 34, 36 are of mirror image construction. Only onemember - 21. Each forward lower
side rail member 26 is connected to the associated intermediate lowerside rail member 30 at a joint 38. Similarly, each intermediate lowerside rail member 30 is connected to the associated rear lowerside rail member 34 at a joint 42. - 22. A forward end portion of the intermediate lower
side rail member 30 is constructed and arranged to be telescopically received within a rearward end portion of the forward lowerside rail member 26 and is welded in place to form the joint 38. Joint 42 is of similar construction. That is, a forward end portion of the rearward lowerside rail member 34 is constructed and arranged to be telescopically received within a rearward end portion of the intermediate lowerside rail member 30 and is welded in place to form the joint 42. - 23. The forward lower
side rail member 26 has an inwardly spaced forwardmost portion 50 (where the terms “inwardly” and “outwardly” in the present detailed description refer respectively to the directions toward and away from a longitudinally extending centerline of the space frame 10) which transitions into an outwardly angledmiddle portion 52 which in turn transitions into arearward portion 54. The intermediate lowerside rail member 30 is essentially straight. The hydroformed tubular rear lowerside rail member 34 includes ashort forward portion 56 which transitions into a central upwardly archingportion 58 which transitions into a relatively straightrearward end portion 60. Thecentral portion 58 forms a rear wheel well on thespace frame 10. - 24. An upper
longitudinal structure 62 is mounted on each side of thespace frame 10. Each upperlongitudinal structure 62 is formed from a pair of tubular hydroformed members. Specifically, each upperlongitudinal structure 62 includes a tubular hydroformed forward upperlongitudinal member longitudinal member longitudinal members space frame 10 are connected at joints 44. Preferably the joint 44 is formed by placing a forward tubular end of the rearward upperlongitudinal member 70 telescopically within a rearward end of the forward upperlongitudinal member 68 and welding the pair ofmembers - 25. The
members members members longitudinal member 66 is an integral hydroformed tubular member that includes an essentially straight pillar-formingportion 78 and an arcuatelongitudinally extending portion 82. Each pillar-formingportion 78 is connected to a respective forward lowerside rail member 26 at a joint 75 and extends upwardly therefrom so that the pillar-formingportion 78 of each forms a forward-most or “A” pillar structure of thespace frame 10. - 26. Each rearward upper
longitudinal member 70 has an arcuate forward longitudinally extendingportion 86 which transitions into ashort end portion 90. As considered below, thelongitudinally extending portions 82 of the forward upperlongitudinal member 66 form joints 87 with a tubular hydroformed firstU-shaped cross member 94 of thespace frame 10; and thelongitudinally extending portions 86 form joints 89 with a tubular hydroformed secondU-shaped cross member 96. Each pair of longitudinally extendingportions space frame 10 defines a roof rail structure between the associated A pillar-formingportion 78 of the forward upperlongitudinal member 66 and thejoints 89 with across member 96 on respective sides of thespace frame 10. - 27. The first
U-shaped cross member 94 and the secondU-shaped cross member 96 extend laterally across thespace frame 10. Eachcross member cross portion integral leg portions junctures cross portion leg portions U-shaped members side rail members - 28. The
leg portions 102 of theU-shaped member 94 are essentially straight and extend upwardly from respectiveside rail structures 22 to form a pair of laterally spaced intermediate or “B” pillar structures on thespace frame 10 that extend between the associated lowerside rail structure 22 and the associated roof rail structure. - 29. Similarly, the
leg portions 104 of the secondU-shaped member 96 form a pair of rearward-most or “C” pillar structures on thespace frame 10 that extend between the associated lowerside rail structure 22 and the associated roof rail structure. Thecross portions U-shaped members - 30. A pair of laterally extending tubular
hydroformed cross members longitudinal members cross member 126 is connected to the upperlongitudinal members joints 129. Each end of thecross member 126 is welded in ahydroformed recess 133 formed within the forward upperlongitudinal member joints 129 are formed on thelongitudinally extending portion 82 of eachmember portion 78 and thelongitudinally extending portion 82 of each forward upperlongitudinal member tubular cross member 128 has flattened ends that are placed in overlying, abutting relation with thelongitudinally extending portions 82 of the forward upperlongitudinal members - 31. A plurality of laterally extending, longitudinally spaced tubular
hydroformed cross members side rail structures 22. Thecross members central portions hydroformed cross member side rail structure 22. Specifically, thecross member 134forms joints 150 with the forward lowerside rail members 26, 28 respectively; thecross member 136forms joints 154 with the intermediate lowerside rail members cross member 138forms joints 158 with the intermediate lowerside rail members cross member 140forms joints 162 with the rearward lowerside rail members - 32. A hydroformed tubular
U-shaped member 166 and a hydroformed tubularelongated member 168 extend laterally across the forward-most end of thespace frame 10. TheU-shaped member 166 includes an essentially straighttubular cross portion 170 which transitions throughjunctures 171 at opposite ends thereof into outwardly and upwardly extendingtubular leg portions 172. Thecross portion 170 provides the lower cross structure connected between the lower side rails 22 and theleg portions 172 provide a pair of upright structures at the front end of thespace frame 10. TheU-shaped member 166 is preferably welded at thejunctures 171 thereof to the lowerside rail structures 22 to form joints 173. More particularly, preferably, theU-shaped member 166 is placed in abutting contact with the lowerside rail structures 22 and welded. Wall portions of each lowerside rail structure 22 may be cut out to receive portions of theU-shaped member 166 to form thejoints 173. - 33. The
elongated member 168 includes an essentially straight central portion 176 that transitions angularly downwardly at each end thereof into relatively short downwardly extendingend portions 178. Theend portions 178form joints 182 withrespective leg portions 172 of theU-shaped member 166. - 34. A pair of tubular hydroformed forward upper
side rail members front portion 12 of thespace frame 10. Each upperside rail member leg portion 172 of theU-shaped member 166 and a joint 186 at a rearward end thereof with an associated forward upperlongitudinal member side rail members intermediate portions side rail member 26, 28 to define a front wheel well 187 on each side of thefront portion 12 of thespace frame 10. - 35. A tubular hydroformed
U-shaped cross member 189 is mounted at the rearward-most end of thespace frame 10. TheU-shaped member 189 has atubular cross portion 190 and a pair ofleg portions 191 extending fromjunctures 192 at opposite ends of thecross portion 190. Thecross portion 190 provides a cross structure connected between the lowerside rail structures 22 and theleg portions 191 provide a pair of upright structures on therearward portion 18 of thespace frame 10. Eachleg portion 191 of theU-shaped cross member 189 forms a joint 118 with the free end of the associated rearward upperlongitudinal member juncture 192 forms a joint 119 with an associated lowerside rail structure 22. - 36. The preferred hydroforming process used to form each hydroformed member of each of the exemplary space frames described above can be understood from FIG. 20. Each hydroformed member used to construct the
space frame 10 is formed from a tubular blank 200 constructed of a suitable metal material. Each tubular blank 200 has a closed transverse cross section and open tubular ends. Each tubular blank 200 may be constructed by any suitable method. For example, the transverse cross section of each tubular blank may be shaped by roll forming a continuous longitudinally extending strip of sheet metal in a roll forming operation. The transverse cross section may be closed subsequently by a seam welding operation. Thus, preferably, each of the hydroformed tubular members of eachexemplary space frame 10 has only a single longitudinally extending seam weld that is formed in creating the original tubular blank. This is distinct from more conventional tubular frame members, which comprise two C-shaped or “clam-shell” halves welded to one another in facing relation along two seams. The tubular blank is then cut to the length required to make a particular hydroformed member. - 37. If required by the part geometry, it is within the scope of the invention to form a single tubular blank from two separately roll formed tubular blanks of different diameters which have been butt-welded to one another at a butt-welded connection. That is, if the diameter of a single hydroformed member increases (or decreases) greatly along its longitudinal length, the tubular blank used to make that hydroformed member can be constructed by butt welding two blanks of different diameter. The diameters of the two ends to be butt-welded can be equalized either by using a reduction tool to reduce the diameter of one end of the larger diameter tubular blank or, alternately, by using a flaring or expansion tool to expand the diameter of an end portion of the smaller diameter blank, or a combination of both. The result of either operation is to equalize the diameters of the two ends to be butt-welded together. The butt-welded connection is formed prior to the hydroforming operation, but the butt-welding operation can be performed either before or after any pre-bending operations are performed, which operations are considered immediately below. The blank may optionally be “pre-bent”, that is, bent prior to being placed in a hydroforming die assembly, if the geometry of the part is complex or if there are to be any sharp bends in the finished member. For example, if there is a sharp bend (a bend of greater than 30°) in the hydroformed member, preferably the present invention bends the blank according the teachings of Ser. No. 09/299,595, filed Oct. 7, 1997, entitled METHOD AND APPARATUS FOR WRINKLE-FREE HYDROFORMING OF ANGLED TUBULAR PARTS, hereby incorporated by reference in its entirety. The teachings of Ser. No. 09/299,595 can be used to avoid wrinkle formation during the bending operation, particularly on the concave portion of each bend in a hydroformed part. Examples of sharp bends in the individual hydroformed parts of the
space frame 10 include the bend between eachleg portion 102 and thecross portion 98 of the firstU-shaped member 94 and the bend between theforward portion 50 andmiddle portion 52 of the forward lowerside rail member 26. - 38. It should be understood that the methodology of Ser. No. 60/061,238 would preferably not be used for parts that are bent at an angle of less than 30?. Preferably, straight parts (such as
cross member 140, for example) are hydroformed in accordance with the teachings of Ser. No. 08/915,910, filed Aug. 21, 1997, entitled Hydroforming Die Assembly For Pinch-Free Tube Forming, hereby incorporated by reference in its entirety. A blank may also be bent in a CNC bending machine prior to being placed in the die assembly. A suitable lubricant may be applied to the exterior of the blank prior to placing it in the die assembly. - 39. With reference again to FIG. 20, the tubular blank 200 is then placed between the die halves 202, 204 of the
die assembly 206 and assembly is closed. The tubular blank 200 is preferably immersed in a fluid bath so that it is filled with hydroforming fluid. Ahydroforming ram assembly ram member assembly ram members - 40. The
ram members ram members - 41. The tubular blank 200 expands into conformity with the surfaces 222 defining the hydroforming die cavity so as to irregularly outwardly expand the
metallic wall 220 of the blank 200 into conformity with the surfaces 222 of thedie assembly 206 to provide themetallic wall 220 with a shape corresponding to the desired shape for the member. The shape of each die cavity used to form each hydroformed member of thespace frame 10 in accordance with the present invention is particularly adapted to the shape of the new and advantageous hydroformed tubular members contemplated herein. - 42. If holes are to be formed in a hydroformed member, the holes may be formed whole the member is still in the die assembly during the hydroforming operation or may be formed after the hydroformed member is removed from the die assembly along with any other required further processing of the member. More particularly, holes may be formed during the hydroforming process in what is known in the art as a hydropiercing operation. A hydropiercing operation is disclosed in U.S. Pat. No. 5,460,026 which is hereby incorporated by reference in its entirety into the present application. Alternatively, holes or notches may be cut in a hydroformed member after the hydroforming operation is completed, such as by laser cutting. A net pad can be used to form a recess in a hydroformed member (such as recess 133).
