US20130229005A1 - Vehicle Cross-Member Assembly with Adhesive Reservoirs - Google Patents
Vehicle Cross-Member Assembly with Adhesive Reservoirs Download PDFInfo
- Publication number
- US20130229005A1 US20130229005A1 US13/682,483 US201213682483A US2013229005A1 US 20130229005 A1 US20130229005 A1 US 20130229005A1 US 201213682483 A US201213682483 A US 201213682483A US 2013229005 A1 US2013229005 A1 US 2013229005A1
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- United States
- Prior art keywords
- rail
- adhesive
- interconnecting member
- assembly
- icm
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
- B62D21/02—Understructures, i.e. chassis frame on which a vehicle body may be mounted comprising longitudinally or transversely arranged frame members
-
- 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
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
- B23K26/28—Seam welding of curved planar seams
-
- 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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
-
- 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
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B23K33/004—Filling of continuous seams
- B23K33/006—Filling of continuous seams for cylindrical workpieces
-
- 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
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B23K33/004—Filling of continuous seams
- B23K33/008—Filling of continuous seams for automotive applications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B37/1284—Application of adhesive
-
- 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
- B23K2101/006—Vehicles
-
- 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
- B23K2101/18—Sheet panels
- B23K2101/185—Tailored blanks
-
- 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
- B23K2101/28—Beams
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/14—Titanium or alloys thereof
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/15—Magnesium or alloys thereof
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
- B23K2103/166—Multilayered materials
- B23K2103/172—Multilayered materials wherein at least one of the layers is non-metallic
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/20—Ferrous alloys and aluminium or alloys thereof
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/30—Organic material
- B23K2103/42—Plastics
-
- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
-
- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1051—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by folding
-
- 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
- Y10T29/49826—Assembling or joining
-
- 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
- Y10T29/49826—Assembling or joining
- Y10T29/49947—Assembling or joining by applying separate fastener
- Y10T29/49954—Fastener deformed after application
- Y10T29/49956—Riveting
Definitions
- an interconnecting member fits inside of the rail 550 .
- the interconnecting member can include a series of complementary reservoirs formed on the outer surface of interconnecting member, e.g., 230 , as shown in FIG. 9 .
- a second crimping is performed on the rail 550 after the assembly to form protrusions.
- Complementary reservoirs and protrusions are located at the same positions to create mechanical interlocks between the two members.
- the interlock can also be created by a single step crimping on the interconnector-rail assembly without pre-existing protrusions.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Plasma & Fusion (AREA)
- Body Structure For Vehicles (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
Description
- This application is a continuation and claims the benefit of U.S. patent application Ser. No. 13/221,142 titled “Vehicle Support Frames with Interlocking Features for Joining Members of Dissimilar Materials” filed Aug. 30, 2011, U.S. patent application Ser. No. 13/239,592 titled “Vehicle Support Frames with Interlocking Features for Joining Members of Dissimilar Materials” filed Sep. 22, 2011, and U.S. patent application Ser. No. 13/545,584 titled “Vehicle Support Frames with Interlocking Features for Joining Members of Dissimilar Materials” filed Jul. 10, 2012, which are hereby incorporated by reference in their entirety.
- The present disclosure relates to vehicle support frames with rails having dissimilar materials and methods for manufacturing the same.
- Conventional vehicle support frames can be composed of different materials including, for example, steel, aluminum and reinforced polymer composites. Vehicle manufacturers attempt to strike a balance between weight reduction and structural rigidity. It is desirable to design lightweight vehicle frames for full-sized light trucks. Aluminum structural members can be designed to achieve up to a 50% weight reduction while still meeting performance targets. Joining aluminum members to steel frame rails presents challenges as the two materials, when welded, have limited structural integrity.
- One existing reference teaches the use of an overlapping configuration for the rails of dissimilar materials. A first and second structural member sandwiches one end of a third structural member and adhesive is applied therebetween. The second structural member is thereafter welded to the first structural member. U.S. Patent Publication No. 2009/0188206, titled “System and Method for Joining Dissimilar Materials” teaches an overlapping configuration with a surface weld on the second structural member. Still, it is desirable to have a vehicle cross-member assembly as opposed to a collinear assembly; it is also desirable to improve this design by providing a point of access for spot weld fixtures or other weld fixtures that require a clamped fitting.
