Chassis assembly with hybrid materials

Abstract

A chassis assembly having a hybrid material for mitigating mass is provided. The assembly includes an upper structure comprising a metal. The upper structure has a plurality of first bonding surfaces each parallel to one another at different heights relative to a z-axis of its 3-dimensional coordinate. The assembly also includes a lower structure made of a polymer composite material. The lower structure has a plurality of second bonding surfaces each parallel to one another at different heights relative to its z-axis. The second bonding surfaces are arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is joined with the upper structure at the first and second bonding surfaces. The assembly also includes an adhesive disposed between the first and second bonding surfaces to join the lower and upper structures at the first and second bonding surfaces, thereby defining a bonding gap between the first and second bonding surfaces.

Description

Technical Field

[0001] introduction

[0002] The present disclosure relates to automotive chassis components, and more particularly to chassis components having hybrid materials for mass reduction. Background Art

[0003] Lightweight chassis design is desirable. However, lightweight design is often relatively expensive and therefore sometimes cost-prohibitive. Furthermore, in reducing overall mass, manufacturers face the challenge of achieving performance targets related to stiffness, strength, durability, noise, vibration, ride and handling, and crash response. Summary of the Invention

[0004] Therefore, while current undercarriage assemblies perform their intended purpose, a new and improved undercarriage assembly is needed.

[0005] According to one aspect of the present disclosure, a chassis assembly comprising a hybrid material for weight reduction is provided. The assembly includes an upper structure, which is either a single metal piece or a metal assembly. The upper structure has a plurality of first bonding surfaces. These first bonding surfaces are parallel to each other at different heights relative to the z-axis of their three-dimensional coordinates.

[0006] In this aspect, the assembly further comprises a lower structure made of a polymer composite material. The lower structure has a plurality of second bonding surfaces. These second bonding surfaces are parallel to each other at different heights relative to their z-axis. The second bonding surfaces are arranged to align with the first bonding surface in a complementary relationship so that the lower structure is coupled to the upper structure at the first bonding surface and the second bonding surface. The assembly further comprises an adhesive disposed between the first bonding surface and the second bonding surface to couple the lower structure and the upper structure at the first bonding surface and the second bonding surface, thereby defining a bonding gap between the first bonding surface and the second bonding surface.

[0007] In one embodiment of this aspect, the one of the metal piece or metal assembly comprises one of steel and aluminum. In another embodiment, the polymer composite reinforcement comprises one of glass fiber and carbon fiber and basalt fiber and ultra-high molecular weight polyethylene fiber and poly (p-phenylene terephthalamide) fiber and wollastonite.

[0008] In another embodiment of this aspect, the bonding gap is between 0.25 millimeters and 1.5 millimeters. In yet another embodiment, the bonding gap is between 0.5 millimeters and 1 millimeter. In still another embodiment, the bonding gap is between 0.6 millimeters and 0.8 millimeters. In yet another embodiment, the adhesive includes, but is not limited to, one of an epoxy-based adhesive, a urethane-based adhesive, or an acrylic-based adhesive. In another example, any adhesive capable of being used as a structural adhesive has a modulus equal to or greater than 500 MPa and a tensile strength equal to or greater than 10 MPa.

[0009] In one embodiment of this aspect, the upper structure includes an upper hollow portion and the lower structure includes a lower hollow portion. The upper hollow portion and the lower hollow portion are arranged in conjunction with one another so as to define a closed hollow portion of the assembly.

[0010] In another embodiment, at least one mechanical fastener is disposed through one of the second bonding surfaces of the lower structure and extending through the upper structure. The upper structure includes a protective rib formed thereon, the protective rib opposing one of the first bonding surfaces and disposed about the mechanical fastener.

[0011] In yet another embodiment, the upper portion includes a pair of brackets formed thereon, the pair of brackets opposing one of the first bonding surfaces.

[0012] According to another aspect of the present disclosure, there is provided a chassis assembly having a hybrid material for mitigating mass. The assembly includes an upper structure, the upper structure being one of a metal single piece and a metal assembly. The upper structure has a plurality of first bonding surfaces. Each of the first bonding surfaces is parallel to one another at different heights with respect to a z-axis of its 3-dimensional coordinate.

[0013] In this aspect, the assembly includes a lower structure, the lower structure including one of a fiber-reinforced composite material, such as a glass fiber-reinforced composite material or a carbon fiber-reinforced composite material. The lower structure has a plurality of second bonding surfaces. Each of the second bonding surfaces is parallel to one another at different heights with respect to a z-axis thereof. The second bonding surfaces are arranged in a complementary relationship to align with the first bonding surfaces such that the lower structure is joined with the upper structure at the first bonding surfaces and the second bonding surfaces.