- 43. It can be appreciated that the transverse cross section of many of the hydroformed members varies along the length of the particular hydroformed member. For example, the transverse cross sections of the
leg portions 102 and thecross portion 98 of the tubular hydroformed cross member 94 (FIG. 1) vary long the longitudinal length thereof. Thecross portion 98 has a relatively small substantially rectangular cross-section and theleg portions 102 have relatively large substantially rectangular cross-section near the free ends thereof and an irregular transverse cross section in the middle portions thereof. It can be understood that altering the cross-sectional configuration of this tubular hydroformed member or of any other tubular hydroformed member disclosed herein can be accomplished without departing from the principles of the present invention. - 44. It can thus be understood that each hydroformed member used to construct the
space frame 10 is of generally of tubular construction. Forming a space frame of individual tubular hydroformed members offers may advantages, but Joining these tubular hydroformed members together to form thespace frame 10 is a critical part of space frame construction. Several representative types of joints formed between tubular hydroformed members are described below and illustrated in the drawings. A preferred welding method is considered thereafter. - 45. Several of the space frame joints are shown in detail in FIGS. 2-19. FIGS. 2-4 show enlarged fragmentary views of
joints joints hydroformed cross member 140 and the hydroformed rearward lowerside rail member 34 in thespace frame 10, themembers - 46. Thus, joint 162 can be broadly understood to be a vehicle space frame joint comprising a first space frame structure in the form of a tubular elongated
first member 140 and a second, intersecting space frame structure in the form of an elongated tubular hydroformedsecond member 34. Thefirst member 140 includes anend segment 315 that has a predetermined length and anexterior surface 316 that defines an exterior configuration of theend segment 315. The hydroformedsecond member 34 is defined by an outwardly deformed tubularmetallic wall 314 fixed into a predetermined exterior surface configuration. The hydroformedsecond member 34 has anintermediate segment 318 that includes a pair of opposing first andsecond wall portions second wall portions intermediate segment 318 include generally aligned first andsecond openings second wall portions second openings exterior surface 316 of theend segment 315 of thefirst member 140, and are preferably formed by laser cutting. - 47. As best seen in FIG. 6, the joint 162 is formed by placing the
end segment 315 of thefirst member 140 through the first andsecond openings exterior surface 325 thereof are in abutting engagement with edge portions of theopenings end segment 315 so that it extends through thefirst opening 324 with aterminal end portion 328 thereof disposed within (and preferably slightly beyond) thesecond opening 326. The joint 162 further includeswelding material 330 that is constructed and arranged to fixedly secure the intermediate and endsegments welding material 330 being applied in the areas of the juncture between theexterior surface 325 of theend segment 315 and the edge portions of theopenings welding material 330 is applied in the areas of the juncture between theexterior surface 325 of theend segment 315 and aperiphery 327 of thefirst opening 324 and in the area of juncture between anexterior surface portion 332 of theterminal end portion 328 of theend segment 315 and aperiphery 329 of thesecond opening 326. - 48. Preferably, the
end segment 315 of the first member has a generally uniform cross section along its length and preferably the first andsecond openings intermediate segment 318 of the hydroformedsecond member 34 are of approximately equal size and shape as shown, for example, in FIGS. 5 and 6. It can be understood, however, that this is exemplary only and not intended to be limiting. It is contemplated that in some embodiments of the joint 162, the exterior surface of the end segment 315 (and, therefore, the cross section of the end segment) will vary (i.e., be nonuniform) along the length of the end segment and that, consequently, theopenings - 49. It is contemplated that the cross section of the
first member 140 will be uniform along its entire length in some embodiments of thespace frame 10 and of the joint 162. Alternatively, the cross section of thefirst member 140 can be nonuniform along its length in other joint 162 orspace frame 10 embodiments. Thefirst member 140 may be formed by any known metal forming process such as by roll forming, or by hydroforming. Thus, it can be understood that in one preferred embodiment of the joint 162 and of thespace frame 10, it is contemplated that the forming of thefirst member 140 is accomplished by a roll forming operation. An embodiment of the joint 162 is contemplated, for example, in which thefirst member 140 is roll formed into a quadrilateral configuration. In another preferred embodiment of the joint 162 and of thespace frame 10, thefirst member 140 is formed by hydroforming a tubular blank having a tubular metallic wall so that thefirst member 140 is defined by an outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration. It will be understood that when the first member 140 (and theend segment 315 thereof) is formed by hydroforming, it can be constructed to have a uniform cross section in some embodiments of the joint 162 and to have a nonuniform cross section in other embodiments of the joint 162. - 50. Thus, it can be appreciated that when the
members intermediate segment 318 can have a wide range of constructions and it can be understood that the embodiment of the hydroformedsecond member 34 is exemplary only and not intended to limit the scope of the invention. In the exemplary embodiment of joint 162 shown, the opposing first andsecond wall portions second member 34 are essentially planar and parallel, but, although this is one preferred embodiment of the joint 162, this planar and parallel configuration of thewall portions intermediate segment 318 is not a requirement. The opposingwall portions walls intermediate segment 318 of the hydroformedsecond member 34 can have a generally uniform cross section along its length or, alternatively, a nonuniform cross section along its length. - 51. It can be understood that the present invention contemplates a method of forming a vehicle space frame joint 162 comprising (a) forming a tubular elongated
first member 140 constructed of a metallic material that includes anend segment 315. The end segment 315 has a predetermined length and an exterior surface 325 that defines an exterior configuration of the end segment 315; (b) forming an elongated tubular hydroformed second member 34 by hydroforming a tubular blank having a tubular metallic wall so as to irregularly outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member 34 having an intermediate segment 318 that includes first and second spaced apart wall portions 320, 322; (c) forming generally aligned first and second openings 324, 326 within the first and second wall portions 320, 322, respectively, of the intermediate segment 318 of the second member 34, the first and second openings 324, 326 being of complimentary configuration to portions of the exterior surface 325 of the end segment 315 of the first member 140; (d) placing the end segment 315 of the first member 140 through the first and second openings 324, 326 such that portions of the exterior surface 325 of the end segment are in abutting engagement with edge portions of the openings 324, 326; and (e) welding the intermediate segment 318 and the end segment 315 together in the area of the abutting engagement between exterior surface portions 325 of the end segment 315 and the edge portions of the openings. More particularly, the welding material is applied in an area of juncture betweenexterior surface portions 325 of theend segment 315 and the surfaces adjacent theperiphery 327 of thefirst opening 324 and in an area of juncture between an exterior surface portion of theterminal end portion 328 of theend segment 315 and surfaces adjacent the periphery of thesecond opening 326. - 52. As mentioned, in one preferred embodiment, the forming of the
first member 140 is accomplished by roll forming, and in one preferred example of roll forming, the first member is roll formed to have a quadrilateral configuration, although it can be understood that thefirst member 140 can be roll formed to have a wide range of cross-sectional configurations. In another preferred embodiment, as mentioned, the first member is of tubular hydroformed construction. In this case, the forming of thefirst member 140 is accomplished by hydroforming a second tubular blank having a tubular metallic wall so as to outwardly deform the second tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a second die assembly. More preferably, the second tubular blank is irregularly outwardly deformed during the hydroforming process for hydroforming the first member so that thefirst member 140 has a nonuniform cross section along its length. - 53. FIGS. 7-9 show an enlarged view of the joint 182 (see FIG. 1). It can be appreciated that although joint 182 is the connection between the
U-shaped cross member 166 and thecross member 168, the joint 182 can be broadly understood to be a vehicle space frame joint comprising a first space frame structure in the form of a first elongated tubularhydroformed member 166 defined by an outwardly deformed first tubularmetallic wall 360 fixed into a predetermined irregular exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated tubularhydroformed member 168 defined by an outwardly deformed second tubularmetallic wall 342 fixed into a predetermined exterior surface configuration. Thefirst member 166 includes a tubularfirst segment 344 that includes a pair of spaced first andsecond wall portions second member 168 includes anend segment 358 having a pair of spaced cantilevered first andsecond wall portions second wall portions - 54. The
first segment 344 is positioned between the cantilevered first andsecond wall portions end segment 358 such that theinterior surfaces second wall portions end segment 358 and theexterior surfaces second wall portions first segment 344 are in abutting relation. - 55.
Welding material 380 is disposed in bond forming relation between theinterior surfaces second wall portions end segment 358 and the abuttingexterior surfaces first segment 344. - 56. As best shown, for example, in FIGS. 8 and 9, the
end segment 358 has a pair of connectingwall portions second wall portions wall portion end segment 358 has anotch 372 cut therein (by laser cutting or by any other appropriate means) to form the cantileveredwall portions first segment 344 to be received between the first andsecond wall portions end segment 358 in abutting relation therewith. - 57. It can be understood that the respective
metallic walls hydroformed members metallic wall 342 of the second blank is irregularly outwardly deformed during the hydroforming procedure so that the secondhydroformed member 168 has an irregularly outwardly deformed tubularmetallic wall 342. Thefirst segment 344 of thefirst member 166 can be constructed to have a generally uniform cross section, or, alternatively, the cross section of thefirst segment 344 can vary along its length. Similarly, theend segment 358 of thesecond member 168 can have a generally uniform cross section as shown in the exemplary embodiment of FIGS. 7-9, or the cross section can vary (i.e., be nonuniform). - 58. It can be understood, therefore, that the respective first and
second wall portions first segment 344 and of theend segment 358 are essentially planar and parallel in some preferred embodiments of the joint 182 (as shown in FIGS. 7-9), but in other preferred embodiments of the joint 182 can be constructed to be, for example, arcuate or, alternatively, to be planar and nonparallel and so on. Thus, it can be understood that thewall portions second wall portions members wall portions walls 346 and 348 (and thereforewalls 360 and 362) can be nonparallel. - 59. A method of forming a space frame joint 182 can be understood from FIGS. 7-9, the method comprising (a) hydroforming a first blank having a first tubular
metallic wall 340 so as to irregularly outwardly deform thefirst wall 340 into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubularhydroformed member 166. The first elongated tubularhydroformed member 166 includes a tubularfirst segment 344 that includes a pair of spaced, generally opposing first andsecond wall portions second wall portions exterior surfaces metallic wall 342 so as to outwardly deform thesecond wall 342 into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second tubularhydroformed member 168. The second tubularhydroformed member 168 includes atubular end segment 358 that includes a pair of spaced, generally opposing first andsecond wall portions wall portions second wall portions wall portion end segment 358 to form anotch 372 in each connecting wall portion to allow thefirst segment 344 to be received between the first andsecond wall portions end segment 358; (d) positioning thefirst segment 344 of thefirst member 166 within thenotches 372 and between the first andsecond wall portions end segment 358 so that theexterior surfaces second wall portions first segment 344 and theinterior surfaces second wall portions end segment 358 are in abutting engagement; and (e) welding theinterior surfaces second wall portions end segment 358 with theexterior surfaces second wall portions first segment 344. - 60. The
joints joints 110 and 112 can be understood from this discussion. The joint 75 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of a first elongated tubular hydroformed member 26 (the essentiallystraight portion 54 thereof) defined by a first outwardly deformed tubularmetallic wall 390 fixed into a predetermined exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated tubular hydroformed member 66 (i.e., the pillar-formingportion 78 of the forward upper longitudinal member 66) defined by a second outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration. - 61. The
first member 26 includes anintermediate segment 394 having generally opposing first andsecond wall portions wall portion 400 extending between the first andsecond wall portions first member 418. The first andsecond wall portions intermediate segment 394 provide a pair of generally opposinginterior surfaces first wall portion 396 has a weld opening 424 formed therein. - 62. The
second member 66 has anend segment 408 that has generally opposing first andsecond wall portions exterior surfaces - 63. As can be best appreciated from the cross-sectional views of FIGS. 11 and 12, the first and end
segments end segment 408 is positioned between the first andsecond wall portions intermediate segment 394, the pair ofinterior surfaces exterior surfaces - 64. A section of at least one connecting
wall portion intermediate segment 394 is cut out and removed to form at least oneopening 418 to allow theend segment 408 to be positioned in abutting relation with theintermediate segment 394 as aforesaid (and as shown in FIGS. 11 and 12). - 65. The
end segment 408 is positioned within theopening 418 so that the opposingexterior surfaces end segment 408 are disposed adjacent to the opposinginterior surfaces intermediate segment 390 and to thewelding opening 424. - 66. A section of the
first wall portion 396 of theintermediate segment 394 is cut out and removed to form a weld opening 424 therein constructed and arranged such that when theend segment 408 is in abutting relation with theintermediate segment 394, anexterior surface 414 of theend segment 408 is adjacent theweld opening 424. - 67.