- Therefore, it is desirable to have improved interconnecting techniques for joining two structural members composed of dissimilar materials.
- The present disclosure addresses one or more of the above-mentioned issues. Other features and/or advantages will become apparent from the description which follows.
- One exemplary embodiment of the present disclosure relates to a method of manufacturing a vehicle cross-member assembly, includes: adding adhesive to an adhesive reservoir in an interconnecting member composed of a first material; overlapping a first rail composed of a second material with the interconnecting member; and welding the interconnecting member to a second rail in a position perpendicular with respect to the second rail. The second rail is composed of a different material than the first rail.
- Another exemplary embodiment of the present disclosure relates to a method of manufacturing a vehicle cross-member assembly, the method including: adding adhesive to an adhesive reservoir in a first rail composed of a first material; overlapping an interconnecting member composed of a second material with the first rail; and welding the interconnecting member to the second rail in a position perpendicular to the second rail. The second rail is composed of a different material than the first rail.
- Another exemplary embodiment of the present disclosure relates to a vehicle cross-member assembly, having: a first rail composed of a first material; a second rail, perpendicularly positioned with respect to the first rail, composed of a second material; and an interconnecting member composed of the second material having adhesive in reservoirs formed thereon to join the interconnecting member and the first rail. The interconnecting member is welded to the second rail.
- Yet another exemplary embodiment of the present disclosure relates to a vehicle cross-member assembly, having: a first rail composed of a first material having adhesive in reservoirs formed thereon; a second rail, perpendicularly positioned with respect to the first rail, composed of a second material; and an interconnecting member composed of the second material. The interconnecting member is welded to the second rail.
- One advantage of the present disclosure is that it provides improved interconnecting techniques for joining two structural members composed of dissimilar materials.
- Another advantage of the present disclosure is that it teaches the manufacture and use of light-weight vehicle structural frames that can be utilized with vehicles of different sizes, including full-sized truck frames. The weight reduction for the disclosed frame assemblies compared to contemporary structural frames can be as great as 50%. Fuel efficiency and performance can be enhanced by the use of the disclosed frame assemblies.
- Another advantage of the present disclosure is that it teaches joining techniques for structural members having dissimilar material composition and a closed-section configuration. Structural members can be positioned at any angle with respect to each other.
- Joining vehicle frame assembly rails composed of dissimilar materials will be explained in greater detail below by way of example with reference to the figures, in which the same reference numbers are used in the figures for identical or essentially identical elements. The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. In the figures:
-
FIG. 1 is a top perspective view of a vehicle support frame assembly. -
FIG. 2 is a partial perspective view of the vehicle support frame assembly ofFIG. 1 atcircle 2. -
FIG. 3 is a perspective view of the interconnecting member ofFIG. 2 . -
FIG. 4 is a perspective view illustrating application of adhesive in reservoirs formed in the interconnecting member ofFIG. 3 . -
FIG. 5 is a perspective view illustrating the assembly of the interconnecting member and cross rail ofFIG. 2 . -
FIG. 6 is a perspective view of a die for forming recesses in a cross rail. -
FIG. 7 is a partial perspective view of another exemplary vehicle support frame assembly with adhesive outside of the interconnecting member. -
FIG. 8 is a partial perspective view the vehicle support frame assembly ofFIG. 7 from the inside of the cross rail. -
FIG. 9 is a perspective view illustrating application of adhesive outside of an interconnecting in another exemplary vehicle support frame assembly. -
FIG. 10 is a partial perspective view of the vehicle support frame assembly ofFIG. 9 illustrating application of adhesive inside of the cross rail at the corners. -
FIG. 11 is a partial perspective view of the interconnecting member ofFIG. 9 . -
FIG. 12 is a perspective view of another exemplary embodiment of an interconnecting member and rail with adhesive outside of the interconnecting member. -
FIG. 13 is a partial perspective view the vehicle support frame assembly ofFIG. 12 from the inside of the cross rail. -
FIG. 14 is a cross-sectional view the vehicle support frame assembly ofFIG. 12 at line 14-14. -
FIG. 15 is an assembly view of another exemplary vehicle support frame assembly. -
FIG. 16 is a perspective view of the interconnecting member for use with the vehicle support frame assembly ofFIG. 15 . -
FIG. 17 is as perspective view of another exemplary interconnecting member for use with a vehicle support frame assembly. - Referring to the drawings, wherein like characters represent examples of the same or corresponding parts throughout the several views, there are shown vehicle support frames having joined structural members composed of different materials. Particularly, lighter weight aluminum structural members are joined to steel side rails in most embodiments. The aluminum and steel members are joined through an interconnecting member juxtaposed between them. The disclosed interconnecting members mitigate several challenges incumbent with joining dissimilar materials by teaching an interconnecting member having multiple portions. Each portion can be composed of a different material. Once attached to each other the portions form as a link or bridge between rails attached to a portion of the interconnecting member. In some embodiments, the rails are attached to the interconnecting member via MIG welding.