[0014] The assembly further includes an adhesive disposed between the first and second bonding surfaces to couple the lower structure and the upper structure at the first and second bonding surfaces, thereby defining a bonding gap between the first and second bonding surfaces of between 0.25 mm and 1.5 mm. In this aspect, the assembly includes at least one mechanical fastener disposed through one of the second bonding surfaces of the lower structure and extending through the upper structure. The upper structure includes a protective rib formed thereon, the protective rib opposing one of the first bonding surfaces and disposed around the mechanical fastener.

[0015] In one embodiment, the one of the metal piece and the metal assembly comprises one of steel and aluminum. In another embodiment, the polymer composite reinforcement is one of glass fiber, carbon fiber, and fiber reinforced material.

[0016] In yet another embodiment, the bonding gap is between 0.5 mm and 1 mm. In yet another embodiment, the bonding gap is between 0.6 mm and 0.8 mm. In one other embodiment, the adhesive comprises one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive.

[0017] In one embodiment, the upper structure includes an upper hollow portion, and the lower structure includes a lower hollow portion. The upper hollow portion and the lower hollow portion are arranged to be coupled to each other to define an enclosed hollow portion of the assembly. In another embodiment, the upper portion includes a pair of brackets formed thereon, the pair of brackets opposing one of the first bonding surfaces.

[0018] According to another aspect of the present disclosure, a method for manufacturing a chassis assembly comprising a hybrid material for weight reduction is provided. The method includes providing an upper structure, the upper structure being one of a single metal piece and a metal assembly. The upper structure includes a plurality of first flanges. Each first flange has a first bonding surface. The first bonding surfaces are parallel to each other at different heights relative to the z-axis of the three-dimensional coordinate.

[0019] The method further includes providing a lower structure made of a polymer composite material. The lower structure includes a plurality of second flanges. Each second flange has a second bonding surface. The second bonding surfaces are parallel to each other at different heights relative to the z-axis. The second bonding surfaces are arranged to align with the first bonding surfaces in a complementary relationship, such that the lower structure is coupled to the upper structure at the first bonding surface and the second bonding surface.

[0020] The method also includes applying an adhesive to the second bonding surface and aligning the first bonding surface with the second bonding surface.

[0021] The method also includes coupling the lower structure to the upper structure at the first bonding surface and the second bonding surface such that the adhesive is disposed between the first bonding surface and the second bonding surface, thereby defining a bonding gap between the first bonding surface and the second bonding surface between 0.25 mm and 1.5 mm.

[0022] In one embodiment, the polymer composite reinforcement includes one or both of glass fibers and carbon fibers.

[0023] Solution 1. A chassis assembly having a hybrid material for reducing mass, the assembly comprising:

[0024] an upper structure that is one of a single metal piece and a metal assembly, the upper structure having a plurality of first bonding surfaces, each of the first bonding surfaces being parallel to one another at a different height relative to a z-axis of a 3-dimensional coordinate thereof;

[0025] a lower structure made of a polymer composite material, the lower structure having a plurality of second bonding surfaces, each of the second bonding surfaces being parallel to one another at a different height relative to its z-axis, the second bonding surfaces being arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is coupled to the upper structure at the first bonding surfaces and the second bonding surfaces; and

[0026] An adhesive is provided between the first bonding surface and the second bonding surface to couple the lower structure and the upper structure at the first bonding surface and the second bonding surface, thereby defining a bonding gap between the first bonding surface and the second bonding surface.

[0027] Option 2. The assembly of Option 1, wherein the one of the single metal piece and the composite metal piece comprises one of steel and aluminum.

[0028] Option 3. The assembly of Option 1, wherein the polymer composite reinforcement comprises one of glass fiber and carbon fiber.

[0029] Option 4. The assembly according to Option 1, wherein the bonding gap is between 0.25 mm and 1.5 mm.

[0030] Option 5. The assembly according to Option 1, wherein the bonding gap is between 0.5 mm and 1 mm.

[0031] Option 6. The assembly of Option 1, wherein the bonding gap is between 0.6 mm and 0.8 mm.

[0032] Option 7. The assembly of Option 1, wherein the adhesive comprises one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive.

[0033] Option 8. The component according to Option 1, wherein the upper structure includes an upper hollow portion and the lower structure includes a lower hollow portion, and the upper hollow portion and the lower hollow portion are arranged to be connected to each other, thereby defining a closed hollow portion of the component made of a mixed material.