Welding material 428 is disposed in bond forming relation between aperipheral edge portion 431 of the weld opening 424 and the adjacentexterior surface 414 of theend segment 408, thus fixing the first andsecond members puddle weld 427 formed within theopening 424 and amig weld 429 formed along theupper edge 430. As stated, there can optionally be a second weld opening on the opposite side of thesegment 394 for a second puddle weld. Themig weld 429 can be applied to theupper edge 430 of theopening 418 on one longitudinally extending side of thesegment 394 or on both sides as shown (see FIG. 12). - 68. It can be understood that the joint 75 is exemplary only and not intended to limit the scope of the invention. Preferably, the
second member 66 is a tubular hydroformed member, but it is within the scope of the invention to form the second member by roll forming (particularly roll forming a quadrilateral configuration) or using any other suitable construction. - 69. When hydroforming is used to form either the first or
second members - 70. Preferably, the first and
second wall portions intermediate segment 394 and the first andsecond wall portions exterior surfaces surfaces - 71. As best seen in FIG. 12, the
intermediate segment 394 has a pair of generally opposing connectingwall portions wall portions intermediate segment 394 to form a pair of generally aligned first and second openings (only one 418 is formed in theintermediate segment 394 in the exemplary joint shown in FIGS. 10-12). Thesecond member 66 is positioned such that it extends through two aligned openings (one opening being in each connectingwall portion 400, 402) in the first member so that the second member extends outwardly from the first member on two sides thereof. - 72. It can be understood, therefore that when an end segment of the second member is used to form the joint with the
first member 26, preferably only one opening (opening 418) is formed in thefirst member 26 to receive thesecond member 66 and one (or more) weld openings are provided for welding the twomembers openings 424 provides welding access to the second member at a location at or near the free end of the end segment of the second member (when theend segment 408 is in the position, for example, shown in FIG. 11) without the necessity of forming a large opening in thewall portion 402 to expose a portion of theend segment 408. - 73. The joint 75 can be constructed utilizing a method of forming a vehicle space frame joint 75 comprising (a) hydroforming a first blank having a first tubular
metallic wall 390 to outwardly deform the first wall into an exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubularhydroformed member 26. Thefirst member 26 includes aintermediate segment 394 having generally opposing first andsecond wall portions wall portions second wall portions interior surfaces metallic wall 392 to outwardly deform the second wall into an exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubular hydroformed member that includes aend segment 408 having generally opposing first andsecond wall portions exterior surfaces wall portions intermediate segment 394 to form an opening of sufficient dimension to receive the end segment of the second member and cutting a section of thefirst wall portion 396 of theintermediate segment 394 to form a weld opening 424 therein; (d) positioning theend segment 408 into saidopening 418 and between the first andsecond wall portions intermediate segment 394 so that the exterior surface of the first wall portion of the end segment is disposed adjacent the weld opening; and (e) welding the first andsecond members weld opening 424. - 74. The joints 185 (see FIGS. 1 and 7) and 186 (see FIGS. 1 and 13-15) are identical.
Joint 186 will be considered in detail.Joint 186 is shown in isolation in FIGS. 13-15. The joint 186 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of an elongated tubular hydroformed first member 66 (specifically, the pillar-formingportion 78 thereof) defined by a first outwardly deformed tubularmetallic wall 432 fixed into a predetermined exterior surface configuration and an intersecting space frame structure in the form of an elongated tubular hydroformedsecond member 184 defined by a second outwardly deformed tubular metallic wall fixed 434 into a predetermined exterior surface configuration. - 75. The
first member 66 includes a tubular hydroformedfirst end segment 436 that includes a pair of spaced generally opposing first andsecond wall portions second wall portions exterior surfaces second member 184 includes a tubularhydroformed end segment 450 that includes a pair of spaced generally opposing first andsecond wall portions wall portions second wall portions - 76. The opposing first and
second wall portions first segment 436 and the opposing first andsecond wall portions end segment 450 are constructed and arranged such that when thefirst segment 436 is received between the first andsecond wall portions end segment 450, theinterior surfaces end segment 450 and theexterior surfaces first segment 436 are in abutting relation; - 77. Each connecting
wall portion end segment 450 has anotch 456 sufficient to allow thefirst segment 436 to be received between the first andsecond wall portions end segment 450 in abutting relation therewith as aforesaid. Thefirst segment 436 is positioned in thenotches 456 between the first andsecond wall portions end segment 450 in abutting relation therewith.Welding material 464 is disposed in bond forming relation between adjacent portions of the first andsecond wall portions end segment 450 and adjacent exterior surfaces of thefirst segment 436. - 78. The
metallic wall 434 of thesecond members 184 is shaped during the hydroforming process to provide theend segment 450 with a somewhat enlarged cross section relative to an elongatedcentral portion 461 of themember 184. A hydroformed transition portion 463 is provided between thecentral portion 461 and theend segment 450. - 79. The
metallic wall 432 of thefirst member 66 can be shaped during the hydroforming process to have either a uniform cross section (as shown in the fragmentary view of FIGS. 13-15) or can be shaped to have a varying cross section. Thefirst segment 436 of thefirst member 66 can be constructed to have a generally uniform cross section, or, alternatively, the cross section of thefirst segment 436 can vary along its length. Similarly, theend segment 450 of thesecond member 184 can have a generally uniform cross section as shown in the exemplary embodiment of FIGS. 13-15, or the cross section can vary (i.e., be nonuniform). - 80. It can be understood therefore, that the respective first and
second wall portions second members interior surfaces second wall portions members wall portions walls 438 and 440 (and thereforewalls 452 and 454) can be nonparallel. - 81. The joint 118 is shown in FIGS. 16 and 17. The joint 118 can be viewed broadly as a vehicle space frame joint comprising a first space frame structure in the form of an elongated tubular hydroformed first member 189 (that is, the upwardly extending
leg portion 191 thereof) defined by a first irregularly outwardly deformedmetallic wall 470 fixed into a predetermined irregular exterior surface configuration and a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member 62 (that is, theend portion 90 thereof) defined by a second irregularly outwardly deformedmetallic wall 472 fixed into a predetermined irregular exterior surface configuration. Thefirst member 189 includes afirst end segment 474 having spaced generally opposing first and second wall portions 473 (FIG. 17), 475 (FIG. 18) and a connectingwall portion 476 extending therebetween. The first andsecond wall portions first end segment 474. Thefirst end segment 474 has an opening 498 (formed by a notch cut into a first connecting wall portion 477) opposite the connectingwall 476. - 82. The
second member 62 includes asecond end segment 484 having spaced generally opposing first and second wall portions 486 (see FIG. 17), 488 (see FIG. 18) and first and second connectingwall portions second wall portions second end segment 484 provide spaced generally opposing exterior surfaces 489 (only one of which is visible, see FIG. 16). Thesecond end segment 484 has a terminal opening 494 defined by aterminal edge surface 496. - 83. The first and
second wall portions second end segments second end segment 484 is received through theopening 498 and is disposed between the first andsecond wall portions first end segment 474, the first end segment interior surfaces 469 and the second end segment exterior surfaces 489 are in adjacent relation. More specifically, a section of the first connectingwall portion 477 of thefirst end segment 474 is cut out and removed to form a notch or opening 498 at the terminal end portion thereof, and the first and second members are positioned such that thesecond end segment 484 extends generally through thenotch 498 so that the interior andexterior surfaces Welding material 481 is disposed in bond forming relation between the first andsecond wall portions second end segment 484 and the first andsecond wall portions first end segment 474. - 84. Preferably, the first connecting
wall portion 490 of thesecond end segment 484 is welded to anedge 479 on the first connectingwall portion 477 of thefirst end segment 474 formed by the cutting to form thenotch 498. It can be appreciated that the embodiment of the joint 118 shown in FIGS. 16-17 is exemplary and is not intended to limit the scope of the invention. For example, the cross sections of themember 189 is exemplary only. Thus, although the first andsecond wall portions interior surfaces 469 defined thereby) and the first andsecond wall portions exterior surfaces 489 defined thereby) are preferably generally planar and parallel, this is exemplary only. Thewalls wall portions first end segment 474 and the first and second connectingwall portions second end segment 484 are generally planar and parallel, this is exemplary only and not intended to be limiting. It can be understood that the connectingwall portions other member - 85. The present invention contemplates a method of forming a vehicle space frame joint 118, comprising (a) hydroforming a first blank having a first tubular
metallic wall 470 so as to outwardly deform the first wall into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first tubularhydroformed member 189. The first tubular member includes afirst end segment 474 having spaced generally opposing first andsecond wall portions wall portions second wall portions interior surfaces 469 along thefirst end segment 474; (b) hydroforming a second blank having a second tubularmetallic wall 472 so as to outwardly deform the second wall into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubularhydroformed member 62. The secondtubular member 62 includes asecond end segment 484 having spaced generally opposing first andsecond wall portions wall portions second wall portions second end segment 484 provide spaced generally opposing exterior surfaces 489. Thesecond end segment 484 has aterminal edge surface 496; (c) cutting and removing a section of the first connectingwall portion 476 of thefirst end segment 474 to form anotch 498 in the first end segment; (d) positioning the first andsecond members second end segment 484 extends through thenotch 498 in the first end segment so that theinterior surfaces 469 of thefirst end segment 474 are adjacent to theexterior surfaces 489 of thesecond end segment 484 and so that theterminal edge surface 496 of thesecond end segment 484 engages the second connectingwall portion 476 of thefirst end segment 474; and (e) welding the first andsecond wall portions second end segment 484 to the first andsecond wall portions first end segment 474. - 86. Preferably, as best seen in FIG. 17, the first connecting
wall portion 490 of the second end segment is welded to anedge 479 on the first connectingwall portion 477 formed by the cutting and preferably the terminal edge surface 497 of thesecond end segment 484 is welded to the second connectingwall portion 476 of thefirst end segment 474. - 87.