- The teachings herein are applicable to any type of vehicle frame including frames for pickup trucks, vans, minivans, sports utility vehicles, sedans, coupes, commercial vehicles, and all utility vehicles.
- Referring now to
FIG. 1 , there is shown therein a vehicle cross-member assembly (or support frame) 10. The illustratedcross-member assembly 10 is configured for use in a pickup truck. Cross-member assembly 10 (as shown) is taken from the rear section of the truck frame, which supports the truck bed (not shown).Assembly 10 is a support frame.Side rail assemblies assembly 10 and the vehicle. In the shown embodiment,side rail assemblies Rails rails rearward steel cross-member 40. Attached to cross-member 40 is atow hitch 50. Each end of the rails is fitted with aside bracket 60 for interconnectingcross-member 40 with the rails and for connecting therails cross-member assembly 10, shown inFIG. 1 , there is anothersteel cross-member 70 intersecting eachside rail cross-member 70. -
Rails 90, 100 (as shown inFIG. 1 ) are positioned perpendicularly with respect torails Rails tire support frame 75.Rails member 80, as discussed hereinbelow.Rails member 80. As discussed below, in this embodiment, adhesive is used to attach the interconnecting member to rails. - Now with reference to
FIG. 2 there is shown a partial perspective view of thecross-member assembly 10 ofFIG. 1 atcircle 2. Theassembly 10 hasrails side rail 20 is not weld compatible with the material used for therail 100. In this embodiment, theside rail 20 is composed of steel and thecross rail 100 is made of aluminum. - Shown in
FIG. 2 is an intersection of theside rail 20, interconnectingmember 80 andrail 100. Interconnecting member (or “ICM”) 80 passes throughside rail 20 at a 90 degree angle or perpendicularly.ICM 80 is welded to side rail. Interconnectingmember 80 is a steel tube in the illustrated embodiment ofFIG. 2 . - As shown in
FIG. 3 , the interconnectingmember 80 has a series of oblong recesses orreservoirs 110 formed via crimping on an outer surface of the interconnecting member. Reservoirs are configured to hold adhesive 120 therein, as shown inFIG. 4 . Different types of adhesives can be used including e.g., resins or two-way epoxies.Rail 100 also includes a series of crimps 130 (as shown inFIG. 2 ) formed on the outer surface ofrail 100.Crimps 130 are located at the same longitudinal position asreservoirs 110 when the interconnectingmember 80 is assembled with therail 100 to form an interlock between the two members. In the illustrated embodiment,rail 100 includes eightcrimps 130. - The support frame assembly of
FIGS. 2-3 is manufactured using a method of manufacture as described hereinbelow. The method includes the steps of: (1) adding adhesive to an adhesive reservoir in an interconnecting member, as shown and discussed with respect toFIG. 4 ; (2) overlapping the cross-member and the interconnecting member, e.g., as shown inFIG. 5 ; (3) performing a second crimping; and (4) welding the interconnecting member to a side rail, in a position perpendicular with respect to the second rail, as shown inFIG. 2 . - With respect to the first step, adding adhesive to an adhesive reservoir in the interconnecting member, this step is shown in
FIG. 4 . InFIG. 4 an operator, O, is shown holding the interconnectingmember 80 in one hand and anadhesive applicator 140 in the other hand.Adhesive 120 is inserted in thereservoirs 110. In this embodiment, adhesive 120 is applied to fill thereservoirs 110. Less or more adhesive can be used. - Once the adhesive is applied, the operator moves to the next step, as shown in
FIG. 5 . Therail 100 and interconnectingmember 80 are positioned in an overlapping configuration, as shown inFIG. 5 . In this embodiment,ICM 80 is inserted in therail 100 with a spatial gap of approximately 0.5 mm between the inner surface of rail and the outer surface of ICM on each side. In other embodiments, the spatial gap between rail and ICM can be greater or less than 0.5 mm. In other embodiments,ICM 80 andrail 100 can overlap in different configurations. E.g., in one embodiment,rail 100 is inserted in theICM 80. - After