[0034] Option 9. The assembly according to Option 1 further comprises at least one mechanical fastener, wherein the at least one mechanical fastener is arranged to pass through the second bonding surface of the lower structure and extend through the upper structure, and the upper structure includes a protective rib formed thereon, the protective rib being opposite to one of the first bonding surfaces and arranged around the mechanical fastener.

[0035] Option 10. The assembly of Option 1, wherein the upper portion includes a pair of brackets formed thereon, the pair of brackets opposing one of the first bonding surfaces.

[0036] Solution 11. A chassis assembly having a hybrid material for reducing mass, the assembly comprising:

[0037] an upper structure that is one of a single metal piece and a metal assembly, the upper structure having a plurality of first bonding surfaces, each of the first bonding surfaces being parallel to one another at a different height relative to a z-axis of a 3-dimensional coordinate thereof;

[0038] a lower structure comprising one of a glass fiber and a carbon fiber reinforced polymer composite material, the lower structure having a plurality of second bonding surfaces, each of the second bonding surfaces being parallel to one another at a different height relative to a z-axis thereof, the second bonding surfaces being arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is coupled to the upper structure at the first bonding surfaces and the second bonding surfaces;

[0039] an adhesive disposed between the first bonding surface and the second bonding surface to couple the lower structure and the upper structure at the first bonding surface and the second bonding surface, thereby defining a bonding gap between the first bonding surface and the second bonding surface of between 0.25 mm and 1.5 mm; and

[0040] At least one mechanical fastener is disposed through one of the second bonding surfaces of the lower structure and extends through the upper structure, the upper structure including a protective rib formed thereon, the protective rib being opposite to one of the first bonding surfaces and disposed around the mechanical fastener.

[0041] Scheme 12. The assembly of Scheme 11, wherein the one of the metallic single piece and the metallic assembly comprises one of steel and aluminum.

[0042] Scheme 13. The assembly of Scheme 11, wherein the polymer composite reinforcement comprises one of glass fiber and carbon fiber.

[0043] Scheme 14. The assembly of Scheme 11, wherein the bonding gap is between 0.5 millimeters and 1 millimeter.

[0044] Scheme 15. The assembly of Scheme 11, wherein the bonding gap is between 0.6 millimeters and 0.8 millimeters.

[0045] Scheme 16. The assembly of Scheme 11, wherein the adhesive comprises one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive.

[0046] Scheme 17. The assembly of Scheme 11, wherein the upper structure comprises an upper hollow portion and the lower structure comprises a lower hollow portion, the upper hollow portion and the lower hollow portion arranged in conjunction with one another to define a closed hollow portion of the assembly.

[0047] Scheme 18. The assembly of Scheme 11, wherein the upper portion comprises a pair of brackets formed thereon, the pair of brackets opposite one of the first bonding surfaces.

[0048] Scheme 19. A method of manufacturing a chassis assembly having a hybrid material for mass reduction, the method comprising:

[0049] providing an upper structure, the upper structure being one of a metallic single piece and a metallic assembly, the upper structure comprising a plurality of first flanges, each first flange having a first bonding surface, each of the first bonding surfaces parallel to one another at different heights with respect to a z-axis of 3-dimensional coordinates thereof;

[0050] providing a lower structure made of a polymer composite, the lower structure comprising a plurality of second flanges, each second flange having a second bonding surface, each of the second bonding surfaces parallel to one another at different heights with respect to a z-axis thereof, the second bonding surfaces arranged in a complementary relationship to align with the first bonding surfaces such that the lower structure is joined with the upper structure at the first bonding surfaces and the second bonding surfaces;

[0051] applying an adhesive on the second bonding surfaces;

[0052] aligning the first bonding surface with the second bonding surface; and

[0053] The lower structure is coupled to the upper structure at the first and second bonding surfaces such that the adhesive is disposed between the first and second bonding surfaces, thereby defining a bonding gap between the first and second bonding surfaces of between 0.25 mm and 1.5 mm.

[0054] Option 20. The method according to Option 19, wherein the polymer composite reinforcement comprises one of glass fiber and carbon fiber.

[0055] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0057] FIG. 1A is a perspective view of a chassis assembly according to one embodiment of the present disclosure.

[0058] FIG. 1B yes FIG. 1A A detached view of a component.

[0059] FIG. 1C yes FIG. 1A A perspective view of the upper portion of the assembly.

[0060] FIG. 2 yes FIG. 1A A cross-sectional view of the assembly in FIG. 1 taken along line 2 - 2 .

[0061] FIG. 3A yes FIG. 2 Magnified view of circle 3A in FIG.

[0062] FIG. 3B yes FIG. 2 Magnified view of circle 3B in FIG.