Joints tubular member 94 defined by a first outwardly deformed tubularmetallic wall 506 fixed into a predetermined exterior surface configuration and a second, intersecting space frame structure in the form of a second elongated hydroformedtubular member 66 defined by a second outwardly deformed tubularmetallic wall 508 fixed into a predetermined exterior surface configuration. It can be appreciated from FIG. 19 that the joint 87 is formed at a juncture ortransition 106 between thetubular cross portion 98 and theleg portion 102 of thecross member 94. - 88. The
first member 94 includes afirst segment 512 having a cross section that defines anexterior surface portion 514 therealong. Thesecond member 66 includes asecond segment 516 having a cross section that defines anexterior surface portion 518 therealong. It can be appreciated from FIG. 1 that the secondhydroformed segment 516 of the secondhydroformed member 66 is part of thelongitudinally extending portion 82 of the forward upperlongitudinal member 66. - 89. The first and
second members surface portions Welding material 520 is disposed in bonding relation between thesurfaces second segments - 90. It can be appreciated from the description of the joint 87 that it is contemplated to provide a
space frame 10 for a motor vehicle comprising a pair of tubular hydroformed upperlongitudinal members 66, 68 (that is, the forward upper longitudinal members), each being defined by an outwardly deformed metallic wall fixed into a predetermined exterior surface configuration and each having apillar forming portion 78 and alongitudinally extending portion 82. The space frame farther includes a tubularhydroformed cross member 94 defined by an outwardly deformed metallic wall fixed into a predetermined exterior surface configuration and having across portion 98 and a pair ofleg portions 102 extending fromjunctures 106 at each end of the cross portion. Thelongitudinally extending portion 82 of each upperlongitudinal member juncture 106 of thecross member 98 each include asegment exterior surface portion - 91. A pair of longitudinally extending, laterally spaced
side rail structures 22 are included in thespace frame 10 and theside rail structures 22 and thehydroformed members pillar forming portion 78 of each upperlongitudinal member 66 is connected to and forms a pillar on a respectiveside rail structure 22, (b) theleg portions 102 of thecross member 94 are each connected to a respectiveside rail structure 22 and extend upwardly therefrom to provide one of a pair ofintermediate pillars 102 and (c) thecross portion 98 of thecross member 94 connects the pair ofside rail structures 22 in laterally spaced relation. The upperlongitudinal members cross member 94 are assembled together such that theexterior surface portion 518 of each upperlongitudinal member exterior surface portion 514 of the associatedjuncture 106 are in abutting relation. Welding material is disposed in bonding relation between each pair of abuttingsurface portions longitudinally extending portion 82 of each upperlongitudinal member juncture 106 of thecross member 94. - 92. Preferably, the
pillar forming portions 78 of the upperlongitudinal members side rail structures 22. It can be appreciated that the embodiment of the joint 87 and of thespace frame 10 are exemplary only and not intended to limit a scope of invention. The joint 87 can also be constructed to secure the longitudinally extending portion of an upper longitudinal member that is in underlying relation to the associated juncture of the U-shaped cross member of the space frame. Thus, it is contemplated that the longitudinally extending portion of each upper longitudinal member be in overlying relation with the associated juncture of the cross member in some space frame embodiments (as shown, for example, in FIG. 1), and that the associated juncture be in overlying relation thereto in other embodiments. Similarly, it is not intended to limit the construction of the engaging surface is 514, 518 to planar surfaces. Thesurfaces - 93. It can be understood from the description of joint 87 and of the description of the structure and construction of the
space frame 10 that a method of forming a space frame for a motor vehicle is contemplated and within the scope of invention, the method comprising: (1) forming a pair of upperlongitudinal members U-shaped cross member 94 by hydroforming wherein an angularly shaped tubular metallic blank is placed into a die assembly having die surfaces defining a die cavity, and pressurized fluid is provided into an interior of the blank so as to expand the blank into conformity with the die surfaces. Each upper longitudinal hydroformed member includes a pillar-formingportion 78 and alongitudinally extending portion 82. Thehydroformed cross member 94 includes across portion 98 andleg portions 102 extending fromjunctures 106 at each end of the cross portion. Thelongitudinally extending portion 82 of each upper longitudinalhydroformed member juncture 106 of thecross member 94 each include asegment exterior surface portion side rail structures 22 with thehydroformed members pillar forming portion 78 of each upper longitudinalhydroformed member side rail structure 22, (b) theleg portions 102 of thehydroformed cross member 94 are each connected to a respectiveside rail structure 22 and extend upwardly therefrom to provide one of a pair of intermediate pillars, and (c) thecross portion 98 of thehydroformed cross member 94 connects theside rail structures 22 in laterally spaced relation. The upper longitudinal hydroformed members and the hydroformed cross member are positioned such that theexterior surface portion 518 of each upperlongitudinal member exterior surface portion 514 of the associatedjuncture 106 are in abutting relation; and welding said abutting surface portions to fixedly secure the longitudinally extending portion of each upper longitudinal member to the associated juncture of the cross member. - 94. The joint 87 allows two hydroformed members to be joined quickly and easily. Because the tubular hydroformed members are in abutting relation, the joint 87 can accommodate a high degree of stacked tolerance. It can be understood that although it is preferred that both
surfaces members - 95.FIG. 19 shows a portion of a
body panel 521 in phantom to illustrate that thehydroformed members space frame 10 preferably provide aligned (i.e., co-planar), outwardly facingsurfaces members exterior surfaces - 96. It can also be appreciated from the various views of the joints shown, for example, in FIGS. 2-17 that many of the individual hydroformed members (such as
hydroformed members 26 in FIG. 3 and 140 in FIG. 4) have essentially rectangular cross sections. This should not be construed as limiting the scope of the invention to joints formed between rectangular portions (i.e., portions having rectangular transverse cross sections) of hydroformed members. Hydroformed members having rectangular cross sections are often advantageous in space frame construction because they allow welds to be made along straight paths (such asweld 429 in FIG. 10, for example) and provide outwardly facing surfaces that facilitate installation of body panels to the frame. It is understood, however, that the joints shown in FIGS. 2-19 are intended to be illustrative only and are not limited to members having rectangular cross sections. The joints in FIGS. 2-19 are intended to teach broad principles for joining hydroformed members and for joining a nonhydroformed member to hydroformed member which principles can be applied to hydroformed members having a wide range of cross sectional geometries. - 97. While the invention has been disclosed and described with reference with a limited number of embodiments, it will be apparent that variations and modifications may be made thereto without departure from the spirit and scope of the invention. Therefore, the following claims are intended to cover all such modifications, variations, and equivalents thereof in accordance with the principles and advantages noted herein.
Claims (48)
1. A method of forming a vehicle space frame joint, comprising:
forming an elongated first member constructed of a metallic material that includes an end segment, said end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment;
forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform said tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, said hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions;
forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, said first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member;
placing the end segment of the first member through said first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of said openings; and
welding the intermediate segment and the end segment together in the area of said abutting engagement between exterior surface portions of the end segment and said edge portions of said openings.
2. The method as defined in wherein the forming of said first member is accomplished by a roll forming operation.
claim 1
3. The method as defined in wherein the forming of said first member is accomplished by hydroforming a second tubular blank having a tubular metallic wall so as to outwardly deform said second tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a second die assembly.
claim 1
4. The method as defined in wherein said end segment includes a terminal end portion, and wherein the edge portion of said second opening is welded to said exterior surface portion of said end segment adjacent said terminal end portion.
claim 1
5. The method as defined in wherein the end segment of the hydroformed first member has a generally uniform cross section along the length thereof and wherein the first and second openings in the intermediate segment of the hydroformed second member are of approximately equal size and shape.
claim 4
6. The method as defined in wherein the opposing first and second wall portions of the intermediate segment are essentially planar and parallel.
claim 1
7. The method as defined in wherein said hydroformed second member has a varying cross sectional configuration along its length.
claim 6
8. A vehicle space frame joint, comprising:
a first space frame structure in the form of a tubular elongated first member, said first member including an end segment having a predetermined length and an exterior surface that defines an exterior configuration of the end segment;
a second, intersecting space frame structure in the form of a elongated tubular hydroformed second member defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration, said hydroformed second member having an intermediate segment that includes a pair of opposing first and second wall portions, said first and second wall portions of the intermediate segment including generally aligned first and second openings formed within the first and second wall portions, respectively, said first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member;
said end segment extending through said first and second openings such that portions of the exterior surface thereof are in abutting engagement with edge portions of said openings; and
welding material constructed and arranged to fixedly secure said first and second segments together, said welding material being applied in the areas of the juncture between the exterior surface of the end segment and said edge portions of said openings.
9. A vehicle space frame joint as defined in , wherein the end segment of the first member has a generally uniform cross section along the length thereof and wherein the first and second openings in the intermediate segment of the hydroformed second member are of approximately equal size and shape.
claim 8
10. A vehicle space frame joint as defined in , wherein the first member is of tubular hydroformed construction defined by an outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration.
claim 8
11. A vehicle space frame joint as defined in , wherein said hydroformed second member has a varying cross sectional configuration along its length.
claim 8
12. A vehicle space frame joint as defined in , wherein said first space frame structure is roll formed into a quadrilateral configuration.
claim 8
13. A vehicle space frame joint as defined in wherein the opposing first and second wall portions of the hydroformed second member are essentially planar and parallel.
claim 12
14. A vehicle space frame joint as defined in wherein the intermediate segment of the hydroformed second member has a generally uniform cross section along its length.
claim 11
15. A method of forming a vehicle space frame joint, comprising:
hydroforming a first blank having a first tubular metallic wall so as to irregularly outwardly deform the first wall into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubular hydroformed member, said first elongated tubular hydroformed member including a tubular first segment that includes a pair of spaced generally opposing first and second wall portions, said first and second wall portions having spaced generally opposing exterior surfaces;
hydroforming a second blank having a second tubular metallic wall so as to outwardly deform the second wall into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second tubular hydroformed member, said second tubular hydroformed member including a tubular end segment that includes a pair of spaced generally opposing first and second wall portions and first and second connecting wall portions extending therebetween, said first and second wall portions defining spaced interior wall surfaces;
cutting and removing an end section of each connecting wall portion of the end segment to form a notch in each connecting wall portion to allow the first segment to be received between the first and second wall portions of the end segment;
positioning the first segment of the first member within the notches and between the first and second wall portions of the end segment so that said exterior surfaces of the first and second wall portions of the first segment and said interior surfaces of the first and second wall portions of the end segment are in abutting engagement; and
welding the interior surfaces of said first and second wall portions of said end segment with the exterior surfaces of the first and second wall portions of said first segment.
16. A method of forming a vehicle space frame joint as defined in wherein the second tubular metallic wall of the second blank is irregularly outwardly deformed during said hydroforming procedure.
claim 15
17. A method of forming a vehicle space frame joint as defined in wherein the first segment of the first hydroformed member has a generally uniform cross section.
claim 16
18. A method of forming a vehicle space frame joint as defined in wherein the end segment of the second member has a generally uniform cross section.
claim 17
19. A method of forming a vehicle space frame joint as defined in wherein the first and second wall portions of the first and second members and the exterior and interior surfaces defined thereby, respectively, are essentially planar.
claim 18
20. A method of forming a vehicle space frame joint as defined in wherein the first and second wall portions of the first and second members and the exterior and interior surfaces defined thereby, respectively, are essentially parallel.
claim 19
21. A method of forming a vehicle space frame joint as defined in wherein the opposing connecting wall portions of the end segment of the second member are generally planar.
claim 20
22. A method of forming a vehicle space frame joint as defined in wherein the opposing connecting wall portions of the end segment of the second member are generally parallel.
claim 21
23. A vehicle space frame joint, comprising:
a first space frame structure in the form of a first elongated tubular hydroformed member defined by an irregularly outwardly deformed first tubular metallic wall fixed into a predetermined irregular exterior surface configuration,
a second, intersecting space frame structure in the form of a second elongated tubular hydroformed member defined by an outwardly deformed second tubular metallic wall fixed into a predetermined exterior surface configuration,
said first member including a tubular first segment that includes a pair of spaced first and second wall portions, said first and second wall portions providing first and second exterior surfaces, respectively;
said second member including an end segment having a pair of spaced cantilevered first and second wall portions, said first and second wall portions defining spaced interior wall surfaces;
the first segment being positioned between said cantilevered first and second wall portions of said end segment such that the interior surfaces of said first and second wall portions of said end segment and said exterior surfaces of said first and second wall portions of said first segment are in abutting relation;
welding material being disposed in bond forming relation between said interior surfaces of said first and second wall portions of said end segment and said abutting exterior surfaces of said first segment.
24. A vehicle space frame joint as claimed in , wherein the metallic wall of the second blank is irregularly outwardly deformed during said hydroforming procedure so that said second hydroformed member has an irregularly outwardly deformed tubular metallic wall.
claim 23
25. A vehicle space frame joint as claimed in , wherein the first segment of the first member has a generally uniform cross section.
claim 24
26. A vehicle space frame joint as claimed in , wherein the end segment of the second member has a generally uniform cross section.
claim 25
27. A vehicle space frame joint as defined in wherein the first and second wall portions of the first segment and of the end segment are essentially parallel and planar.
claim 26
28. A vehicle space frame joint as defined in wherein the opposing first and second connecting wall portions of the end segment and of the first segment are generally parallel and planar.
claim 24
29. A method of forming a vehicle space frame joint, comprising:
hydroforming a first blank having a first tubular metallic wall to outwardly deform the first wall into an exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first elongated tubular hydroformed member, said first member including an intermediate segment having generally opposing first and second wall portions and generally opposing first and second connecting wall portions extending therebetween, the first and second wall portions providing a pair of generally opposing interior surfaces;
hydroforming a second blank having a second tubular metallic wall to outwardly deform the second wall into an exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubular hydroformed member, said second member including an end segment having generally opposing first and second wall portions providing a pair of generally opposing exterior surfaces;
cutting and removing a section of one said connecting wall portions of the intermediate segment to form an opening of sufficient dimension to receive said end segment of said second member and cutting a section of the first wall portion of the first segment to form a weld opening therein;
positioning the end segment into said opening and between the first and second wall portions of the intermediate segment so that the exterior surface of the end segment is disposed adjacent said weld opening; and
welding the first and second members together through said weld opening.
