Vehicle structure having cross members overlapped by apertured rails

• US 20040150208A1
• Filed: 01/31/2003
• Published: 08/05/2004
• Est. Priority Date: 01/31/2003
• Status: Abandoned Application

• Current Assignee: Daimler Chrysler Corporation (Mercedes-Benz Group AG)
• Original Assignee: Daimler Chrysler Corporation (Mercedes-Benz Group AG)
• Inventors: Bhandarkar, Ram, Fraczek, Stephen, Koli, Rajesh, Vallurupalli, Rama, Nathan, Brian, Thom, Gerald R., Enck, Brian A.
• Application Number:
  US10/356,458
• Publication Number:
  US 20040150208A1
• Time in Patent Office: Days
• US Class Current: 280/781
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: B62D 27/023 Assembly of structural joints

Abstract

A vehicle structure includes a combination of hydro-formed, generally tubular shaped rails joined by an overlapping joint to a two-piece cross member. The overlapping joint is formed between a rail aperture and the cross member. To retain the structural strength lost by removing material from the rails, a weld joint is formed about the total perimeter of contact between the rail aperture and the cross member. The cross member includes a shoulder area formed to nest within the rail aperture. The two-piece cross member assembly reduces total parts while providing a plurality of cross member geometries and the necessary tolerance flexibility at the rail connections. The cross member is formed of two generally C-shaped members having butted or overlapping mating surfaces joined by a perimeter weld joint.

Claims

1. A vehicle structure comprising:

at least one cross-member having at least one mating shoulder formed thereon;

at least one rail having at least one receiving aperture sized to slidably mate with said mating shoulder;

an overlapping joint formed with said receiving aperture slidably mated at said mating shoulder; and

a weld joint formed at said overlapping joint to join said rail to said cross-member.

2. The structure of claim 1, wherein said rail further comprises a generally tubular body.

3. The structure of claim 2, wherein said tubular body further comprises a hydro-formed single part.

4. The structure of claim 1, wherein said weld joint further comprises a fillet weld circumferentially formed about an entire perimeter of said receiving aperture.

5. The structure of claim 1, wherein said at least one rail forms an upper overlapping joint above said at least one cross-member.

6. The structure of claim 1, wherein said at least one cross-member forms an upper overlapping joint above said at least one rail.

7. The structure of claim 1, wherein said at least one rail further comprises a pair of generally parallel longitudinal members of said vehicle structure.

8. The structure of claim 7, wherein said cross-member further comprises a linking member of said vehicle structure approximately perpendicularly aligned between said longitudinal members.

9. An overlapped structural portion of a vehicle frame comprising:

a cross-member having a shoulder formed thereon;

a generally tubular rail having a receiving aperture sized to slidably mate with said shoulder;

said cross member formed as a two-piece body including an upper part joined to a lower part;

an overlapping joint formed with said receiving aperture slidably mated to said shoulder; and

a weld joint formed at said overlapping joint to join said rail to said cross-member.

10. The vehicle frame of claim 9, further comprising:

a first piece of said two-piece body having said shoulder formed on an outer surface thereof and a perimeter wall extending from perimeter edges of said outer surface; and

a first mating edge circumferentially formed about a distal end of said wall.

11. The vehicle frame of claim 10, further comprising:

a second piece of said two-piece body having a generally C-shaped outer perimeter and a second mating edge; and

a body weld joint joining the first piece to the second piece with said second mating edge aligned with said first mating edge.

12. The vehicle frame of claim 9, wherein said receiving aperture further comprises a pair of generally C-shaped apertures each formed in opposed walls of said tubular rail.

13. The vehicle frame of claim 12, wherein each C-shaped aperture further comprises an aperture height selected to match a mating geometry of said shoulder.

14. The vehicle frame of claim 9, wherein said tubular rail further comprises a hydro-formed single part having a generally rectangular shape with eased corners.

15. A method to join vehicle frame components comprising the steps of:

shaping a receiving shoulder onto a cross-member;

forming an aperture dimensionally conforming to said receiving shoulder in a tubular rail;

mating said cross-member with said tubular rail at said aperture; and

welding said cross-member to said tubular rail at said receiving shoulder.

16. The method of claim 15, comprising constructing said cross-member as a two-piece body.

17. The method of claim 15, comprising dimensionally adjusting said aperture to permit location of said tubular rail relative to said cross-member within a frame construction tolerance.