[0063] FIG. 3C yes FIG. 2 Magnified view of circle 3C.

[0064] FIG. 4 is a partial view of a chassis assembly having protective ribs according to another embodiment of the present disclosure.

[0065] FIG. 4A yes FIG. 4 Magnified view of circle 4A in FIG.

[0066] FIG. 5 is a flow chart of a method of manufacturing a chassis component having a hybrid material for weight reduction according to one example of the present disclosure.

[0067] FIG. 6A is a perspective view of a chassis assembly with a bracket according to another embodiment of the present disclosure.

[0068] FIG. 6B yes FIG. 6A Exploded view of the components in . DETAILED DESCRIPTION

[0069] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0070] The present disclosure provides a chassis assembly having a hybrid material for reduced mass and a method for manufacturing such a chassis assembly. While typical chassis are manufactured as a single-piece component of a single material, the present disclosure provides a two-piece hybrid material assembly comprising an upper structure and a lower structure joined in a single bonding process. The upper structure comprises metal, and the lower structure comprises a polymer composite, resulting in a chassis assembly having a relatively reduced mass while achieving performance targets related to stiffness, strength, durability, noise, vibration, ride and handling, and crash response.

[0071] According to one aspect of the present disclosure, FIGS. 1A-1B and FIG. 4A A chassis assembly 10 is illustrated having a hybrid material for weight reduction. As shown, the assembly 10 includes an upper structure 12 and a lower structure 14 coupled by an adhesive 16. In this embodiment, the upper structure 12 comprises metal and may be a single piece. In other embodiments, the upper structure 12 may comprise multiple parts. FIGS. 1B-1C and FIG. 4A As depicted in FIG, the upper structure 12 has a plurality of first flanges 18, wherein each first flange 18 includes a first bonding surface 20. As shown, the first bonding surfaces 20 are parallel to each other at different heights relative to the z-axis of their 3D coordinates. It will be understood that the upper structure 12 can be made of any suitable metal or metal alloy, such as steel, aluminum, or magnesium, without departing from the spirit or scope of the present invention.

[0072] FIG. 1A and FIG. 1BThe assembly 10 is depicted as also including a lower structure 14, which is made of a polymer composite material for structural reinforcement and underbody protection. As shown, the lower structure 14 has a plurality of second flanges 22, each of which includes a second bonding surface. The second bonding surfaces 24 are parallel to each other at different heights relative to the z-axis. The second bonding surfaces 24 are arranged to align with the first bonding surface 20 in a complementary relationship, such that the lower structure 14 is coupled to the upper structure 12 at the first bonding surface 20 and the second bonding surface 24. The polymer composite material of the second bonding surface 24 reduces galvanic corrosion when coupled to the metal of the first bonding surface 20. Additionally, galvanic corrosion can be reduced in several ways. In one example, the second flanges can be made using only glass fiber reinforcement. In another example, the second flanges can be made using carbon fiber reinforcement, with a glass fiber reinforcement layer added to the second bonding surface during molding. In this example, the glass fiber layer serves to isolate the metal from direct contact with the carbon fiber, thereby reducing the potential risk of galvanic corrosion. It will be appreciated that the lower structure 14 may be made of any suitable polymer composite material, such as a carbon fiber reinforced polymer composite material or a glass fiber reinforced polymer composite material, or both, without departing from the spirit or scope of the present invention. Furthermore, it will be appreciated that the reinforced polymer composite material may be a composite material made of a polymer reinforced with fibers, such as, but not limited to, one of carbon fiber, glass fiber, and basalt fiber. The polymer may be any suitable polymer without departing from the spirit or scope of the present disclosure.

[0073] FIG. 1B and FIG. 4A The assembly 10 is shown further comprising an adhesive 16 disposed between the first bonding surface 20 and the second bonding surface 24 to couple the upper structure 12 to the lower structure 14 at the first bonding surface 20 and the second bonding surface 24. As shown, placement of the adhesive 16 between the first bonding surface 20 and the second bonding surface 24 defines a bonding gap 26 between the first bonding surface 20 and the second bonding surface 24. In one embodiment, the bonding gap 26 may be between 0.25 mm and 1.5 mm, preferably between 0.5 mm and 1 mm, and more preferably between 0.6 mm and 0.8 mm.

[0074] In addition, the adhesive 16 may include one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive. It will be understood that any suitable epoxy-based adhesive, urethane-based adhesive, or acrylic-based adhesive may be used without departing from the spirit or scope of the present disclosure. Examples of the adhesive 16 may be, but are not limited to, Fusor® 380NS / 383NS adhesives from LORD / Parker or Pliogrip™ 5760B / 400 from Ashland without departing from the spirit or scope of the present disclosure.