30. The method of forming a vehicle space frame joint as defined in , wherein the first and second wall portions of the intermediate segment and the first and second wall portions of the end segment are generally planar and parallel.
claim 29
31. A vehicle space frame joint, comprising:
a first space frame structure in the form of a first elongated hydroformed tubular member defined by a first outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration, said first member including an intermediate segment having generally opposing first and second wall portions, a connecting wall portion extending between said first and second wall portions, and an opening into said first member, the first and second wall portions of said intermediate segment providing a pair of generally opposing interior surfaces, said first wall portion having a weld opening formed therein;
a second, intersecting space frame structure in the form of a second elongated tubular hydroformed member defined by a second outwardly deformed tubular metallic wall fixed into a predetermined exterior surface configuration, said second member including an end segment having generally opposing first and second wall portions providing a pair of generally opposing exterior surfaces;
said end segment being positioned within said opening so that the opposing exterior surfaces thereof are disposed adjacent to the opposing interior surfaces of said intermediate segment and to the weld opening; and
welding material being disposed in bond forming relation between a peripheral edge portion of the weld opening and the adjacent exterior surface of the intermediate segment, thus fixing said first and second members together.
32. A vehicle space frame joint as defined in , wherein the first and second wall portions of the intermediate segment and the first and second wall portions of the end segment are generally planar and parallel.
claim 31
33. A method of forming a space frame joint, comprising:
hydroforming a first blank having a first tubular metallic wall so as to outwardly deform the first wall into a predetermined exterior surface configuration determined by the engagement of the first wall with die surfaces of a first die assembly to form a first tubular hydroformed member, said first tubular member including a first end segment having spaced generally opposing first and second wall portions and first and second connecting wall portions extending therebetween, said first and second wall portions providing spaced generally opposing interior surfaces along said first end segment;
hydroforming a second blank having a second tubular metallic wall so as to outwardly deform the second wall into a predetermined exterior surface configuration determined by the engagement of the second wall with die surfaces of a second die assembly to form a second elongated tubular hydroformed member, said second member including a second end segment having spaced generally opposing first and second wall portions and first and second connecting wall portions extending therebetween, said first and second wall portions of said second end segment providing spaced generally opposing exterior surfaces and said second end segment having a terminal edge surface;
cutting and removing a section of the first connecting wall portion of the first end segment to form a notch in the first end segment;
positioning the first and second members such that the second end segment extends through said notch in the first end segment so that the interior surfaces of the first end segment are adjacent to the exterior surfaces of the second end segment and so that said terminal edge surface of said second end segment engages said second connecting wall portion of said first end segment; and
welding the first and second wall portions of said second end segment to said first and second wall portions of said first end segment.
34. A method of forming a space frame joint as defined in further comprising welding the first connecting wall portion of the second end segment to an edge on the first connecting wall portion formed by said cutting.
claim 33
35. A method of forming a space frame joint as defined in wherein the first and second wall portions of the first end segment and the interior surfaces defined thereby and the first and second wall portions of the second end segment and the exterior surfaces formed thereby are generally parallel and planar.
claim 34
36. A method of forming a space frame joint as defined in , further comprising welding said terminal edge surface of said second end segment to said second connecting wall portion of said first end segment.
claim 35
37. A method of forming a space frame joint as defined in wherein the first and second connecting wall portions of the first end segment and the first and second connecting wall portions of the second end segment are generally planar and parallel.
claim 36
38. A vehicle space frame joint, comprising:
a first space frame structure in the form of an elongated tubular hydroformed first member defined by a first irregularly outwardly deformed metallic wall fixed into a predetermined irregular exterior surface configuration;
a second, intersecting space frame structure in the form of an elongated tubular hydroformed second member defined by a second irregularly outwardly deformed metallic wall fixed into a predetermined irregular exterior surface configuration;
said first member including a first end segment having spaced generally opposing first and second wall portions and a connecting wall extending therebetween, said first and second wall portions providing spaced generally opposing interior surfaces along said first end segment, said first end segment having an opening opposite said connecting wall;
said second member including a second end segment having spaced generally opposing first and second wall portions and first and second connecting wall portions extending therebetween, said first and second wall portions of said second and segment providing spaced generally opposing exterior surfaces and said second end segment having a terminal opening defined by a terminal edge surface;
the first and second wall portions of each of the first and second end segments being constructed and arranged such that the second end segment is received through said opening and disposed between the first and second wall portions of the first end segment, and said first end segment interior surfaces and said second end segment exterior surfaces are in adjacent relation; and
welding material being disposed in bond forming relation between the first and second wall portions of the second end segment and the first and second wall portions of the first end segment.
39. A method of forming a space frame for a motor vehicle, said method comprising:
forming a pair of upper longitudinal members and a U-shaped cross member by hydroforming, wherein an angularly shaped tubular metallic blank is placed into a die assembly having die surfaces defining a die cavity, and pressurized fluid is provided into an interior of said blank so as to expand said blank into conformity with said die surfaces,
each upper longitudinal hydroformed member including a pillar forming portion and a longitudinally extending portion, said hydroformed cross member including a cross portion and leg portions extending from junctures at each end of the cross portion,
the longitudinally extending portion of each upper longitudinal hydroformed member and each juncture of the hydroformed cross member each including a segment that defines an exterior surface portion;
providing a pair of side rail structures; and
assembling said side rail structures with said hydroformed members so that (a) the pillar forming portion of each upper longitudinal hydroformed member is connected to and forms a pillar structure on a respective side rail structure, (b) the leg portions of the hydroformed cross member are each connected to a respective side rail structure and extend upwardly therefrom to provide one of a pair of intermediate pillars, and (c) the cross portion of the hydroformed cross member connects said side rail structures in laterally spaced relation,
positioning the upper longitudinal hydroformed members and the hydroformed cross member such that the exterior surface portion of each upper longitudinal member and the exterior surface portion of the associated juncture are in abutting relation; and
welding said abutting surface portions to fixedly secure the longitudinally extending portion of each upper longitudinal member to the associated juncture of the cross member.
40. A method as defined in wherein said pillar forming portions of said upper longitudinal members define the A pillars on the side rail structures.
claim 39
41. A method as defined in wherein the longitudinally extending portion of each upper longitudinal member is in overlying relation with the associated juncture of the cross member.
claim 40
42. A method as defined in wherein each juncture of the cross member is in overlying relation with the longitudinally extending portion of the associated upper longitudinal member.
claim 40
43. A method as defined in wherein the exterior surface portions of each upper longitudinal member and of each juncture are planar.
claim 41
44. A space frame for a motor vehicle, comprising,
a pair of tubular hydroformed upper longitudinal members, each being defined by an irregularly outwardly deformed metallic wall fixed into a predetermined irregular exterior surface configuration and each having a pillar forming portion and a longitudinally extending portion;
a tubular hydroformed cross member defined by an irregularly outwardly deformed metallic wall fixed into a predetermined irregular exterior surface configuration and having a cross portion and a pair of leg portions extending from junctures at each end of the cross portion;
the longitudinally extending portion of each upper longitudinal member and each juncture of the cross member each including a segment that defines an exterior surface portion;
a pair of longitudinally extending, laterally spaced side rail structures;
the side rail structures and the hydroformed members being assembled such that the pillar forming portion of each upper longitudinal member is connected to and forms a pillar on a respective side rail structure, the leg portions of the cross member are each connected to a respective side rail structure and extend upwardly therefrom to provide one of a pair of intermediate pillar structures and the cross portion of the cross member connects the pair of side rail structures in laterally spaced relation,
the upper longitudinal members and the cross member being assembled together such that the exterior surface portion of each upper longitudinal member and the exterior surface portion of the associated juncture are in abutting relation; and
welding material disposed in bonding relation between each pair of abutting surface portions to fixedly secure the longitudinally extending portion of each upper longitudinal member to the associated juncture of the cross member.
45. A method as defined in wherein said pillar forming portions of said upper longitudinal members define the A pillars on the side rail structures.
claim 44
46. A method as defined in wherein the longitudinally extending portion of each upper longitudinal member is in overlying relation with the associated juncture of the cross member.
claim 45
47. A method as defined in wherein each juncture of the cross member is in overlying relation with the longitudinally extending portion of the associated upper longitudinal member.
claim 46
48. A method as defined in wherein the exterior surface portions of each upper longitudinal member and of each juncture are planar.