ICM 80 andrail 100 are placed in an overlapping configuration, pressure is applied to the rail and/or ICM, as shown inFIG. 6 . This is part of a two-step crimping process—(i) forming reservoirs in the ICM and then (ii) crimping the cross member with compatible crimps. InFIG. 6 , there is astamp press 150 having amandrel 160 configured to formcrimps 130 in therail 100 and/orICM 80.Crimps 130 in therail 100 are formed to match crimps orreservoirs 110 onICM 80.Crimps 130 act as a secondary mechanical interlock betweenrail 100 and interconnectingmember 80 in this embodiment. Thepress 150 is configured to evenly distribute the adhesive between therail 100 andICM 80. In this embodiment, thepress 150 is configured to apply pressure to thecross rail 100 andICM 80 so as to cause adhesive to ooze out of the reservoirs of the ICM. Adhesive is spread between the outer surface of the ICM and the inner surface of therail 100 to form a joint between the two members.Rail 100 has four sets of twocrimps 130 formed on each side of the outer surface of rail.Rail 100 andICM 80 are rotated in 90 degree iterations between each press. - The finished assembly of the
ICM 80 andrail 100 is shown inFIG. 7-8 . After, the pressing process, adhesive 120 seeps out of one end of therail 100 and one end of theICM 80. As shown inFIG. 7 , adhesive 120 is squeezed in the crimping process. Adhesive 120 seeped out of the end ofrail 100 to overflow on the outside of the ICM and rail, thereby forming a barrier between thecross rail 100 andICM 80 joint and the surrounding environment.FIG. 8 is a cross-section in therail 100 taken from the inside the rail looking toward the side rail 20 (ofFIG. 2 ). As shown inFIG. 8 , adhesive 120 is squeezed in the crimping process so as to seep out of an end ofICM 80. Adhesive 120 that seeps out of end of theICM 80 overflows on the inside of the rail, thereby forming a barrier between the rail and ICM joint and the surrounding environment on an inside surface as well. - Another exemplary
support frame assembly 200 is partially shown and discussed with respect toFIGS. 9-14 . Shown is a method of manufacturing thesupport frame assembly 200, which is a vehicle cross-member assembly. The method includes the steps of: (1) adding adhesive to an adhesive reservoir in an interconnecting member, as shown and discussed with respect toFIG. 9-11 ; (2) overlapping the cross rail and the interconnecting member, e.g., as shown inFIG. 12 ; (3) crimping the overlapped ICM and rail; and (4) welding the interconnecting member to a side rail in a position perpendicular to the second rail, as shown inFIG. 2 . - With respect to the first step, adding adhesive to an adhesive reservoir in the interconnecting member, this step is shown in
FIG. 9 . Anadhesive applicator 210 includes atip 220 marked at “M” for filling eachreservoir 230 in an interconnectingmember 240 to a desired level. InFIG. 9 , an operator, I, is shown with theadhesive applicator 210 in one hand.ICM 240 includes at least threeadhesive reservoirs 230 on each surface in this configuration.Adhesive 250 is inserted in the reservoirs.Adhesive 250 is also applied at a midpoint (280), 360 degrees around an outer surface of interconnectingmember 240. TheICM 240 with adhesive 250 is also illustrated inFIG. 11 . - In this embodiment,
additional adhesive 250 is applied to the inner walls ofrail 270, as shown inFIG. 10 .Adhesive 250 is longitudinally applied alongcorners 290 ofcross rail 270, as shown inFIG. 10 .FIG. 10 is a cross-section view of therail 270 pre-assembly withICM 240. - Once the adhesive 250 is applied, the operator moves to the next step, as shown in
FIG. 12 . Therail 270 and interconnectingmember 240 are positioned in an overlapping configuration, as shown inFIG. 12 . In this embodiment,ICM 240 is inserted in therail 270. AfterICM 240 andrail 270 are placed in an overlapping configuration, pressure is applied to therail 270 andICM 240. The press is configured to evenly distribute the adhesive between the rail and ICM by squeezing the adhesive out of the reservoirs and to create matching crimps between the rail and ICM for interlocking the two parts.Rail 270 has four sets of threecrimps 260 formed on each side of the outer surface of rail. In this embodiment, the adhesive used is an epoxy (e.g., a two-part epoxy). Alternative one-part epoxies or other adhesives can also be used. -