[0075] FIGS. 1C-3C The upper structure 12 is shown to include a first front portion 30, a first middle portion 32, and a first rear portion 34. As depicted, each of the front portion, middle portion, and rear portion is integrally formed with the upper structure 12, which has a first flange 18 and a first joining surface 20 that are parallel to each other at different heights relative to its z-axis. In this embodiment, the first front portion 30, the first middle portion 32, and the first rear portion 34 are hollow, defined by first hollow cores 36, 37, and 38, respectively.

[0076] also, FIGS. 1C-3C The lower structure 14 is depicted and includes a second front portion 40, a second middle portion 42, and a second rear portion 44. Each of the second front portion 40, the second middle portion 42, and the second rear portion 44 is integrally formed with the lower structure 14, and the lower structure has a second flange 22 and a second joining surface 24, which are parallel to each other at different heights relative to the z-axis thereof. In this embodiment, the second front portion 40, the second middle portion 42, and the second rear portion 44 are hollow, defined by second hollow cores 46, 47, and 48, respectively.

[0077] like FIGS. 2-3C As shown in , the second front portion 40, the second middle portion 42, and the second rear portion 44 are integrally formed with the lower structure 14 such that the lower structure 14 is coupled to the upper structure 12 at the first bonding surface 20 and the second bonding surface 24 in a complementary relationship. That is, the second bonding surface 24 of the second front portion 40 is arranged to align with the first bonding surface 20 of the first front portion 30 in a complementary relationship, the second bonding surface 24 of the second middle portion 42 is arranged to align with the first bonding surface 20 of the first middle portion 32 in a complementary relationship, and the second bonding surface 24 of the second rear portion 44 is arranged to align with the first bonding surface 20 of the first rear portion 34 in a complementary relationship. FIGS. 2-3CAs depicted in FIG, the lower structure 14 is coupled to the upper structure 12 in a complementary relationship such that the first and second front portions 30, 40 are enclosed, the first and second middle portions 32, 42 are enclosed, and the first and second rear portions 34, 44 are enclosed. This creates a hollow portion and further contributes to a reduced overall mass of the assembly 10. Furthermore, the upper and lower structures 12, 14 are preferably coupled in a simultaneous coupling process or single-step joining operation.

[0078] It will be understood that the upper structure 12 may be formed by stamping, welding, casting, or any other suitable means without departing from the spirit or scope of the present disclosure. It will also be understood that the lower structure 14 may be formed by compression molding, resin transfer molding, autoclave molding, or any other suitable means without departing from the spirit or scope of the present disclosure.

[0079] FIGS. 1A-1B and FIG. 4 The assembly 10 is illustrated and includes at least one mechanical fastener 50, preferably a plurality of mechanical fasteners 50, disposed through one of the second bonding surfaces 24 of the lower structure 14 and extending through the upper structure 12. For each mechanical fastener 50, the upper structure 12 includes a protective rib 52 (e.g., a pair) formed thereon. As shown, the protective ribs 52 are formed on the upper structure 12, opposite one of the first bonding surfaces 20 and disposed around the mechanical fastener 50, thereby providing enhanced security during manipulation of the assembly 10. Where further securing the upper and lower structures together is desired, the mechanical fasteners 50 may be used. It will be appreciated that self-tapping screws or any other suitable fasteners may be used without departing from the spirit or scope of the present disclosure.

[0080] FIG. 5 A method for manufacturing a chassis assembly 10 having a hybrid material for reducing mass according to another aspect of the present disclosure is shown. FIGS. 1A-1C ) is a flow chart of a method 110. As shown, the method 110 includes the step of providing an upper structure 12 (e.g., the upper structure 12 discussed above) in box 112, the upper structure comprising metal and being a single workpiece. In other examples, the upper structure 12 may include multiple parts. FIG. 1B and FIG. 1C As depicted in FIG, the upper structure 12 has a plurality of first flanges 18, wherein each first flange 18 includes a first bonding surface 20. As shown, the first bonding surfaces 20 are parallel to each other at different heights relative to the z-axis of their 3D coordinates. It will be understood that the upper structure 12 can be made of any suitable metal or metal alloy, such as steel or aluminum, without departing from the spirit or scope of the present invention.