claim 46
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/729,944 US20010000119A1 (en) | 1997-10-16 | 2000-12-06 | Hydroformed space frame and joints therefor |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US6220497P | 1997-10-16 | 1997-10-16 | |
US09/173,554 US6092865A (en) | 1997-10-16 | 1998-10-16 | Hydroformed space frame and method of manufacturing the same |
US09/517,750 US6302478B1 (en) | 1997-10-16 | 2000-03-03 | Hydroformed space frame joints therefor |
US09/729,944 US20010000119A1 (en) | 1997-10-16 | 2000-12-06 | Hydroformed space frame and joints therefor |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/517,750 Division US6302478B1 (en) | 1997-10-16 | 2000-03-03 | Hydroformed space frame joints therefor |
Publications (1)
Publication Number | Publication Date |
---|---|
US20010000119A1 true US20010000119A1 (en) | 2001-04-05 |
Family
ID=46203820
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/517,750 Expired - Lifetime US6302478B1 (en) | 1997-10-16 | 2000-03-03 | Hydroformed space frame joints therefor |
US09/729,944 Abandoned US20010000119A1 (en) | 1997-10-16 | 2000-12-06 | Hydroformed space frame and joints therefor |
US09/930,969 Expired - Lifetime US6412857B2 (en) | 1997-10-16 | 2001-08-17 | Hydroformed space frame and joints therefor |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/517,750 Expired - Lifetime US6302478B1 (en) | 1997-10-16 | 2000-03-03 | Hydroformed space frame joints therefor |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/930,969 Expired - Lifetime US6412857B2 (en) | 1997-10-16 | 2001-08-17 | Hydroformed space frame and joints therefor |
Country Status (1)
Country | Link |
---|---|
US (3) | US6302478B1 (en) |
Cited By (40)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004041625A1 (en) | 2002-11-06 | 2004-05-21 | Thyssenkrupp Stahl Ag | Connecting joint for shell elements |
US6739624B2 (en) | 1997-10-16 | 2004-05-25 | Magna International Inc. | Frame assembly for a motor vehicle |
US20040108754A1 (en) * | 2002-11-01 | 2004-06-10 | Masanori Igarashi | Rear structure of vehicle body |
WO2004078563A1 (en) * | 2003-03-07 | 2004-09-16 | Wilhelm Karmann Gmbh | Motor vehicle body pillar |
DE10252790B3 (en) * | 2002-11-06 | 2004-12-23 | Thyssenkrupp Stahl Ag | Connection knot for shell elements |
US20050116460A1 (en) * | 2003-10-17 | 2005-06-02 | Mcgill Scott M. | Method of manufacturing a frame assembly |
US20050166382A1 (en) * | 2004-01-30 | 2005-08-04 | Bruggemann Charles J. | Method of forming thickened tubular members |
US20050196228A1 (en) * | 2004-03-08 | 2005-09-08 | Bruggemann Charles J. | Hydroformed dovetail joint and method of joining tubular members |
US20050258667A1 (en) * | 2001-11-30 | 2005-11-24 | Axel Grueneklee | Sheet steel connection joints of sections consisting of sheet steel |
US20060090950A1 (en) * | 2004-10-28 | 2006-05-04 | Stanley Krise | High-rise go-chart chassis |
EP1762467A1 (en) * | 2005-09-08 | 2007-03-14 | Ford Global Technologies, LLC | Hydroformed automotive pillar |
US20070108803A1 (en) * | 2005-11-16 | 2007-05-17 | Ford Global Technologies, Llc | Interlocked pillar and roof rail joint |
US20070246235A1 (en) * | 2006-04-21 | 2007-10-25 | Deere & Company, A Delaware Corporation | Implement frame tube joint with weldable connector |
FR2900207A1 (en) * | 2006-04-20 | 2007-10-26 | Renault Sas | Beam and crosspiece assembly for vehicle, has bracket comprising support surface perpendicular to connection surface, where connection and support surfaces are supported on groove and assembling surface of beam, respectively |
FR2900623A1 (en) * | 2006-05-05 | 2007-11-09 | Renault Sas | HYDROFORMED OR PROFILED MULTIFUNCTION PAVILLION TRAVERSE |
GB2441626A (en) * | 2006-09-06 | 2008-03-12 | Ford Global Tech Llc | A double cell crushable joint for an automotive front end. |
US20080073926A1 (en) * | 2006-09-26 | 2008-03-27 | Ford Global Technologies, Llc | Tubular structural joint for automotive front end |
US20080115363A1 (en) * | 2003-01-16 | 2008-05-22 | Marando Richard A | Cast aluminum node for connecting vehicle frame members and method of manufacturing same |
CN100482516C (en) * | 2001-11-09 | 2009-04-29 | 麦格纳国际公司 | Modular underbody for a motor vehicle |
US20100038874A1 (en) * | 2008-08-15 | 2010-02-18 | Varela Tomaz D | Internal stiffener for hollow structure |
WO2010092547A1 (en) * | 2009-02-11 | 2010-08-19 | Dario Di Camillo | Vehicle body, more particularly land vehicle body |
ITBO20090492A1 (en) * | 2009-07-28 | 2011-01-29 | Ferrari Spa | FRAME OF A VEHICLE EQUIPPED WITH AN EXTRUDED CENTRAL UPRIGHT |
US8517423B1 (en) * | 2012-03-20 | 2013-08-27 | Club Car, Llc | Modular frame structure for off road vehicle |
US20140265447A1 (en) * | 2013-03-14 | 2014-09-18 | Ford Global Technologies, Llc | Roof panel to side-pillar hydroformed reinforcement for vehicles |
US9199525B2 (en) | 2011-12-09 | 2015-12-01 | Aisin Seiki Kabushiki Kaisha | Vehicle door frame and inner member for vehicle door frame |
US9751568B2 (en) | 2015-12-07 | 2017-09-05 | Honda Motor Co., Ltd. | Body frame structure for a vehicle |
WO2019045932A1 (en) * | 2017-08-31 | 2019-03-07 | Divergent Technologies, Inc. | Apparatus and methods for connecting tubes in transport structures |
US10280607B2 (en) * | 2016-10-27 | 2019-05-07 | Fred A. Wagner, III | Connection system and method of using same |
US20190246546A1 (en) * | 2018-02-09 | 2019-08-15 | Morris Industries Ltd. | Agricultural implement frame assembly |
US10686304B2 (en) | 2016-10-27 | 2020-06-16 | Fred A. Wagner, III | Connection system and method of using same |
US11235809B2 (en) | 2019-12-05 | 2022-02-01 | Hyundai Motor Company | Vehicle body for vehicles |
US11242093B2 (en) * | 2019-11-20 | 2022-02-08 | Hyundai Motor Company | Roof carrier for vehicle |
US11279412B2 (en) * | 2019-12-05 | 2022-03-22 | Hyundai Motor Company | Vehicle body |
US11286003B2 (en) | 2019-12-05 | 2022-03-29 | Hyundai Motor Company | Vehicle body structure |
US11325652B2 (en) | 2019-12-05 | 2022-05-10 | Hyundai Motor Company | Body for vehicle |
US11325657B2 (en) | 2019-12-05 | 2022-05-10 | Hyundai Motor Company | Body for vehicle |
US11332192B2 (en) | 2019-12-05 | 2022-05-17 | Hyundai Motor Company | Vehicle body |
CN114616167A (en) * | 2019-10-25 | 2022-06-10 | 卡特彼勒公司 | Space frame central upper frame node connecting piece |
US11358646B2 (en) | 2019-12-05 | 2022-06-14 | Hyundai Motor Company | Vehicle body forming structure and vehicle body using the same |
US11472490B2 (en) * | 2019-12-05 | 2022-10-18 | Hyundai Motor Company | Body for vehicle |
Families Citing this family (71)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6623067B2 (en) | 1997-10-16 | 2003-09-23 | Magna International Inc. | Door seal interface structure for a motor vehicle space frame |
JP2001233254A (en) * | 2000-02-22 | 2001-08-28 | Mitsubishi Automob Eng Co Ltd | Vehicle body structure |
US6241310B1 (en) * | 2000-05-17 | 2001-06-05 | Asc Incorporated | Vehicle structure with integral node |
ITBO20000448A1 (en) * | 2000-07-21 | 2002-01-21 | Baldussi Ezio | BODY FOR VEHICLES. |
GB2365391B (en) * | 2000-08-08 | 2002-09-04 | Lotus Car | Land vehicle |
US6373021B1 (en) * | 2001-01-25 | 2002-04-16 | General Motors Corporation | Method for electrical resistance welding a metal tube to a metal sheet |
CA2439821C (en) * | 2001-03-02 | 2009-06-30 | Magna International Inc. | Hybrid space frame for motor vehicule |
DE10126183A1 (en) * | 2001-05-30 | 2002-12-12 | Karmann Gmbh W | Device for increasing the strength of a hollow molded part of a vehicle body |
DE10201911A1 (en) * | 2002-01-19 | 2003-08-07 | Thyssenkrupp Stahl Ag | Connection node between two hollow profiles of a frame structure, especially for vehicles |
DE10202957A1 (en) * | 2002-01-26 | 2003-08-07 | Porsche Ag | Superstructure for motor vehicles |
JP3941563B2 (en) * | 2002-04-02 | 2007-07-04 | 日産自動車株式会社 | Vehicle front structure |
US6601910B1 (en) * | 2002-05-31 | 2003-08-05 | Kevin G. Duggan | Expandable ram system |
US6905137B2 (en) * | 2002-11-21 | 2005-06-14 | Volvo Trucks North America, Inc. | Composite cross member system |
DE10256608A1 (en) * | 2002-12-03 | 2004-07-01 | Wilhelm Karmann Gmbh | Sidewall module for a motor vehicle and manufacturing method for a motor vehicle body |
US6739166B1 (en) | 2002-12-17 | 2004-05-25 | General Motors Corporation | Method of forming tubular member with flange |
US20040150208A1 (en) * | 2003-01-31 | 2004-08-05 | Brian Nathan | Vehicle structure having cross members overlapped by apertured rails |
JP4195325B2 (en) * | 2003-04-23 | 2008-12-10 | 三菱アルミニウム株式会社 | Body frame structure |
US20050035586A1 (en) * | 2003-08-12 | 2005-02-17 | Martin Samuel V. | Magnetically pulse welded underbody |
JP3917965B2 (en) * | 2003-08-26 | 2007-05-23 | 本田技研工業株式会社 | Body front structure |
DE10347556B4 (en) * | 2003-08-27 | 2005-09-01 | Thyssenkrupp Stahl Ag | Pillar in a supporting structure of a motor vehicle in spaceframe construction |
EP1658218B1 (en) * | 2003-08-27 | 2007-10-31 | ThyssenKrupp Steel AG | Post in a carrier structure of a motor vehicle in a spaceframe style |
DE10344939A1 (en) * | 2003-09-27 | 2005-04-28 | Karmann Gmbh W | Frame structure and method for its production |
US7060929B2 (en) * | 2004-02-24 | 2006-06-13 | General Motors Corporation | Sheet-to-tube resistance spot welding using servo gun |
DE102004025855A1 (en) * | 2004-05-24 | 2006-01-26 | Wilhelm Karmann Gmbh | Method for producing a frame structure with at least two hollow profile elements |
US7066533B2 (en) * | 2004-06-03 | 2006-06-27 | Ford Global Technologies, Llc | Tubular front end structure for automobiles and method for making the same |
US7251915B2 (en) * | 2004-09-10 | 2007-08-07 | Pullman Industries, Inc. | Frame system for motor vehicle |
JP2006088924A (en) * | 2004-09-24 | 2006-04-06 | Mitsubishi Automob Eng Co Ltd | Vehicle body structure |
US7229113B2 (en) * | 2004-10-25 | 2007-06-12 | General Motors Corporation | Structural assembly for vehicles and method of making same |
US7222912B2 (en) * | 2004-11-23 | 2007-05-29 | Ford Global Technologies, Llc | Automotive vehicle body with hydroformed cowl |
DE102004061795A1 (en) * | 2004-12-22 | 2006-07-13 | Wilhelm Karmann Gmbh | Method for producing a welded connection between two nested hollow profiles |
US7090273B2 (en) * | 2005-01-12 | 2006-08-15 | Ford Global Technologies, Llc | Seal apparatus for an improved front-end to body-side joint of a vehicle |
CA2588386C (en) * | 2005-02-23 | 2014-01-21 | Magna International Inc. | Joining structure for side members and cross members in chassis frames |
US7275785B2 (en) * | 2005-06-08 | 2007-10-02 | Ford Global Technologies, Llc | Rear subframe attachment mount for hydroformed frame |
US7574801B2 (en) * | 2005-06-16 | 2009-08-18 | Ford Global Technologies, Llc | Single set geometry method for assembly of a vehicle |