ICM 240 includes anoptional reservoir 230—as exposed in FIGS. 9 and 11—that can be filled with adhesive or left unfilled (e.g., as shown inFIG. 9 ).Reservoir 230 can be filled, for example, for more overlapping or stronger joints. In those embodiments,ICM 240 is inserted farther intocross rail 270 and three reservoirs on each side of the rail are filled to link ICM and cross rail. The use of optional reservoirs allows for commonality of parts for the cross rails and ICMs between different vehicle platforms. - After, the pressing process, adhesive 250 seeps out of one end of the
rail 270 and one end of theICM 240. As shown inFIG. 13 , adhesive 250 is squeezed in a crimping process so as to seep out of an end ofICM 240. Adhesive 250 that seeps out of the ends of rail and ICM forms a barrier between therail 270 andICM 240 joint and the surrounding environment on the inside surface and outside surface as well. Different types of adhesives can be used to create barriers of different kinds. In the illustrated embodiment ofFIG. 13 a less viscous adhesive is used than in the embodiment ofFIG. 8 , for example, thus a thicker barrier is formed by the overflow of adhesive on the exterior of the ICM and in the interior of the rail. -
FIG. 14 illustrates a cross-section in thesupport frame assembly 200 ofFIG. 12 at line 14-14 shown therein. As shown, adhesive 250 is completely filled between theICM 240 andrail 270 at all four corners through the overlap length.Rail 270 is journaled onto theICM 240.Adhesive 250 is evenly distributed at the shown cross-section and the entire overlap as well. - Now with reference to
FIGS. 15-16 there is shown another exemplary embodiment of asupport frame assembly 500.FIGS. 15-16 show partial perspective views of thesupport frame 500. The support frame (or support frame assembly) 500 hasrails side rail 510 is not weld compatible with the material used for the cross-member. In this embodiment, theside rail 510 is composed of steel and therail 520 is made of aluminum. Shown is an interconnectingmember 530 formed with theside rail 510. Interconnecting 530 is casted withside rail 510 in this embodiment. Inother embodiments ICM 530 is, e.g., welded to rail 510. Interconnectingmember 530 is a steel tube. As shown inFIGS. 15 and 16 , therail 520 has a series of recesses orreservoirs 540 formed on the outer surface of therail 520.Reservoirs 540 are oblong in shape and configured to hold adhesive therein. Different types of adhesives can be used including e.g., resins or two-way epoxies. - The support frame assembly of
FIGS. 15-16 is manufactured using a method of manufacture as described hereinbelow. A method of manufacturing a vehicle cross-member assembly includes: adding adhesive to an adhesive reservoir in a rail; overlapping an interconnecting member with the rail by inserting the rail inside of the interconnecting member; performing a second crimping to distribute the adhesive and create the interlock between the two members; and, if needed, welding the interconnecting member to a side rail in a position perpendicular to the side rail, the side rail composed of a different material than the cross-member rail. - In another embodiment, as shown in
FIG. 17 , an interconnecting member fits inside of therail 550. The interconnecting member can include a series of complementary reservoirs formed on the outer surface of interconnecting member, e.g., 230, as shown inFIG. 9 . A second crimping is performed on therail 550 after the assembly to form protrusions. Complementary reservoirs and protrusions are located at the same positions to create mechanical interlocks between the two members. The interlock can also be created by a single step crimping on the interconnector-rail assembly without pre-existing protrusions. - Reservoirs can be any combination of recesses, protrusions, or a recess with protrusion and so forth. Reservoirs can be formed using known forming procedures (e.g., stamping, hydroforming, or die casting). Additionally, any of the aforementioned assembly or forming process steps can be executed by an operator, automated machine or a combination of the two.
- Those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
Claims (19)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/682,483 US20130229005A1 (en) | 2011-07-28 | 2012-11-20 | Vehicle Cross-Member Assembly with Adhesive Reservoirs |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201161512559P | 2011-07-28 | 2011-07-28 | |
US13/221,142 US8915530B2 (en) | 2011-07-28 | 2011-08-30 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US13/682,483 US20130229005A1 (en) | 2011-07-28 | 2012-11-20 | Vehicle Cross-Member Assembly with Adhesive Reservoirs |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/221,142 Continuation US8915530B2 (en) | 2011-07-28 | 2011-08-30 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
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US20130229005A1 true US20130229005A1 (en) | 2013-09-05 |
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Application Number | Title | Priority Date | Filing Date |
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US13/221,142 Expired - Fee Related US8915530B2 (en) | 2011-07-28 | 2011-08-30 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US13/239,592 Abandoned US20130026793A1 (en) | 2011-07-28 | 2011-09-22 | Vehicle Support Frames with Interlocking Features for Joining Members of Dissimiliar Materials |
US13/545,584 Expired - Fee Related US9108678B2 (en) | 2011-07-28 | 2012-07-10 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US13/682,483 Abandoned US20130229005A1 (en) | 2011-07-28 | 2012-11-20 | Vehicle Cross-Member Assembly with Adhesive Reservoirs |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
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US13/221,142 Expired - Fee Related US8915530B2 (en) | 2011-07-28 | 2011-08-30 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US13/239,592 Abandoned US20130026793A1 (en) | 2011-07-28 | 2011-09-22 | Vehicle Support Frames with Interlocking Features for Joining Members of Dissimiliar Materials |
US13/545,584 Expired - Fee Related US9108678B2 (en) | 2011-07-28 | 2012-07-10 | Vehicle support frames with interlocking features for joining members of dissimilar materials |
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US (4) | US8915530B2 (en) |
CN (1) | CN103010305A (en) |
DE (2) | DE102012214558A1 (en) |
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US8915530B2 (en) | 2011-07-28 | 2014-12-23 | Ford Global Technologies, Llc | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US9108678B2 (en) | 2011-07-28 | 2015-08-18 | Ford Global Technologies, Llc | Vehicle support frames with interlocking features for joining members of dissimilar materials |
US9039061B2 (en) | 2011-08-30 | 2015-05-26 | Ford Global Technologies, Llc | Vehicle frame assemblies with threaded connections |
WO2020262045A1 (en) * | 2019-06-28 | 2020-12-30 | 株式会社神戸製鋼所 | Coupling device for tubular member, different-material joining method using same, and manufacturing method for tubular member equipped with different-material-joining auxiliary member |
JP2021007964A (en) * | 2019-06-28 | 2021-01-28 | 株式会社神戸製鋼所 | Tubular member joining device, and different material joining method and manufacturing method of tubular member with auxiliary member for joining different materials using the same |
JP7211906B2 (en) | 2019-06-28 | 2023-01-24 | 株式会社神戸製鋼所 | Device for joining tubular members, method for joining dissimilar materials using same, and method for manufacturing tubular member with auxiliary member for joining dissimilar materials |
JP7473615B2 (en) | 2019-06-28 | 2024-04-23 | 株式会社神戸製鋼所 | Method for joining dissimilar materials using a joining device for tubular members and method for manufacturing a tubular member with an auxiliary member for joining dissimilar materials |
Also Published As
Publication number | Publication date |
---|---|
US20130026796A1 (en) | 2013-01-31 |
DE102012216495A1 (en) | 2013-03-28 |
US20130026793A1 (en) | 2013-01-31 |
CN103010305A (en) | 2013-04-03 |
US20130026794A1 (en) | 2013-01-31 |
DE102012214558A1 (en) | 2013-02-28 |
US9108678B2 (en) | 2015-08-18 |
US8915530B2 (en) | 2014-12-23 |
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Owner name: FORD GLOBAL TECHNOLOGIES, LLC, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KNITTEL, JOHN MARTIN;CHEN, XIAOMING;MEHTA, SANJAY;AND OTHERS;SIGNING DATES FROM 20121126 TO 20121127;REEL/FRAME:029507/0921 |
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AS | Assignment |
Owner name: FORD GLOBAL TECHNOLOGIES, LLC, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KNITTEL, JOHN MARTIN;CHEN, XIAOMING;MEHTA, SANJAY;AND OTHERS;SIGNING DATES FROM 20121126 TO 20121127;REEL/FRAME:030600/0366 |
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