[0081] like FIG. 5As shown in FIG, the method 110 further includes providing a lower structure 14 ( FIGS. 1A-1C and discussed above), the lower structure is made of polymer composite materials to achieve structural reinforcement and underbody protection. FIG. 1A and FIG. 1B As shown in FIG, the lower structure 14 has a plurality of second flanges 22, each of which includes a second bonding surface. The second bonding surfaces 24 are parallel to each other at different heights relative to the z-axis. The second bonding surfaces 24 are arranged to align with the first bonding surface 20 in a complementary relationship, so that the lower structure 14 is coupled to the upper structure 12 at the first bonding surface 20 and the second bonding surface 24. The polymer composite material of the second bonding surface 24 reduces galvanic corrosion when coupled to the metal of the first bonding surface 20. Additionally, galvanic corrosion can be reduced in several ways. In one example, the second flanges may be reinforced solely with glass fiber. In another example, the second flanges may be reinforced with carbon fiber, wherein a glass fiber layer may be added to the second bonding surface during molding. In this example, the glass fiber layer will serve to isolate the metal from direct contact with the carbon fiber and thereby reduce the potential risk of galvanic corrosion. It will be understood that the lower structure 14 may be made of any suitable polymer composite material, such as a carbon fiber reinforced polymer composite, a glass fiber reinforced polymer composite, or both, without departing from the spirit or scope of the present invention.

[0082] As depicted, the method 110 also includes the step of applying an adhesive 16 to the second bonding surface 24 in block 116. Furthermore, the adhesive 16 may include one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive. It will be appreciated that any suitable epoxy-based adhesive, urethane-based adhesive, or acrylic-based adhesive may be used without departing from the spirit or scope of the present disclosure. Examples of adhesives 16 include Fusor® 380NS / 383NS adhesives 16 from LORD / Parker or Pliogrip™ 5760B / 400 from Ashland without departing from the spirit or scope of the present disclosure.

[0083] In this example, method 110 also includes the step of aligning the first bonding surface 20 with the second bonding surface 24 at block 118. As shown, adhesive 16 is disposed between the first bonding surface 20 and the second bonding surface 24 to couple the upper structure 12 and the lower structure 14 at the first bonding surface 20 and the second bonding surface 24. The steps of applying adhesive 16 and aligning the first bonding surface 20 with the second bonding surface 24 can be accomplished by any suitable means known in the art without departing from the spirit or scope of the present disclosure. For example, the lower structure 14 can be held on a fixed platform, fixture, or apparatus (not shown). In this example, while the lower structure 14 remains stationary, a nozzle apparatus can be used to apply adhesive 16 to the second bonding surface 24 of the lower structure 14. A movable apparatus (not shown) can then be used to move, raise, and lower the upper structure 12 on the lower structure 14 and align the first bonding surface 20 with the second bonding surface 24.

[0084] The method 110 further includes the step of coupling the upper structure 12 and the lower structure 14 by lowering the upper structure 12 and adjusting the position of the upper structure 12 at block 120. Lowering and adjusting the upper structure 12 on the lower structure 14 couples the lower structure 14 to the upper structure 12 at the first bonding surface 20 and the second bonding surface 24 such that the adhesive 16 is disposed between the first bonding surface 20 and the second bonding surface 24. When the upper structure 12 and the lower structure 14 are coupled at the first bonding surface 20 and the second bonding surface 24, a bonding gap 26 is defined between the first bonding surface 20 and the second bonding surface 24. Thus, the upper structure 12 and the lower structure 14 are preferably coupled in a simultaneous coupling process or a single-step coupling operation.

[0085] In one example, the bonding gap 26 may be between 0.25 mm and 1.5 mm. In another example, the bonding gap 26 may be between 0.5 mm and 1 mm. In yet another example, the bonding gap 26 may be between 0.6 mm and 0.8 mm.

[0086] When the upper structure 12 and the lower structure 14 are coupled, the assembly 10 is held in place on a fixture (not shown) to allow the adhesive 16 between the first bonding surface 20 and the second bonding surface 24 to cure. The curing time may vary depending on the adhesive 16 used. By way of example only, the curing time may be between 2 minutes and 24 hours.

[0087] FIG. 6A and FIG. 6B A chassis assembly 210 having a hybrid material for weight reduction according to another embodiment of the present disclosure is illustrated. As shown, the assembly 210 includes an upper structure 212 and a lower structure 214 coupled by an adhesive 216. FIGS. 1A-1C and FIG. 4AAs in the case of the assembly 10, the upper structure 212 comprises metal and may be a single piece. In other embodiments, the upper structure 212 may comprise multiple parts. FIGS. 1A-1C and FIG. 4A As in the case of component 10, FIG. 6A and FIG. 6B The upper structure 212 in FIG. 1 also has a plurality of first flanges 218, wherein each first flange 218 includes a first bonding surface 220. Thus, the first bonding surfaces 220 are parallel to each other at different heights relative to the z-axis of their 3D coordinates. It will be appreciated that the upper structure 212 may be made of any suitable metal or metal alloy, such as steel or aluminum, without departing from the spirit or scope of the present invention.