US7828329B2 (en) * | 2006-06-01 | 2010-11-09 | Philip Biscan | Transport frame |
DE102006041093B4 (en) * | 2006-09-01 | 2014-10-30 | Audi Ag | Carrier assembly for a vehicle |
US7543883B2 (en) * | 2006-10-11 | 2009-06-09 | Ford Global Technologies, Llc | Roof rail with integrally formed pinched flanges |
US7547063B2 (en) * | 2006-11-14 | 2009-06-16 | Ford Global Technologies, Llc | Unitized vehicle frame subassembly and method of assembling a side frame for a vehicle |
EP1927530B1 (en) | 2006-12-01 | 2009-10-14 | Ford Global Technologies, LLC | A subframe mount for an automotive frame |
US7571957B2 (en) * | 2007-02-01 | 2009-08-11 | Magna International | Component integration panel system with closed box section |
US8171641B2 (en) * | 2007-02-23 | 2012-05-08 | Ford Motor Company | Vehicle framing method and frame |
US8960776B2 (en) * | 2007-04-20 | 2015-02-24 | Honda Motor Co., Ltd. | Vehicle bed frame assembly, system and method |
ITTO20070404A1 (en) * | 2007-06-08 | 2008-12-09 | Rosfin S R L | PROCEDURE FOR THE CONSTRUCTION OF THE CARRYING STRUCTURE OF A BODYWORK OF A MOTOR VEHICLE, AND THE STRUCTURE CARRIED OUT SO MUCH. |
DE202008006308U1 (en) * | 2008-05-07 | 2008-07-17 | Horsch Maschinen Gmbh | Frame for agricultural tillage implement |
US7887122B2 (en) * | 2008-06-12 | 2011-02-15 | Ford Global Technologies, Llc | One-piece shotgun with impact energy absorber |
DE102009030349B4 (en) * | 2009-06-25 | 2020-01-02 | GM Global Technology Operations LLC (n. d. Ges. d. Staates Delaware) | Side structure of a vehicle |
US8262155B2 (en) * | 2009-12-06 | 2012-09-11 | Honda Motor Co., Ltd. | Overmolded joint for beam assembly |
JP2012017068A (en) * | 2010-07-09 | 2012-01-26 | Aisin Seiki Co Ltd | Combined structural member |
BR112013023808A2 (en) | 2011-03-17 | 2016-12-13 | Zephyros Inc | link assembly |
DE102011103090A1 (en) * | 2011-05-25 | 2012-11-29 | Thyssenkrupp Steel Europe Ag | Vehicle body and its use |
US9126628B2 (en) * | 2011-12-01 | 2015-09-08 | Ford Global Technologies, Llc | Lightweight vehicle beam |
TWI482716B (en) * | 2012-11-20 | 2015-05-01 | Kwang Yang Motor Co | Modular vehicle frame for small vehicles |
CN103847792B (en) * | 2012-11-29 | 2018-07-24 | 光阳工业股份有限公司 | The modularity bicycle frame device of dilly |
US9139235B2 (en) | 2013-05-21 | 2015-09-22 | Ford Global Technologies, Llc | Vehicle frame rail and pillar connection |
DE102013112152A1 (en) * | 2013-11-05 | 2015-05-07 | Deutsches Zentrum für Luft- und Raumfahrt e.V. | Vehicle and car body for a vehicle |
US9321345B2 (en) * | 2014-05-14 | 2016-04-26 | Ford Global Technologies, Llc | Apparatus and method for joining a hydro-formed tube to an extrusion |
US10960929B2 (en) | 2014-07-02 | 2021-03-30 | Divergent Technologies, Inc. | Systems and methods for vehicle subassembly and fabrication |
EP3925766B1 (en) | 2014-07-02 | 2023-11-08 | Divergent Technologies, Inc. | Tubular frame of vehicle |
JP6049146B2 (en) * | 2014-09-24 | 2016-12-21 | 富士重工業株式会社 | Body frame structure |
DE102015204963B4 (en) * | 2015-03-19 | 2023-10-12 | Ford Global Technologies, Llc | Front section of a motor vehicle |
DE102015004983A1 (en) * | 2015-04-18 | 2016-10-20 | GM Global Technology Operations LLC (n. d. Ges. d. Staates Delaware) | Carrier element for absorbing forces in a vehicle |
US9908692B2 (en) | 2015-05-06 | 2018-03-06 | ASFI Partners, L.P. | Multi-piece storage tank pad with separate connectors |
KR101786676B1 (en) * | 2015-12-14 | 2017-10-18 | 현대자동차 주식회사 | Front vehicle body structure |
DE102016000605A1 (en) * | 2016-01-21 | 2017-07-27 | Gm Global Technology Operations, Llc | Automobile tail |
US9988093B2 (en) * | 2016-09-28 | 2018-06-05 | Ford Global Technologies, Llc | Exoskeleton vehicle upper body structure |
US10029736B1 (en) * | 2017-01-17 | 2018-07-24 | Ford Global Technologies, Llc | Roof frame including a brace reinforcing arched members |
KR20210077367A (en) * | 2019-12-17 | 2021-06-25 | 현대자동차주식회사 | Vehicle body assembly structure |
KR20220020676A (en) * | 2020-08-12 | 2022-02-21 | 현대자동차주식회사 | Frame connecting structure |
US11400985B2 (en) | 2020-12-04 | 2022-08-02 | Ford Global Technologies, Llc | Roof joint struc ture |
US11352072B1 (en) | 2021-01-11 | 2022-06-07 | Ford Global Technologies, Llc | Rear sill assembly of a unibody pickup truck |
US20230415815A1 (en) * | 2022-06-22 | 2023-12-28 | Ford Global Technologies, Llc | Body on frame vehicle front end structure |
Family Cites Families (61)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1846567A (en) | 1923-05-17 | 1932-02-23 | Metropolitan Eng Co | Manufacture of vehicle frames |
US1581931A (en) | 1923-11-13 | 1926-04-20 | Lamplugh Henry Arthur | Construction of vehicle bodies |
FR694774A (en) | 1930-04-30 | 1930-12-08 | Carrosserie Automobile Fernand | Body |
US2269451A (en) | 1940-05-15 | 1942-01-13 | Ford Motor Co | Automobile body construction |
DE867059C (en) | 1940-10-18 | 1953-02-16 | Auto Union A G | Front structure for self-supporting car bodies of motor vehicles |
US2389907A (en) | 1941-12-09 | 1945-11-27 | Midland Steel Prod Co | Vehicle structure |
US2668722A (en) | 1948-11-30 | 1954-02-09 | Daimler Benz Ag | Frame for motor vehicles |
US3159419A (en) | 1961-10-30 | 1964-12-01 | Budd Co | Die-formed sheet metal structures and method of making the same |
GB1279421A (en) | 1968-07-04 | 1972-06-28 | Pierre Cuq | Process and apparatus for transforming a cylindrical cupped blank into a hollow metallic part |
IT951709B (en) * | 1971-12-10 | 1973-07-10 | Siam Soc Italiana Arredamenti | STRUCTURE WITH COMPONIBLE ELEMENTS PARTICULARLY FOR METAL FURNITURE SUCH AS TABLES CHAIRS SHELVES AND SIMILAR |
DE2336213C2 (en) | 1973-07-17 | 1983-01-20 | Volkswagenwerk Ag, 3180 Wolfsburg | Framework for the construction of a vehicle |
IT1165208B (en) | 1979-05-25 | 1987-04-22 | Fiat Auto Spa | SUPPORTING FRAME FOR MOTOR VEHICLES |
IT1172248B (en) | 1981-09-14 | 1987-06-18 | Fiat Auto Spa | PROCEDURE TO PERFORM THE MUTUAL FIXING OF ELEMENTS OF THE VEHICLE BODY AND BODY OBTAINED WITH THIS PROCEDURE |
DE3217640A1 (en) | 1982-03-12 | 1983-11-17 | Brose Fahrzeugteile GmbH & Co KG, 8630 Coburg | VEHICLE DOOR |
DE3346986A1 (en) | 1983-12-24 | 1985-07-18 | Fleck, Andreas, 2000 Hamburg | CAR BOX |
US4735355A (en) | 1984-10-10 | 1988-04-05 | Mr. Gasket Company | Method for construction of vehicle space frame |
US4660345A (en) | 1984-10-10 | 1987-04-28 | Mr. Gasket Company | Vehicle space frame, castings therefor and method for remote construction |
US4726166A (en) | 1986-03-14 | 1988-02-23 | American Motors Corporation | Vehicle frame rail assembly and underbody construction |
US4759111A (en) | 1987-08-27 | 1988-07-26 | Ti Automotive Division Of Ti Canada Inc. | Method of forming reinforced box-selection frame members |
NO165284C (en) | 1988-09-09 | 1991-01-23 | Norsk Hydro As | PROCEDURE FOR MANUFACTURING THE BODY FRAME AND THE BODY FRAME. |
JPH02246877A (en) | 1989-03-20 | 1990-10-02 | Mazda Motor Corp | Front body structure for automobile |
DE3918280A1 (en) | 1989-06-05 | 1990-12-06 | Audi Ag | MOTOR VEHICLE BODY |
US5481892A (en) | 1989-08-24 | 1996-01-09 | Roper; Ralph E. | Apparatus and method for forming a tubular member |
US5094313A (en) | 1990-08-06 | 1992-03-10 | Mauws Laurence J | Utility vehicle |
EP0561822B1 (en) * | 1990-12-20 | 1994-08-10 | Audi Ag | Bearer joint for vehicle bodywork, especially longitudinal bearer joint, and process for replacing an aluminium bearer |
DE4040946C1 (en) * | 1990-12-20 | 1992-03-05 | Audi Ag, 8070 Ingolstadt, De | |
US5106249A (en) | 1991-01-07 | 1992-04-21 | Ford Motor Company | Method and apparatus for joining plastic panels to aluminum space frames |
DE4122862C2 (en) * | 1991-07-10 | 1996-08-29 | Ges Innenhochdruckverfahren | Connection of hollow parts and process for their production |
NO173538C (en) | 1991-09-06 | 1993-12-29 | Norsk Hydro As | Construction beam and method of production of the same |
US5314146A (en) | 1992-03-13 | 1994-05-24 | Spectrum Astro, Inc. | Multi-mission spacecraft bus having space frame structural design |
US5271687A (en) | 1992-04-03 | 1993-12-21 | Ford Motor Company | Space frame joint construction |
US5209541A (en) | 1992-04-13 | 1993-05-11 | Ford Motor Company | Space frame joint construction |
US5228259A (en) | 1992-04-29 | 1993-07-20 | Ford Motor Company | Space frame connector |
US5320403A (en) | 1992-04-29 | 1994-06-14 | Ford Motor Company | Space frame torque box |
EP0568215A1 (en) | 1992-04-29 | 1993-11-03 | Ford Motor Company Limited | Space frame construction |
US5332281A (en) | 1992-04-30 | 1994-07-26 | Ford Motor Company | Space frame construction |
US5213386A (en) | 1992-05-11 | 1993-05-25 | Ford Motor Company | Space frame construction |
US5233856A (en) | 1992-05-29 | 1993-08-10 | General Motors Corporation | External seal unit for tube hydroforming |
US5190207A (en) * | 1992-06-02 | 1993-03-02 | Deere & Company | Method for welding rectangular tubes |
US5794398A (en) | 1992-08-25 | 1998-08-18 | Kaehler; Klaus | Framework with hollow members process for producing the same and its use |
US5343666A (en) | 1992-10-28 | 1994-09-06 | Ford Motor Company | Space frame joint construction |
US5233789A (en) | 1992-11-16 | 1993-08-10 | General Motors Corporation | Adjustable cable guide assembly for powered sliding vehicle door closer |
US5333775A (en) | 1993-04-16 | 1994-08-02 | General Motors Corporation | Hydroforming of compound tubes |
US5582052A (en) | 1993-05-20 | 1996-12-10 | Benteler Industries, Inc. | Controlled time-overlapped hydroforming |
DE4322063C2 (en) | 1993-07-02 | 1999-07-15 | Schaefer Hydroforming Gmbh | Method and device for cutting out a section of a wall of a hollow body produced by the hydroforming process |
JP3269880B2 (en) * | 1993-07-02 | 2002-04-02 | 本田技研工業株式会社 | Method of manufacturing frame constituent member |
US5720511A (en) | 1993-08-11 | 1998-02-24 | Alumax Extrusions, Inc. | Frame apparatus and process for the manufacture of same |
US5458393A (en) | 1993-08-11 | 1995-10-17 | Alumax Extrusions, Inc. | Space frame apparatus and process for the manufacture of same |
DE4342960C1 (en) | 1993-12-16 | 1994-12-01 | Daimler Benz Ag | Passenger cell for a passenger car with load-bearing body structure |
US5561902A (en) | 1994-09-28 | 1996-10-08 | Cosma International Inc. | Method of manufacturing a ladder frame assembly for a motor vehicle |
US5564785A (en) | 1994-10-17 | 1996-10-15 | Atoma International Inc. | Seat frame assembly for a motor vehicle |
US5641176A (en) | 1995-03-31 | 1997-06-24 | Mascotech Tubular Products, Inc. | Process of hydroforming tubular suspension and frame components for vehicles |
US5581947A (en) | 1995-06-07 | 1996-12-10 | Chrysler Corporation | Vehicle door assembly |
BR9611415A (en) | 1995-06-16 | 1999-02-23 | Dana Corp | Preparation of vehicle chassis components for molecular connection using magnetic pulse welding techniques |
