Land vehicles: bodies and tops – Bodies – Structural detail
Reexamination Certificate
2000-05-18
2001-10-09
Pape, Joseph D. (Department: 3612)
Land vehicles: bodies and tops
Bodies
Structural detail
C296S204000, C296S190050
Reexamination Certificate
active
06299240
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to vehicle frames and more particularly to frame structures which improve cost, weight and stiffness of vehicle frames.
SUMMARY OF THE INVENTION
Motor vehicle frames are the backbone of a vehicle. It is to such frames that all major components are attached. Among many others, these components include the engine, body, and suspension. The vehicle frame however, not only acts as a backbone supporting critical vehicle systems, it is itself a system. Vehicle frames are exposed to vibration and movement throughout vehicle operation and can be designed to improve the overall driving characteristics of the vehicle. For example, a vehicle frame can be tuned to help dampen the motor vibrations and thus generated noises, which passengers may find annoying. Additionally, the stiffness of vehicle frames may need to be increased or decreased depending on the amount of torsional flexion desired for a particular suspension.
Traditional motor vehicle frames are comprised of a series of metal bars or rails which are connected in a ladder shape. Typically, two larger frame rails running along the length of the vehicle. The two larger frame rails are then connected to a series of smaller cross members which run between the two larger frame rails. The frame rails and cross members are then fastened together.
This traditional method of building vehicle frames allows for limited room to modify features such as stiffness and dampening. To enhance the stiffness of a typical ladder shaped frame, larger, thicker frame rails with heavier attachments are required. This adds significant weight and cost to the vehicle frame. To decrease the stiffness, frame rails with thinner walls are required which results in a weaker frame.
It has been an on-going objective of the automotive industry to reduce both cost and weight of motor vehicles. Reducing the weight of a vehicle works to reduce cost for both the manufacturer and the vehicle owner. Lighter weight vehicles and vehicle components result in less expensive shipping and manufacture costs. In turn, lighter weight vehicles decrease energy consumption thus increasing fuel or battery efficiency (in the case of a battery powered vehicle). The result is a reduction in operation cost for vehicle owners. Traditional motor vehicle frames work against this objective. It is therefore desirable to improve the method by which vehicle frames are constructed and adapted to particular vehicle characteristics.
It is an object of the present invention to meet automobile industry needs in improving cost and weight of motor vehicles, while maintaining vehicle performance characteristics. The present invention achieves this by introducing a stiff torque box, integral to the overall vehicle frame, which has improved stiffness and weight characteristics. The stiff torque box is made from extruded aluminum and is formed to have several cavities within. The stiff torque box also maintains formed areas at each corner which have connecting tabs. These tabs are used to connect frame rails to the stiff torque box.
The stiff torque box is used as a cross-link between the right and left hand sides of the vehicle frame. It is positioned such that the internal cavities run horizontal, being parallel to the ground. Looking from the side, the stiff torque box allows the side frame rail segments to be stepped down from a first plane to a second plane, acting as a diagonal link between the two planes.
Initially, using aluminum, as opposed to steel, provides a substantial weight savings. Additionally, the stiff torque box is formed as such to allow the aluminum structure to maintain the required stiffness. If additional stiffness is required, a reinforcement tube can be introduced into the stiff torque box. Also, by introducing a stiff torque box various other stamped components, typically required, would be eliminated.
The stiffness of a frame, so constructed, would allow for an opportunity to use plastic composite vehicle bodies. This is because the frame would be of adequate stiffness such that the body itself would be less relied upon to offer additional stiffness for the overall vehicle. This allows for even more weight savings through the lighter weight plastic composite body.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
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Langer David M
Logan Bryan
Schroeder Del C
Speth David G
Calcaterra Mark P.
DaimlerChrysler Corporation
Pape Joseph D.
Patel Kiran B.
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