[0088] FIG. 6A and FIG. 6B An assembly 210 is depicted that also includes a lower structure 214 made of a polymer composite material. As shown, the lower structure 214 has a plurality of second flanges 222, wherein each second flange 222 includes a second bonding surface. The second bonding surfaces 224 are parallel to each other at different heights relative to their z-axis. The second bonding surfaces 224 are arranged to align with the first bonding surface 220 in a complementary relationship, such that the lower structure 214 is coupled to the upper structure 212 at the first bonding surface 220 and the second bonding surface 224. It will be understood that the lower structure 214 can be made of any suitable polymer composite material, such as a carbon fiber reinforced polymer composite material or a glass fiber reinforced polymer composite material, or both, without departing from the spirit or scope of the present invention.

[0089] and FIGS. 1A-1C As in the case of component 10, FIG. 6B The assembly 210 is shown and further includes an adhesive 216 disposed between the first bonding surface 220 and the second bonding surface 224 to couple the upper structure 212 and the lower structure 214 at the first bonding surface 220 and the second bonding surface 224. As shown, the placement of the adhesive 216 between the first bonding surface 220 and the second bonding surface 224 defines a bonding gap 226 between the first bonding surface 220 and the second bonding surface 224. In one embodiment, the bonding gap 226 may be between 0.25 mm and 1.5 mm, preferably between 0.5 mm and 1 mm, and more preferably between 0.6 mm and 0.8 mm.

[0090] In addition, the adhesive 216 may include one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive. It will be understood that any suitable epoxy-based adhesive, urethane-based adhesive, or acrylic-based adhesive 216 may be used without departing from the spirit or scope of the present disclosure. Examples of the adhesive 216 may be Fusor® 380NS / 383NS adhesive 216 from LORD / Parker or Pliogrip™ 5760B / 400 from Ashland without departing from the spirit or scope of the present disclosure.

[0091] It will be understood that the upper structure can be formed by stamping, welding, casting or any other suitable means without departing from the spirit or scope of the present disclosure. It will also be understood that the lower structure can be formed by compression molding, resin transfer molding, autoclave molding or any other suitable means without departing from the spirit or scope of the present disclosure.

[0092] like FIG. 6A and FIG. 6B As shown in , the upper portion includes mounting brackets 230 formed on a rear end 232 of the upper portion and opposite one of the first bonding surfaces 220. Preferably, the brackets 230 are formed integrally with the upper portion. Alternatively, the brackets 230 can be separate components and attached to the upper portion by any suitable means without departing from the spirit or scope of the present disclosure. As depicted, each bracket 230 includes a pair of opposing walls 234 to which vehicle components can be mounted. In addition, the upper portion includes cylindrical holes 236 formed at a front end 238 of the upper portion, thereby defining a drive unit mount 240. The cylindrical holes 236 allow the drive unit components to extend therethrough during vehicle manufacturing. It should be understood that other applications of the cylindrical holes may be used without departing from the spirit or scope of the present disclosure.

[0093] It will be appreciated that the attachment of other components, such as the suspension links and steering gear, to the upper metal structure may be carried out in any other suitable manner. Furthermore, it will be appreciated that bolt creep is eliminated or reduced as a result.

[0094] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

Claims

1. A chassis assembly having a hybrid material for reducing mass, the assembly comprising: an upper structure that is one of a single metal piece and a metal assembly, the upper structure having a plurality of first bonding surfaces, each of the first bonding surfaces being parallel to one another at a different height relative to a z-axis of a 3-dimensional coordinate thereof; a lower structure made of a polymer composite material, the lower structure having a plurality of second bonding surfaces, each of the second bonding surfaces being parallel to one another at a different height relative to the z-axis thereof, the second bonding surfaces being arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is coupled to the upper structure at the first bonding surfaces and the second bonding surfaces; as well as an adhesive disposed between and in direct contact with the first and second bonding surfaces to couple the lower structure and the upper structure at the first and second bonding surfaces, thereby defining a bonding gap between the first and second bonding surfaces, wherein the first bonding surface is disposed on the second bonding surface when the upper structure is bonded to the lower structure, and wherein the bonding gap is between 0.25 mm and 1.5 mm.

2. The assembly according to claim 1, wherein The one of the single metal piece and the assembly of metal pieces includes one of steel and aluminum.

3. The assembly according to claim 1, wherein The polymer composite reinforcement includes one of glass fiber and carbon fiber.

4. The assembly according to claim 1, wherein The bonding gap is between 0.5 mm and 1 mm.

5. The assembly according to claim 1, wherein The bonding gap is between 0.6 mm and 0.8 mm.

6. The assembly according to claim 1, wherein The adhesive includes one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive.

7. The assembly according to claim 1, wherein The upper structure includes an upper hollow portion, and the lower structure includes a lower hollow portion, the upper hollow portion and the lower hollow portion being arranged to be coupled to each other, thereby defining a closed hollow portion of the assembly made of mixed material.

8. The assembly of claim 1 , further comprising at least one mechanical fastener disposed through the second bonding surface of the lower structure and extending through the upper structure, the upper structure including a protective rib formed thereon, the protective rib being opposite one of the first bonding surfaces and disposed around the mechanical fastener.

9. The assembly of claim 1, wherein: The upper structure includes a pair of brackets formed thereon, the pair of brackets being opposite to one of the first bonding surfaces.

10. A chassis assembly having a hybrid material for reducing mass, the assembly comprising: an upper structure that is one of a single metal piece and a metal assembly, the upper structure having a plurality of first bonding surfaces, each of the first bonding surfaces being parallel to one another at a different height relative to a z-axis of a 3-dimensional coordinate thereof; a lower structure comprising one of a glass fiber and a carbon fiber reinforced polymer composite material, the lower structure having a plurality of second bonding surfaces, each of the second bonding surfaces being parallel to one another at a different height relative to a z-axis thereof, the second bonding surfaces being arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is coupled to the upper structure at the first bonding surfaces and the second bonding surfaces; an adhesive disposed between and in direct contact with the first bonding surface and the second bonding surface to couple the lower structure and the upper structure at the first bonding surface and the second bonding surface, thereby defining a bonding gap between the first bonding surface and the second bonding surface of between 0.25 mm and 1.5 mm, wherein the first bonding surface is disposed on the second bonding surface when the upper structure is bonded to the lower structure; as well as At least one mechanical fastener is disposed through one of the second bonding surfaces of the lower structure and extends through the upper structure, the upper structure including a protective rib formed thereon, the protective rib being opposite to one of the first bonding surfaces and disposed around the mechanical fastener.

11. The assembly according to claim 10, wherein The one of the single metal piece and the assembly of metal pieces includes one of steel and aluminum.

12. The assembly according to claim 10, wherein The polymer composite reinforcement includes one of glass fiber and carbon fiber.

13. The assembly of claim 10, wherein: The bonding gap is between 0.5 mm and 1 mm.

14. The assembly according to claim 10, wherein The bonding gap is between 0.6 mm and 0.8 mm.

15. The assembly of claim 10, wherein: The adhesive includes one of an epoxy-based adhesive, a urethane-based adhesive, and an acrylic-based adhesive.

16. The assembly of claim 10, wherein: The upper structure includes an upper hollow portion, and the lower structure includes a lower hollow portion, the upper hollow portion and the lower hollow portion are arranged to be coupled to each other, thereby defining a closed hollow portion of the assembly.

17. The assembly of claim 10, wherein: The upper structure includes a pair of brackets formed thereon, the pair of brackets being opposite to one of the first bonding surfaces.

18. A method of manufacturing a chassis component having a hybrid material for reducing mass, the method comprising: providing an upper structure, the upper structure being one of a single metal piece and a metal assembly, the upper structure including a plurality of first flanges, each first flange having a first bonding surface, each of the first bonding surfaces being parallel to one another at a different height relative to a z-axis of a 3-dimensional coordinate thereof; providing a lower structure made of a polymer composite material, the lower structure comprising a plurality of second flanges, each second flange having a second bonding surface, each of the second bonding surfaces being parallel to one another at a different height relative to a z-axis thereof, the second bonding surfaces being arranged to align in a complementary relationship with the first bonding surfaces such that the lower structure is coupled to the upper structure at the first bonding surfaces and the second bonding surfaces; applying an adhesive to the second bonding surface; aligning the first bonding surface with the second bonding surface; as well as coupling the lower structure to the upper structure at the first and second bonding surfaces such that the adhesive is disposed between and in direct contact with the first and second bonding surfaces, thereby defining a bonding gap between the first and second bonding surfaces of between 0.25 mm and 1.5 mm, Wherein, when the upper structure is combined with the lower structure, the first combining surface is arranged on the second combining surface.

19. The method according to claim 18, wherein The polymer composite reinforcement includes one of glass fiber and carbon fiber.

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