WO2024182347A1 - Hybrid joints for a vehicle frame - Google Patents

Abstract

A vehicle frame includes a front and rear frame module disposed in spaced relationship with one another. A pair of mid rails each extend between a first rail end connected to the front frame module and a second rail end connected to the rear frame module. A plurality of hybrid joints devoid of welds are present for establishing the connected relationship of the first rail end and the second rail end to the respective front or rear frame modules. In a first aspect, the hybrid joints are each comprised of a bolted joint including a plurality of bolts for interconnecting the front and rear frame modules to the mid rails. In a second aspect, the hybrid joints are each comprised of an adhesive joint, either additionally to or separate from the bolted joint, for bonding the front and rear frame modules to the mid rails with adhesive.

Description

HYBRID JOINTS FOR A VEHICLE FRAME

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63/448,391, filed February 27, 2023, titled “Hybrid Joints For A Vehicle Frame,” the entire disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present disclosure relates to a joint for connecting a front or rear frame module to mid rails of a vehicle frame. More particularly, the present disclosure relates to a joint for connecting both the front and rear frame module to the mid rails of a vehicle frame.

2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Vehicle frames, and in particular truck frames, typically include a front frame module, a rear frame module and mid rails which are joined or connected together via welded joints to collectively form the vehicle frame. For example, as illustrated in Figures 1-2, the front frame module of a truck frame is commonly Mig welded to the mid rails, with the same type of Mig welded joint occurring between the mid rails and the rear frame module to secure the front frame module, the mid rails and the rear frame module collectively to one another. Truck frames are exposed to and thus must perform under high fatigue requirements during use of the vehicle. Yet, the welded joints between the rear/front frame modules and the mid rails provide challenges for the truck frames to meet these fatigue requirements. For example, the mid rails of the truck frame are subjected to high bending and torsion deformation during operation of the vehicle, which translates to high stress levels on the welded joints for the front and rear frame modules. The heat affected zone (HAZ) present in these welded joints presents high challenges, and a potential failure point, for the truck frame relative to meeting the necessary fatigue requirements.

[0005] Accordingly, there remains a continuing need to improve the performance of joints present in a vehicle frame between the front frame module, rear frame module and the mid rails, particularly in the case of a truck frame.

SUMMARY OF THE INVENTION

[0006] The subject invention is directed to a hybrid joint devoid of welds, and thus a replacement to the prior art welded joints, for securing the front frame module and/or the rear frame module to the mid rails of a vehicle (truck) frame. In accordance with a first aspect of the disclosure, the hybrid joint is comprised of a bolted joint for securing the front frame module and/or the rear frame module to the mid rails of the vehicle frame. In accordance with a second aspect of the disclosure, the hybrid joint is comprised of an adhesive joint for securing the front frame module and/or the rear frame module to the mid rails of the vehicle frame, either additionally to or separate from the bolted joint. In either aspect, the hybrid joint improves fatigue performance relative to the prior art welded joints, namely since the hybrid joint is one devoid of a weld and thus the HAZ is no longer present and eliminated as a compromising feature for the hybrid joint. When the adhesive joint is present in the hybrid joint, the adhesive in the hybrid joint can additionally improve distribution of the forces from the mid rails to the respective front or rear frame module, further lowering the stress level for the hybrid joint. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Other aspects and advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0008] Figure l is a perspective view of a vehicle (truck) frame constructed in accordance with the prior art principles and including a plurality of welded joints interconnecting a front frame module and a rear frame module to a pair of mid rails;

[0009] Figure 2 is a magnified view of a portion of Figure 1 more clearly illustrating the welded joint including a weld extending between the front frame module and the mid rail;

[0010] Figure 3 is a perspective view of a vehicle (truck) frame constructed in accordance with the subject disclosure and illustrating a plurality of hybrid joints devoid of welds, and thus a replacement to the prior art welded joints, for interconnecting the front frame module and the rear frame module to the pair of mid rails;

[0011] Figure 4 is a magnified view of a front portion of Figure 3 more clearly illustrating the hybrid joint in accordance with a first aspect and comprised of a bolted joint interconnecting the front frame module to the mid rails;

[0012] Figure 5 is a magnified view of a rear portion of Figure 3 more clearly illustrating the first aspect of the hybrid joint comprised of the bolted joint interconnecting the rear frame module to the mid rails;

[0013] Figure 6 is a cross-sectional view of the hybrid, bolted joints taken along the cross- sectional plane 6-6 in Figures 3-4 to more clearly illustrate the bolted joint between the front frame module and the mid rails and including a plurality of bolts each passing through a plurality of front frame bolt holes defined by a front longitudinal member of the front frame module and a plurality of front rail bolt holes defined by a first rail end of the mid rail for interconnecting the front frame module to the mid rails;

[0014] Figure 7 is a cross-sectional view of the hybrid, bolted joints taken along the cross- sectional plane 7-7 in Figures 3 and 5 to more clearly illustrate the bolted joint between the rear frame module and the mid rails and including the plurality of bolts each passing through a plurality of rear frame bolt holes defined by a front longitudinal member of the rear frame module and a plurality of rear rail bolt holes defined by a second rail end of the mid rail for interconnecting the rear frame module to the mid rails;

[0015] Figure 8 is a perspective view of the hybrid joint in accordance with a second aspect and including an adhesive joint comprised of an adhesive disposed in sandwiched relationship between an inner surface of the front frame module and an outer surface of the mid rail in addition to the plurality of bolts of the bolted joint for bonding the front frame module to the mid rails; and [0016] Figure 9 is a perspective view of the hybrid joint in accordance with the second aspect and additionally including the adhesive joint comprised of an adhesive disposed in sandwiched relationship between an inner surface of the rear frame module and the outer surface of the mid rail in addition to the bolted joint for bonding the rear frame module to the mid rails.

DESCRIPTION OF THE ENABLING EMBODIMENTS

[0017] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiment is directed to a vehicle frame 10, and in particular a truck frame, including a front frame module 12 and a rear frame module 14 disposed in spaced relationship with one another, and a pair of mid rails 16 extending in spaced and generally parallel relationship with one another between a first rail end 26 interconnected to the front frame module 12 and a second rail end 28 interconnected to the rear frame to collectively form the vehicle (truck) frame 10. The front frame module 12 includes a pair of front longitudinal members 17 extending in spaced and generally parallel relationship with one another from a first connecting end 18 to a front end 20 disposed adjacent a front of the vehicle frame 10. The rear frame module 14 similarly includes a pair of rear longitudinal members 21 extending in spaced and generally parallel relationship with one another from a second connecting end 22 to a rear end 24 disposed adjacent a rear of the vehicle frame 10. As best shown in Figure 6, each of the front longitudinal members 17 are hollow at least adjacent the first connecting ends 18 to define a front receiving cavity 19 being generally rectangular in cross-sectional shape. As best shown in Figure 7, each of the rear longitudinal members 21 are also hollow at least adjacent the second connecting ends 22 to define a rear receiving cavity 23 being generally rectangular in cross-sectional shape. Although the front and rear receiving cavities 19, 23 are described and illustrated as having a generally rectangular cross-sectional shape, other cross-sectional shapes could be utilized without departing from the scope of the subject disclosure. Each of the front and rear frame modules 12, 14 include a respective front shock tower 25’ and rear body mount 25” and at least one respective front and rear lateral cross member 27’, 27” extending between the respective front and rear longitudinal members 17, 21.

[0018] The first rail end 26 of each mid rail 16 is interconnected to the first connecting end 18 of the respective front longitudinal member 17 and the second rail end 28 of each mid rail 16 is interconnected to the second connecting end 22 of the respective rear longitudinal members 21 by the plurality of hybrid joints 30. As best illustrated in Figures 6-7, each of the first and second rail ends 26, 28 are complementarily shaped to the respective front and rear receiving cavities 19, 23 defined by the first and second connecting ends 18, 22 of the front and rear longitudinal members 17, 21 such that the pair of mid rails 16 are initially slideably received and nested within the front and rear receiving cavities 19, 23 of the front and rear longitudinal members 17, 21 when beginning to establish the interconnection between the mid rails 16 and the front and rear frame modules 12, 14. In this instance, each of the first and second rails ends 26, 28 have a complementary rectangular cross-sectional shape with a profile slightly smaller than the rectangular cross-sectional shape of the first and second connecting ends 18, 22 to allow the mid rails 16 to be slideably received within the respective front and rear receiving cavities 19, 23. However, the cross-sectional shape of the first and second rail ends 26, 28 could take different forms to match different cross-sectional shapes of the first and second connecting ends 18, 22 when present, in accordance with the principles of the subject disclosure.

[0019] As best illustrated in Figures 3-7, the vehicle frame 10 includes at least one hybrid joint 30 which is devoid of the use and presence of welds, and thus are a replacement of the prior art welded joint, to secure at least the first connecting end 18 of the front longitudinal member 17 or the second connecting end 22 of the rear longitudinal member 21 to the respective first or second rail ends 26, 28 of the mid rails 16. In a preferred arrangement, the vehicle frame 10 includes a plurality of joints 30 which are each devoid of the use and presence of welds to secure both the first connecting ends 18 of the front longitudinal member 17 and the second connecting ends 22 of the rear longitudinal member 21 to the respective first and second rail ends 26, 28 of the mid rails 16.

[0020] In accordance with a first aspect of the disclosure, the hybrid joint 30 is comprised of a bolted joint 31 which includes a plurality of bolts 32 for securing the front frame module 12 and the rear frame module 14 to the mid rails 16 of the vehicle frame 10. More specifically, as best illustrated in the cross-sectional view of the bolted joint 31 shown in Figure 6 for interconnecting the front frame module 12 and the mid rails 16, the first connecting end 18 of the front longitudinal member 17 defines a plurality of front frame bolt holes 34’ and the first rail ends 26 of the mid rails 16 define a plurality of front mid rail bolt holes 36’ such that when the first rail end 26 is slideably disposed within the front receiving cavity 19 defined by the first connecting end 18 of the front longitudinal member 17, the plurality of front frame bolt holes 34’ and front mid rail bolt holes 36’ are disposed in aligned with one another for receiving respective front bolts 32’ of the plurality of bolts 32 passing therethrough. Similarly, as best illustrated in the cross- sectional view of the bolted joint 31 shown in Figure 7 for interconnecting the rear frame module 14 and the mid rails 16 as shown, the second connecting ends 22 of the rear longitudinal members 21 defines a plurality of rear frame bolt holes 34” and the second rail ends 28 of the mid rails 16 defines a plurality of rear mid rail bolt holes 36” such that when the second rail end 28 is slideably disposed within the front receiving cavity 23 defined by the second connecting end 22 of the rear longitudinal member 21, the plurality of rear frame bolt holes 34” and rear mid rail bolt holes 36” are disposed in aligned relationship with one another for receiving respective rear bolts 32” of the plurality of bolts 32 passing therethrough. Once the plurality of bolts 32 are passed through respective ones of the front or rear frame bolt holes 34’, 34” and the front or rear mid rail bolt holes 36’, 36”, a nut 33 is secured to threads 35 on a threaded end 37 of the each of the front and rear bolts 32’, 32” to secure the front and/or rear longitudinal members 17, 21 to the mid rails 16 and complete the interconnection of the front and/or rear frame modules 12, 14 to the mid rails 16. As further illustrated in Figures 6-7, the mid rails 16 can additionally include a plurality of support sleeves 38 extending within the mid rails 16 and disposed in aligned relationship with respective ones of the front or rear mid rail bolt holes 36’, 36” for supporting the plurality of front and rear bolts 32’, 32” passing through the front or rear frame bolt holes 34’, 34” and the respective front or rear mid rail bolt holes 36’, 36” when interconnecting the front or rear frame module 12, 14 to the mid rails 16.

[0021] As previously discussed, use of the hybrid joint 30 comprised of a bolted joint 31 for interconnecting the front and/or rear module 12, 14 to the mid rails 16 improves fatigue performance of the vehicle frame 10 relative to the prior art vehicle frames with welded joints, namely since the hybrid joint 30 is devoid of a weld and thus the HAZ is no longer present and is eliminated as a compromising feature for the hybrid joint 30. The bolted joints 31 also provide flexibility to e-coat and/or transport the front and rear modules 12, 14 and mid-rails 16 in segments, and then at the final assembly station the segments of the vehicle frame 10 (i.e., the front frame module 12, the rear frame module 14, and the mid rails 16) can be bolted and fastened together to the final length. Relatedly, use of the hybrid joint 30 comprised of a bolted joint 31 provides modularity for manufacturing different lengths of vehicle frames 10, while also allowing the various segments to be stacked before interconnection, resulting in reduced space and transportation requirements.

[0022] As best illustrated in Figure 8-9, in accordance with a second aspect of the hybrid joint 30’, an adhesive 40 can extend between an inner surface 42 of the front or rear module 12, 14 and an outer surface 44 of the mid rails 16 to further establish an adhesive joint for interconnecting the front or rear frame module 12, 14 to the mid rails 16. More specifically, as best illustrated in Figure 8, when the hybrid joint 30’ is utilized for joining the front frame module 12 to the mid rails 16, the adhesive 40 of the adhesive joint is disposed within the front receiving cavity 19 in sandwiched relationship between the inner surface 42’ of the first connecting ends 18 of the front longitudinal members 17 and an outer surface 44’ of the first rail end 26 of the mid rails 16. Similarly, as best illustrated in Figure 9, when the hybrid joint 30’ includes the adhesive joint for joining the rear frame module 14 to the mid rails 16, the adhesive 40 is disposed within the rear receiving cavity 23 in sandwiched relationship between the inner surface 42” of the second connecting ends 22 of the rear longitudinal members 21 and the outer surface 44” of the second rail end 28 of the mid rails 16. Use of the adhesive 40 in addition to the plurality of bolts 32 provides an additional adhesive joint which can improve distribution of the forces from the mid rails 16 to the respective front or rear frame module 12 14 during use of the vehicle frame 10, further lowering the stress level for the hybrid joint 30. Put another way, when adhesive 40 is added to the hybrid joint 30’ to bond the front or rear frame module 12, 14 to the mid rails 16, the additional adhesive joint structure further improves distribution of the stresses in the vehicle (truck) frame 10.

[0023] It should be appreciated that the foregoing description of the embodiments has been provided for purposes of illustration. In other words, the subject disclosure it is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varies in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of disclosure.

Claims

CLAIMS What is claimed is:

1. A vehicle frame comprising: a front frame module and a rear frame module disposed in spaced relationship with one another; a pair of mid rails each extending between a first rail end connected to said front frame module and a second rail end connected to said rear frame module; and at least one hybrid joint devoid of welds for establishing said connected relationship of said first rail end or said second rail end to said respective front or rear frame module.

2. The vehicle frame as set forth in Claim 1, wherein said at least one hybrid joint includes a plurality of hybrid joints each devoid of welds for establishing said connected relationship of said first rail ends to said front frame module and said connected relationship of said second rails ends to said rear frame module.

3. The vehicle frame as set forth in Claim 2, wherein said plurality of hybrid joints are each comprised of a bolted joint including a plurality of bolts interconnecting said front and rear frame modules to respective ones of said first rail ends or said second rails ends of said pair of mid rails.

4. The vehicle frame as set forth in Claim 3, further comprising: said front frame module including a pair of front longitudinal members each extending in spaced relationship with one another from a first connecting end to a front end disposed adjacent a front of the vehicle frame; said rear frame module including a pair of rear longitudinal members each extending in spaced relationship with one another from a second connecting end to a rear end disposed adjacent a rear of the vehicle frame; and said plurality of hybrid joints interconnecting said first connecting ends of said front longitudinal members to said first rail ends of said pair of mid rails and said second connecting ends of said rear longitudinal members to said second rail ends of said pair of mid rails.

5. The vehicle frame as set forth in Claim 4, further comprising: each of said front longitudinal members being hollow at least adjacent said first connecting ends to define a front receiving cavity, and said first rail ends being complementarily shaped to and nested within said front receiving cavity; and each of said rear longitudinal members being hollow at least adjacent said second connecting ends to define a rear receiving cavity, and said second rail ends being complimentarily shaped to and nested within said rear receiving cavity.

6. The vehicle frame as set forth in Claim 5, wherein each of said first and second connecting ends having a generally rectangular cross-sectional shape, and each of said first and second rail ends having a complementary rectangular cross-sectional shape with a profile slightly smaller than said generally rectangular cross-sectional shape of said first and second connecting ends.

7. The vehicle frame as set forth in Claim 5, further comprising: said first connecting ends of said front longitudinal member each defining a plurality of front frame bolt holes; said first rail ends of said mid rails each defining a plurality of front mid rail bolt holes disposed in aligned relationship with respective ones of said plurality of front frame bolt holes; and said plurality of bolts including a plurality of front bolts each passing through respectively aligned ones of said plurality of front frame bolt holes and said plurality of front mid rail bolt holes to establish said plurality of bolted joints between said front frame module and said pair of mid rails.

8. The vehicle frame as set forth in Claim 7, further comprising: said second connecting ends of said rear longitudinal member each defining a plurality of rear frame bolt holes; said second rail ends of said mid rails each defining a plurality of rear mid rail bolt holes disposed in aligned relationship with respective ones of said plurality of rear frame bolt holes; and said plurality of bolts including a plurality of rear bolts each passing through respectively aligned ones of said plurality of rear frame bolt holes and said plurality of rear mid rail bolt holes to establish said plurality of bolted joints between said rear frame module and said pair of mid rails.

9. The vehicle frame as set forth in Claim 8, further comprising: a plurality of support sleeves extending within said first and second rail ends of said mid rails and each disposed in aligned relationship with respective ones of said front or rear mid rail bolt holes for supporting respective ones of said plurality of front and rear bolts passing through respective ones of said front or rear frame bolt holes and respective ones of said front or rear mid rail bolt holes.

10. The vehicle frame as set forth in Claim 8, further comprising: a nut secured to threads on a threaded end of the each of said plurality of front and rear bolts.

11. The vehicle frame as set forth in Claim 5, wherein said plurality of hybrid joints each additionally include an adhesive joint comprised of an adhesive bonding said front and rear frame modules to respective ones of said first rail ends or said second rails ends of said pair of mid rails.

12. The vehicle frame as set forth in Claim 11, wherein said adhesive in each of said plurality of adhesive joints for bonding said front frame module to said first rail ends is disposed within said front receiving cavity in sandwiched relationship between an inner surface of said first connecting ends of said front longitudinal members and an outer surface of said first rail ends of said pair of mid rails.

13. The vehicle frame as set forth in Claim 11, wherein said adhesive in each of said plurality of adhesive joints bonding said rear frame module to said second rail ends is disposed within said rear receiving cavity in sandwiched relationship between an inner surface of said second connecting ends of said rear longitudinal members and an outer surface of said second rail ends of said pair of mid rails.

14. The vehicle frame as set forth in Claim 2, wherein said plurality of hybrid joints include an adhesive joint comprised of an adhesive for bonding said front and rear frame modules to respective ones of said first rail ends or said second rails ends of said pair of mid rails.

15. The vehicle frame as set forth in Claim 14, wherein said adhesive extends between an inner surface of said front or rear modules and an outer surface of said pair of mid rails for bonding said front and rear frame modules to respective ones of said first rail ends or said second rails ends of said pair of mid rails.