JPH0999857A (en) | 1995-10-04 | 1997-04-15 | Honda Motor Co Ltd | Body structure for automobile |
US5720092A (en) | 1996-08-21 | 1998-02-24 | General Motors Corporation | Method for hydroforming a vehicle space frame |
US5800003A (en) | 1997-01-08 | 1998-09-01 | Asha Corporation | Vehicle body construction |
US5848853A (en) | 1997-01-08 | 1998-12-15 | Asha Corporation | Vehicle body space frame |
US6099194A (en) * | 1997-08-20 | 2000-08-08 | Dana Corporation | Splice joint for connecting adjacent side rail sections in a vehicle body and frame assembly |
AU742844B2 (en) | 1997-10-16 | 2002-01-17 | Cosma International Inc. | Hydroformed space frame and method of manufacturing the same |
US6308412B1 (en) | 1997-12-31 | 2001-10-30 | Dana Corporation | Joint between cross member and side rail in a vehicle frame assembly |
-
2000
- 2000-03-03 US US09/517,750 patent/US6302478B1/en not_active Expired - Lifetime
- 2000-12-06 US US09/729,944 patent/US20010000119A1/en not_active Abandoned
-
2001
- 2001-08-17 US US09/930,969 patent/US6412857B2/en not_active Expired - Lifetime
Cited By (66)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6739624B2 (en) | 1997-10-16 | 2004-05-25 | Magna International Inc. | Frame assembly for a motor vehicle |
CN100482516C (en) * | 2001-11-09 | 2009-04-29 | 麦格纳国际公司 | Modular underbody for a motor vehicle |
US20050258667A1 (en) * | 2001-11-30 | 2005-11-24 | Axel Grueneklee | Sheet steel connection joints of sections consisting of sheet steel |
US20040108754A1 (en) * | 2002-11-01 | 2004-06-10 | Masanori Igarashi | Rear structure of vehicle body |
US6869136B2 (en) * | 2002-11-01 | 2005-03-22 | Fuji Jukogyo Kabushiki Kaisha | Rear structure of vehicle body |
DE10252790B3 (en) * | 2002-11-06 | 2004-12-23 | Thyssenkrupp Stahl Ag | Connection knot for shell elements |
CN100398382C (en) * | 2002-11-06 | 2008-07-02 | 蒂森克鲁伯钢铁股份公司 | Connecting joint for shell elements |
WO2004041625A1 (en) | 2002-11-06 | 2004-05-21 | Thyssenkrupp Stahl Ag | Connecting joint for shell elements |
US20080115363A1 (en) * | 2003-01-16 | 2008-05-22 | Marando Richard A | Cast aluminum node for connecting vehicle frame members and method of manufacturing same |
WO2004078563A1 (en) * | 2003-03-07 | 2004-09-16 | Wilhelm Karmann Gmbh | Motor vehicle body pillar |
US20050116460A1 (en) * | 2003-10-17 | 2005-06-02 | Mcgill Scott M. | Method of manufacturing a frame assembly |
US20050166382A1 (en) * | 2004-01-30 | 2005-08-04 | Bruggemann Charles J. | Method of forming thickened tubular members |
US7059033B2 (en) * | 2004-01-30 | 2006-06-13 | General Motors Corporation | Method of forming thickened tubular members |
US20050196228A1 (en) * | 2004-03-08 | 2005-09-08 | Bruggemann Charles J. | Hydroformed dovetail joint and method of joining tubular members |
US7386938B2 (en) * | 2004-03-08 | 2008-06-17 | General Motors Corporation | Method of joining hydroformed tubular members |
US20060090950A1 (en) * | 2004-10-28 | 2006-05-04 | Stanley Krise | High-rise go-chart chassis |
EP1762467A1 (en) * | 2005-09-08 | 2007-03-14 | Ford Global Technologies, LLC | Hydroformed automotive pillar |
US8517458B2 (en) | 2005-09-08 | 2013-08-27 | Volvo Car Corporation | Hydroformed automotive pillar |
US20070108803A1 (en) * | 2005-11-16 | 2007-05-17 | Ford Global Technologies, Llc | Interlocked pillar and roof rail joint |
US7431378B2 (en) | 2005-11-16 | 2008-10-07 | Ford Global Technologies, Llc | Interlocked pillar and roof rail joint |
US7293823B2 (en) * | 2005-11-16 | 2007-11-13 | Ford Global Technologies, Llc | Interlocked pillar and roof rail joint |
US20080030050A1 (en) * | 2005-11-16 | 2008-02-07 | Ford Global Technologies, Llc | Interlocked pillar and roof rail joint |
FR2900207A1 (en) * | 2006-04-20 | 2007-10-26 | Renault Sas | Beam and crosspiece assembly for vehicle, has bracket comprising support surface perpendicular to connection surface, where connection and support surfaces are supported on groove and assembling surface of beam, respectively |
AU2007201780B2 (en) * | 2006-04-21 | 2012-12-20 | Deere & Company | Implement frame tube joint with weldable connector |
US20070246235A1 (en) * | 2006-04-21 | 2007-10-25 | Deere & Company, A Delaware Corporation | Implement frame tube joint with weldable connector |
US7766576B2 (en) * | 2006-04-21 | 2010-08-03 | Deere & Company | Implement frame tube joint with weldable connector |
US20100310308A1 (en) * | 2006-04-21 | 2010-12-09 | Richard Joseph Connell | Implement Frame Tube Joint with Weldable Connector |
US9072213B2 (en) | 2006-04-21 | 2015-07-07 | Deere & Company | Implement frame tube joint with weldable connector |
FR2900623A1 (en) * | 2006-05-05 | 2007-11-09 | Renault Sas | HYDROFORMED OR PROFILED MULTIFUNCTION PAVILLION TRAVERSE |
WO2007128927A1 (en) * | 2006-05-05 | 2007-11-15 | Renault S.A.S | Multifunction hydroformed or profiled roof cross member |
GB2441626B (en) * | 2006-09-06 | 2010-08-04 | Ford Global Tech Llc | A double cell crushable joint for an automaotive front end |
GB2441626A (en) * | 2006-09-06 | 2008-03-12 | Ford Global Tech Llc | A double cell crushable joint for an automotive front end. |
US20080073926A1 (en) * | 2006-09-26 | 2008-03-27 | Ford Global Technologies, Llc | Tubular structural joint for automotive front end |
US7441819B2 (en) * | 2006-09-26 | 2008-10-28 | Ford Global Technologies, Llc | Tubular structural joint for automotive front end |
US20100038874A1 (en) * | 2008-08-15 | 2010-02-18 | Varela Tomaz D | Internal stiffener for hollow structure |
US7954832B2 (en) * | 2008-08-15 | 2011-06-07 | Arvinmeritor Technology, Llc | Internal stiffener for hollow structure |
WO2010092547A1 (en) * | 2009-02-11 | 2010-08-19 | Dario Di Camillo | Vehicle body, more particularly land vehicle body |
CN102307775A (en) * | 2009-02-11 | 2012-01-04 | 康赛普特Inn有限公司 | Vehicle body, more particularly land vehicle body |
US8226159B2 (en) | 2009-02-11 | 2012-07-24 | Concept Inn S.R.L. | Vehicle body, more particularly land vehicle body |
ITBO20090492A1 (en) * | 2009-07-28 | 2011-01-29 | Ferrari Spa | FRAME OF A VEHICLE EQUIPPED WITH AN EXTRUDED CENTRAL UPRIGHT |
EP2279928A3 (en) * | 2009-07-28 | 2011-09-07 | Ferrari S.p.A. | Chassis of a vehicle provided with an extruded central pillar |
US20110025100A1 (en) * | 2009-07-28 | 2011-02-03 | Ferrari S.P.A. | Chassis of a vehicle provided with an extruded central pillar |
US8272682B2 (en) | 2009-07-28 | 2012-09-25 | Studio Torta S.p.A. | Chassis of a vehicle provided with an extruded central pillar |
US9199525B2 (en) | 2011-12-09 | 2015-12-01 | Aisin Seiki Kabushiki Kaisha | Vehicle door frame and inner member for vehicle door frame |
US8517423B1 (en) * | 2012-03-20 | 2013-08-27 | Club Car, Llc | Modular frame structure for off road vehicle |
US8690189B2 (en) * | 2012-03-20 | 2014-04-08 | Club Car, Llc | Modular frame structure for off road vehicle |
US20140265447A1 (en) * | 2013-03-14 | 2014-09-18 | Ford Global Technologies, Llc | Roof panel to side-pillar hydroformed reinforcement for vehicles |
US8919866B2 (en) * | 2013-03-14 | 2014-12-30 | Ford Global Technologies, Llc | Roof panel to side-pillar hydroformed reinforcement for vehicles |
US9751568B2 (en) | 2015-12-07 | 2017-09-05 | Honda Motor Co., Ltd. | Body frame structure for a vehicle |
US10686304B2 (en) | 2016-10-27 | 2020-06-16 | Fred A. Wagner, III | Connection system and method of using same |
US10280607B2 (en) * | 2016-10-27 | 2019-05-07 | Fred A. Wagner, III | Connection system and method of using same |
US11306751B2 (en) | 2017-08-31 | 2022-04-19 | Divergent Technologies, Inc. | Apparatus and methods for connecting tubes in transport structures |
WO2019045932A1 (en) * | 2017-08-31 | 2019-03-07 | Divergent Technologies, Inc. | Apparatus and methods for connecting tubes in transport structures |
EP3676820A4 (en) * | 2017-08-31 | 2021-04-28 | Divergent Technologies Inc. | Apparatus and methods for connecting tubes in transport structures |
US11927304B2 (en) * | 2018-02-09 | 2024-03-12 | Morris Equipment Ltd. | Agricultural implement frame assembly |
US20190246546A1 (en) * | 2018-02-09 | 2019-08-15 | Morris Industries Ltd. | Agricultural implement frame assembly |
CN114616167A (en) * | 2019-10-25 | 2022-06-10 | 卡特彼勒公司 | Space frame central upper frame node connecting piece |
US11242093B2 (en) * | 2019-11-20 | 2022-02-08 | Hyundai Motor Company | Roof carrier for vehicle |
US11286003B2 (en) | 2019-12-05 | 2022-03-29 | Hyundai Motor Company | Vehicle body structure |
US11325652B2 (en) | 2019-12-05 | 2022-05-10 | Hyundai Motor Company | Body for vehicle |
US11325657B2 (en) | 2019-12-05 | 2022-05-10 | Hyundai Motor Company | Body for vehicle |
US11332192B2 (en) | 2019-12-05 | 2022-05-17 | Hyundai Motor Company | Vehicle body |
US11279412B2 (en) * | 2019-12-05 | 2022-03-22 | Hyundai Motor Company | Vehicle body |
US11358646B2 (en) | 2019-12-05 | 2022-06-14 | Hyundai Motor Company | Vehicle body forming structure and vehicle body using the same |
US11472490B2 (en) * | 2019-12-05 | 2022-10-18 | Hyundai Motor Company | Body for vehicle |
US11235809B2 (en) | 2019-12-05 | 2022-02-01 | Hyundai Motor Company | Vehicle body for vehicles |
Also Published As
Publication number | Publication date |
---|---|
US6302478B1 (en) | 2001-10-16 |
US6412857B2 (en) | 2002-07-02 |
US20010050497A1 (en) | 2001-12-13 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US6412857B2 (en) | Hydroformed space frame and joints therefor | |
US6533348B1 (en) | Modular space frame | |
US6282790B1 (en) | Hydroformed space frame and method of manufacturing the same | |
EP1441940B1 (en) | Modular underbody for a motor vehicle | |
AU2001250219A1 (en) | Modular space frame | |
US6824204B2 (en) | Hybrid space frame for motor vehicle | |
US6010155A (en) | Vehicle frame assembly and method for manufacturing same | |
US20020162224A1 (en) | Hydroformed vehicle frame assembly and method | |
US20060096099A1 (en) | Automotive crush tip and method of manufacturing | |
US20070163121A1 (en) | Metal frame and method for manufacturing the same | |
WO2006042032A2 (en) | Automotive crush tip and method of manufacturing | |
US6643908B1 (en) | Body side panel for a motor vehicle | |
EP1081022A2 (en) | Method of manufacturing a vehicle body and frame assembly | |
JP2000126832A (en) | Production of vehicle body frame | |
US20050071975A1 (en) | Method of forming vehicle body side structure assembly | |
US7975383B2 (en) | Double hydroformed tube with integral reinforcement | |
US20040150208A1 (en) | Vehicle structure having cross members overlapped by apertured rails |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: COSMA INTERNATIONAL INC., ONTARIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:JAEKEL, FEDERICO G.;GABIEANELLI, GIANFRANCO;HORTON, FRANKJ A.;AND OTHERS;REEL/FRAME:011341/0024;SIGNING DATES FROM 20000712 TO 20000717 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |