Frame of motor vehicle

Abstract

A frame (100) of a motor vehicle (1) comprises a body unit (2), a front suspension attachment structure (12), an engine compartment structure (502) comprising a lower portion (503) and an upper portion (504), and a rear suspension attachment structure (505), a front absorber element (16), a rear absorber element (516) wherein the front absorber element (16) and the rear absorber element (516) comprise aluminum, the front suspension attachment structure (12) and the rear suspension attachment structure (505) comprise aluminum, and the front absorber element (16) and the rear absorber element (516) comprise aluminum. The lower part (503) comprises aluminum, the upper part (504) comprises carbon fibers, the main body unit (2) comprises a shell (310) of carbon fibers and at least two first walls (311, 312) opposite to each other, so that a cavity (313) and one or more carbon fiber baffles (324) are defined between the first walls (311, 312), and the one or more carbon fiber baffles (324) are arranged inside the cavity (313).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the priority of Italian Patent Application No. 102023000013173 filed on June 26, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The invention relates to a frame of a motor vehicle, in particular to a frame of a sports vehicle. Background Art

[0004] As is known, the frame of a motor vehicle has both a supporting function for supporting body elements, ie the outer covering sheet metal such as bumpers or hoods, or various connecting brackets, and a function of absorbing shocks.

[0005] For this reason, the frame must consist of several parts, some of which are better suited to providing a supporting function, for which they must have high stiffness and strength characteristics, and other parts of which are better suited to providing an absorbing function, for which they must have high deformability characteristics.

[0006] In addition, the vehicle frame typically includes a body unit that internally defines a passenger compartment for accommodating at least a driver and possible passengers.

[0007] For safety reasons, the unit must be particularly strong and resistant in order not to crush the occupants in the passenger compartment in the event of an accident.

[0008] In view of all these characteristics, there is a particular need to improve the known vehicle frames.

[0009] More particularly, there is a need, for example, to improve the frame with regard to its overall lightness and, where necessary, with regard to the ideal spatial distribution of components, so that the available volume is sufficient to be allocated to all devices that are necessary or conducive to the operation of the motor vehicle, but without affecting or even simply endangering the supporting and absorbing functions of the frame.

[0010] Furthermore, in the same context, there is a need to efficiently integrate the functionality of the frame from the perspective of overall dimensions with the functionality of typical motor vehicle devices for delivering external air to specific parts relative to the motor vehicle (for example, ducts for delivering cooling air to the brakes or the passenger compartment air conditioning device).

[0011] Furthermore, the frame needs to be designed to find a good compromise to limit the increase in the extension of the parts used for the absorption function while increasing their capacity in terms of progressiveness of shock absorption or reducing the ability of the vehicle to decelerate due to an impact.

[0012] It is an object of the present invention to meet at least one of the needs discussed above, preferably in a simple and reliable manner. Summary of the invention

[0013] The above object can be achieved by the frame of a motor vehicle provided by the present invention.

[0014] In a first aspect, a frame of a motor vehicle is provided, comprising:

[0015] a body unit defining a passenger compartment of the motor vehicle;

[0016] a front suspension attachment structure including an attachment portion secured to the body unit;

[0017] an engine compartment structure fixed relative to the main body unit and defining an engine compartment for accommodating an engine for propelling the motor vehicle, the engine compartment structure comprising a lower portion for supporting the engine and an upper portion for covering the engine compartment from the top;

[0018] a rear suspension attachment structure fixed to the engine compartment structure, the engine compartment structure being disposed between the passenger compartment and the rear suspension attachment structure according to a first straight axis (D);

[0019] one or more attachment elements, which are fixed relative to the front suspension attachment structure and / or the rear suspension attachment structure and are used to allow coupling of a suspension of the motor vehicle to the frame in the region for arranging the suspension;

[0020] a front absorbing element for absorbing a frontal collision of the motor vehicle, the front absorbing element being different from the front suspension attachment structure, being fixed relative to the front suspension attachment structure and extending along the first straight axis (D) from the front suspension attachment structure to an end opposite to the front suspension attachment structure, the front suspension attachment structure being arranged between the front absorbing element and the body unit according to the first straight axis; and

[0021] a rear absorbing element for absorbing a rear impact of the motor vehicle, the rear absorbing element being different from the rear suspension attachment structure, being fixed relative to the rear suspension attachment structure and extending from the rear suspension attachment structure along the first straight axis (D), the rear suspension attachment structure being arranged between the rear absorbing element and the engine compartment structure according to the first straight axis (D);

[0022] in,

[0023] The front absorbent element and the rear absorbent element comprise aluminum;

[0024] The front suspension attachment structure and the rear suspension attachment structure comprise aluminum;

[0025] The lower portion comprises aluminum, and

[0026] The upper portion comprises carbon fiber;

[0027] Wherein, the main unit comprises:

[0028] at least one shell comprising carbon fibers and at least two first walls opposed to one another so as to define a cavity therebetween; and

[0029] One or more baffles comprising carbon fibers are arranged inside the cavity according to an arrangement, and each baffle extends transversely to the first wall between two first ends respectively connected seamlessly to the first wall.

[0030] In one embodiment, the channel extends continuously through the front absorbing element and the front suspension attachment structure between an inlet opening obtained at the end along the first straight axis and an outlet opening obtained in the front suspension attachment structure along a fourth axis (H) transverse to the first straight axis (D) and facing the area where the suspension is placed.

[0031] In one embodiment, the front suspension attachment structure further includes a foldable portion located between the front absorbing element and the attachment portion according to the first straight axis (D), the foldable portion having a first compression stiffness equal to or greater than a second compression stiffness of the front absorbing element and less than a third compression stiffness of the attachment portion.

[0032] In one embodiment, the frame further includes a steering box, which includes a steering tie rod for steering a wheel hub of the motor vehicle; a tubular sleeve extending along a second straight axis (C); and a transmission element coupled to the steering tie rod and the tubular sleeve for axial movement along the second straight axis (C) within the tubular sleeve, wherein the tubular sleeve is rigidly fixed to the front suspension attachment structure.

[0033] In one embodiment, the foldable portion has an end portion according to a third axis (H) orthogonal to the first straight axis (D) and the second straight axis (C), and the end portion has a recess extending in depth along the third axis (H) and intersects with the steering box along the second straight axis (C).

[0034] In one embodiment, the frame further comprises an absorbent body and a releasable securing means for releasably securing the absorbent body to the foldable portion at the recess.

[0035] In one embodiment, the frame further comprises:

[0036] a crossbar constituting a supporting base for a windshield of said motor vehicle; and

[0037] a pair of upright posts, which are respectively fixed at both ends of the crossbar to form an area with a closed outline for placing the windshield;

[0038] wherein the crossbar comprises a first wall away from the region having a closed contour;

[0039] The frame further includes a pipe extending through the crossbar between a first opening (221) obtained on the second wall of the crossbar and a second opening obtained on the first wall, wherein the first wall includes a recessed portion that is recessed to the opposite side relative to the area having a closed contour, and the second opening is formed on the recessed portion.

[0040] In a second aspect, a method for manufacturing the above-mentioned frame is provided, the method comprising the following steps:

[0041] a. Providing a first mold having an inner mold wall for defining the cavity;

[0042] b. fixing the pre-cured partition to the first mold and the first inner wall of the inner wall according to the arrangement inside the cavity;

[0043] c. placing a plurality of raw carbon fiber sheets on the second inner wall of the inner wall at a position suitable for forming at least one of the first walls;

[0044] d. baking the raw carbon fiber sheet disposed inside the first mold together with the separator in an autoclave;

[0045] e. forming a second sand casting mold, the second sand casting mold reproducing the front suspension attachment structure or the rear suspension attachment structure which is hollow inside and contains at least one lost inner core;

[0046] f. Supplying molten metal under low pressure into the second sand casting mold.

[0047] In one embodiment, the partition is arranged inside the first mold to divide the cavity into a plurality of separate compartments.

[0048] In one embodiment, wherein the first mold has a plurality of through holes, which respectively establish connections between the corresponding compartments and the outside of the first mold, the method further comprises the following steps: placing a corresponding bag inside the compartment in the first mold, so that the bag has a corresponding air inlet passing through the through holes on the outside of the first mold, and the air inlet is suitable for allowing pressurized air to flow into the bag, wherein, during step d, the first mold contains the bag located inside the compartment, so that the pressurized air of the autoclave expands the bag during the baking process, thereby pressing the raw carbon fiber sheet against the second inner wall during the baking process. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] In the following, for a better understanding of the present invention, embodiments of the present invention will be described in a non-limiting example manner with reference to the accompanying drawings, in which:

[0050] Figure 1 is a perspective view of a motor vehicle incorporating a frame according to the present invention;

[0051] Figure 2 is a perspective view of a motor vehicle viewed from the side;

[0052] Figure 3 is a schematic perspective view of the frame;

[0053] Figure 4 is a schematic perspective view of the rear portion of the frame on a larger scale;

[0054] Figure 5 is a perspective view of a motor vehicle as viewed from inside a passenger compartment of the motor vehicle;

[0055] Figure 6 is a perspective view of the front of the main unit of the frame with some parts removed for clarity;

[0056] Figure 7 is a schematic perspective view of the front portion of the frame;

[0057] Figure 8 yes Figure 7 An enlarged view of the invention with some parts removed for clarity;

[0058] Fig. 9 is extended through Figure 7 a larger scale perspective view of the front passage;

[0059] Fig.10 is a perspective view showing steps of a method of manufacturing a main body unit;

[0060] Fig.11 is a cross-sectional view showing further steps of the manufacturing method;

[0061] Fig.12 is an exploded view of a closed mold during the manufacturing method;

[0062] Fig.13 It shows open configuration Fig.12 A perspective view of the middle mold;

[0063] Fig.14 Yes Display Fig.11 a cross-sectional view of a step of the manufacturing method after the step;

[0064] Fig.15 is a schematic diagram of a model of a casting mold and a sand casting mold obtained using the model; and

[0065] Fig.16 is used Fig.15 Schematic diagram of a foundry where casting molds are used to manufacture frame components. DETAILED DESCRIPTION

[0066] exist Figure 1 , reference numeral 1 is used to denote the entire motor vehicle.

[0067] Like all motor vehicles, the motor vehicle 1 has a normal direction of travel and comprises a passenger compartment 200 for accommodating at least one driver and, if necessary, one or more passengers.

[0068] The motor vehicle 1 comprises a frame 100 comprising a body unit 2 which defines or surrounds a passenger compartment 200. For example, the body unit 2 may be monolithic. Furthermore, the body unit may comprise or consist of carbon fibers.

[0069] The body unit 2 comprises, in particular, a side end 307 in schematic form. The term "side" should be understood with reference to the direction in which the body unit 2 is arranged in the motor vehicle 1 and with reference to its direction of travel. Alternatively, "side" can also be understood with reference to the direction of the passenger compartment.

[0070] The side end 307 is open toward the passenger cabin 200 , that is, it has an opening that allows a person to enter the passenger cabin 200 .

[0071] In particular, the opening of the side end 307 may be occupied by a side door 304 of the motor vehicle 1 , in particular in a closed position, ie a position in which the side door 304 prevents a person from entering the passenger compartment through the opening.

[0072] In other words, the side door 304 in the closed position covers or conceals the opening and the side end 307 from a perspective outside the motor vehicle 1 .

[0073] The side door 304 is movably coupled to the frame 100 , and more specifically, the side door 304 rotates between a closed position and at least one open position in which access to the opening is permitted.

[0074] The side end 307 comprises a beam, in particular a box beam. The beam extends in a rectilinear direction or axis AA, in particular parallel to the direction of travel, or in any case longitudinally oriented, ie it is oriented to the side of the side door 304 in the closed position.

[0075] The beam has a concave profile according to the axis AA, the profile of the beam being concave upwards in the context of the motor vehicle 1. In other words, the profile of the beam is concave towards the opening of the lateral end 307.

[0076] In particular, the beam is unitary and comprises two uprights 308 defining respective ends of the beam according to axis AA. Furthermore, the beam comprises a longitudinal member or gate 309 extending between the uprights 308 along axis AA.

[0077] The door rail 309 is seamlessly connected to the column 308 , that is, it forms a single body with the column 308 .

[0078] The posts 308 extend transversely relative to the axis AA.

[0079] Thus, the posts 308 form a concave profile of the beam.

[0080] In addition to the side ends 307, the body unit 2 also includes a bottom portion (not shown) defining a floor or ground surface of the passenger compartment.

[0081] In more detail, the body unit 2 comprises another side end opposite and identical to the side end 307 , in particular according to a horizontal direction orthogonal to the direction of travel.

[0082] The floor extends between side end 307 and another side end.

[0083] Preferably, the floor is seamlessly connected to the side end 307 , that is, the floor forms a single body with the side end 307 , and may also form a single body with the other lateral end.

[0084] Typically, the main body unit 2 includes at least one shell 310, and the shell 310 includes carbon fibers.

[0085] The main body unit 2 can be understood as a single shell 310 or multiple shells 310 connected to each other (regardless of the connection type between the shells 310). For example, the shells 310 can be seamlessly connected to each other, that is, forming a single shell, that is, the main body includes a monolithic carbon fiber.

[0086] In this particular case, the beams of the side ends 307 constitute the housing 310 , and preferably the floor also constitutes the housing 310 .

[0087] For the sake of brevity, the following description will refer to a single housing 310 , ie, in particular, to the beams of the side ends 307 .

[0088] However, the teachings provided herein for the detailed description of the housing 310 may be directly applicable to other housings 310 of the main unit 2 or even to the entire main unit 2 considered as a single housing. In other words, each feature disclosed for the housing 310 described in detail may also be applicable to all other housings 310 of the main unit 2 or even to the entire main unit 2 considered as a single housing.

[0089] The housing 310 has at least two walls 311 , 312 facing each other to at least partially define or delimit a cavity 313 between the walls 311 , 312 .

[0090] In particular, the walls 311 , 312 are transverse to the axis AA.

[0091] In addition to or in lieu of the walls 311 , 312 , the beam or housing 310 of the side end 307 may also have other walls that at least partially bound or define the cavity 313 .

[0092] For example, according to axis AA, each upright, or even a single upright 308, is defined by two walls 315, 316 transverse to axis AA. More precisely, walls 315, 316 extend transversely to walls 311, 312 between them.

[0093] In particular, walls 315, 316 are opposed to each other.

[0094] Furthermore, each upright or even a single upright 308 is delimited by a respective wall portion 317 , 318 of the walls 311 , 312 .

[0095] Thus, wall portions 317 , 318 and walls 315 , 316 form one or each of pillars 308 .

[0096] Wall portions 317, 318 or walls 315, 316 oppose one another to at least partially define or delimit a cavity 314, which is a portion of cavity 313. Cavity 314 is completely defined or delimited by walls 315, 316 and wall portions 317, 318. Each column 308 may define a corresponding cavity 314 by, for example, walls 315, 316 or wall portions 317, 318.

[0097] A similar concept applies to the door rail 309 , which is defined by the respective wall portions 319 , 320 of the walls 311 , 312 .

[0098] Furthermore, according to an axis CC, the door rail 309 is delimited by two walls 321 , 322 transverse to the axis CC, which is transverse to the axis AA. More precisely, the walls 321 , 322 extend between the walls 311 , 312 and transverse to the walls 311 , 312 .

[0099] Furthermore, the wall 321 extends transversely to the wall 315 between the walls 315 of the two pillars 308 , while the wall 322 extends transversely to the wall 316 between the walls 316 .

[0100] In particular, the walls 321 , 322 are opposite to each other.

[0101] The housing 310 further includes a plurality of baffles 324 including carbon fibers.

[0102] Each partition 324 may include or be defined by a plate, in particular a flat plate.

[0103] Each partition 324 extends transversely to the walls 311 , 312 between ends seamlessly connected to the walls 311 , 312 , ie forms a single body with the walls 311 , 312 .

[0104] Alternatively or additionally, each of the first set of partitions 324 extends transversely to the walls 315 , 316 of one or the other column 308 between the ends seamlessly connected to the walls 315 , 316 , ie, forms a single body with the walls 311 , 312 .

[0105] Alternatively or additionally, each of the second set of baffles 324 extends transversely to the walls 321, 322 of the longitudinal member 309 between the ends seamlessly connected to the walls 321, 322, respectively, i.e., forms a single body with the walls 311, 312. More precisely, the second set of baffles 324 consists of one of the baffles 324.

[0106] Preferably, several baffles 324 may be grouped together to form a potentially complex geometry.

[0107] For example, two of the baffles 324 have corresponding surfaces 325, 326, in particular, transverse to the walls 311, 312, and extend at acute angles on the respective incident planes, so that the two baffles 324 form a V-shaped or crocodile-mouth structure, as shown in the figure.

[0108] In addition, three of the partitions 324 have corresponding surfaces 327, 328, and 329, in particular, transverse to the walls 311 and 312, wherein the surfaces 327 and 329 are opposite to each other and both are transverse to the surface 328, thereby forming a C-shaped or omega-shaped or U-shaped structure, as shown in the figure.

[0109] Typically, the shape and / or arrangement of the partitions 324 are optimized, for example using a design-aided computer program, in particular based on finite element calculations, with the aim of maximizing the resistance of the shell 310 in order to influence and / or optimize the ratio between the solidity and the total weight of the shell 310 .

[0110] The partitions 324 are arranged to divide the cavity 313 into a plurality of separate compartments 332 .

[0111] Furthermore, at least the majority of the partitions 324 are located in the region of the pillar 308 , ie, inside the cavity 314 of the pillar 308 .

[0112] According to a specific embodiment, the main unit 2 further includes a plurality of bags 360 respectively arranged inside the compartments 332 .

[0113] Possibly, there may be fewer bags 360 than compartments 332. Therefore, the main unit 2 may also include a single bag 360 within a corresponding compartment 332.

[0114] Next, a method of manufacturing the main body unit 2 will be described.

[0115] More specifically, a method of manufacturing the above-mentioned housing 310 having the partition 324 is described in detail, and manufacturing methods of other housings 310 will not be described in detail because they are basically similar to the methods described below.

[0116] In other words, each feature of the method disclosed herein is directly applicable in an independent manner to the method of manufacturing each shell 310 or even the entire main body unit 2 considered as a single shell.

[0117] The method includes providing a mold 340 having inner walls configured or adapted to define a cavity 313. In other words, the inner walls of the mold 340 (clearly understood to be a closed mold) surround a cavity identical to the cavity 313. In yet other words, the inner walls of the mold 340 define a cavity including the cavity 313.

[0118] In view of this, the term cavity 313 is used herein to identify the actual cavity 313 of the housing 310 and the cavity 313 within the closed mold 340 at the end of the method.

[0119] In particular, the mold 340 includes at least two parts 341, 342. More particularly, when the two parts 341, 342 are coupled to each other to surround the cavity 313, the mold 340 is closed.

[0120] Therefore, the inner wall of the mold 340 includes a first inner wall (inner wall for short) 343 of the portion 341 and a second inner wall (inner wall for short) 344 of the portion 342 .

[0121] The method includes securing the separator 324 , which has been pre-cured and is therefore in a finished state, to a mold 340 .

[0122] Therefore, the partition 324 is arranged inside the mold 340 to divide the cavity 313 into compartments 332.

[0123] Therefore, more precisely, the partition 324 is fixed to the portion 341 of the mold 340.

[0124] For example, the partitions 324 are secured (ie, held in their positions) by threaded members 331 such as bolts.

[0125] The method may further comprise placing a plurality of raw carbon fibre sheets 346 on the inner wall 343 at locations suitable for forming at least the wall 312 .

[0126] The inner wall 343 is then used to form at least the wall 312 .

[0127] In fact, in particular, a sheet of raw carbon fiber 346 is arranged on the inner wall 343 , thereby also forming the walls 315 , 316 of each upright 308 , as well as the walls 321 , 322 of the door rail 309 .

[0128] Therefore, the inner wall 343 further also serves to form the walls 315 , 316 and the walls 321 , 322 .

[0129] Additional green carbon fiber sheets 346 may also be placed on the separator 324 , particularly independently on each surface of the separator 324 .

[0130] Furthermore, preferably, separator 324 is connected to raw carbon fiber sheet 346 by an adhesive film configured to melt or at least soften during heating in an autoclave to facilitate joining of heated carbon fiber sheet 346 and separator 324 .

[0131] In particular, the green carbon fiber sheet 346 comprises a carbon fiber fabric impregnated in a resin, more particularly, a thermosetting resin.

[0132] like Fig.12 and Fig.13As shown, portion 341 defines an interior cavity thereof that substantially includes cavity 313 .

[0133] Optionally, the method includes first autoclave heating of the green carbon fiber sheet 346 arranged on the inner wall 343. In the first heating, the green carbon fiber sheet 346 is heated together with the separator 324 fixed to the portion 341 in the region of the inner wall 343.

[0134] Therefore, the first heating is performed by placing the portion 341 having the green carbon fiber sheet 346 and the separator 324 (without the portion 342) in an autoclave.

[0135] In more detail, before the portion 341 having the green carbon fiber sheet 346 and the separator 324 is placed in an autoclave, the portion 341 having the green carbon fiber sheet 346 and the separator 324 is closed in a vacuum bag 355 under vacuum.

[0136] The vacuum bag 355 comprises at least one valve arrangement 356 for connecting the vacuum bag 355 to a vacuum pump 357 .

[0137] The vacuum pump 357 is connected to the vacuum bag 355 through the valve device 356. Therefore, the air in the vacuum bag 355 containing the portion 341 having the green carbon fiber sheet 346 and the separator 324 is sucked using the vacuum pump 357. In this way, the portion 341 having the green carbon fiber sheet 346 and the separator 324 is placed under vacuum.

[0138] At this point, a first heating is performed by placing the vacuum bag 355 containing the portion 341 with the green carbon fiber sheet 346 and the separator 324 in the autoclave.

[0139] Obviously, the first heating is carried out by operating the autoclave.

[0140] After the first heating, for example, after air has been reintroduced into the vacuum bag 355 via the valve arrangement 356, the vacuum bag 355 is removed by breaking the vacuum bag 355 or simply pulling it apart.

[0141] In this regard, the method includes placing a plurality of green carbon fiber sheets 358 on the inner wall 344 at locations suitable for forming at least the wall 311 .

[0142] Preferably, green carbon fiber sheet 358 is of the same type as green carbon fiber sheet 346 .

[0143] Green carbon fiber sheets 358 and / or green carbon fiber plates 346 may be held in place, for example, by an adhesive film configured to melt or at least soften during heating in an autoclave.

[0144] The mold 340 may then be closed with the green carbon fiber sheet 358, the separator 324, and, if desired, the carbon sheet heated by the first heating of the interior.

[0145] The method further includes second autoclave heating of a green carbon fiber sheet 358 disposed inside the mold 340, more precisely, on the inner wall 344, together with the separator 324, and in particular, together with the carbon fiber sheet heated by the first heating.

[0146] In more detail, prior to the second heating, the method comprises placing the bags 360 within the corresponding compartments 332 in the mold 340 .

[0147] In particular, when the mold 340 is closed, the mold 340 has at least one corresponding opening 361 for each compartment 332 , such that the opening 361 establishes communication between the respective compartment 332 and the exterior of the mold 340 .

[0148] In other words, the mold 340 is configured to define or delimit the openings 361 to establish communication between each compartment 332 and the exterior of the mold 340 .

[0149] Obviously, the opening 361 is a through opening, in particular, through the inner wall 343 or the inner wall 344 .

[0150] The bag 360 has a corresponding air inlet 363 through which the bag 360 can be inflated with pressurized air. The air inlet 363 is adapted to allow pressurized air to enter the bag 360.

[0151] The bag 360 is arranged in the compartment 332 , and the air inlet 363 is arranged outside the mold 340 through the opening 361 .

[0152] Therefore, even when the mold 340 is closed, the air inlet 363 protrudes from the mold 340 through the opening 361 .

[0153] In this way, during the second heating, the mold 340 contains a bag 360, which is inflated by the pressurized air of the autoclave. In fact, the pressurized air flows into the bag 360 through the air inlet 363, and the air inlet 363 protrudes from the mold 340 through the opening 361.

[0154] By being inflated, the bag 360 presses the green carbon fiber sheet 358 against the inner wall 344 during the second heating period.

[0155] Thus, the dimensions of the bag 360 allow the bag 360 itself to expand under the pressure of the pressurized air within the compartment 332 , occupying a volume equal to that of the compartment 332 .

[0156] The mold 340, and more particularly the portion 341, may have an opening 365 to allow the bag 360 to be removed from the mold 340 after the second heating.

[0157] The opening 365 is a through hole passing through the inner wall 343 .

[0158] The bag 360 can be reused, particularly for further heating.

[0159] Alternatively, the bag 360 may remain within the compartment 332, which will remain a compartment 332 of the housing 310 or main unit 2. In this case, the opening 365 may be particularly small or even non-existent.

[0160] In this particular case, the result of the second heating is shell 310 .

[0161] Conveniently, during the second heating, the mould 340 is enclosed in a vacuum bag 371 under vacuum.

[0162] The vacuum bag 371 comprises at least one valve arrangement 372 configured to connect the vacuum bag 371 to a vacuum pump 373 .

[0163] The use of vacuum bag 371, valve device 372 and vacuum pump 373 are similar to the use of vacuum bag 355, valve device 356 and vacuum pump 357 respectively, and will not be described in further detail.

[0164] A vacuum bag 371 is connected to each bag 360 outside the mold 340 in a fluid-tight manner.

[0165] The air inlets 363 of the bag 360 protrude from the vacuum bag 371 so that they can perform their function.

[0166] Thus, the air inlet 363 continues to allow pressurized air from the autoclave to flow into the bag 360 , thereby causing the bag 360 to expand.

[0167] Meanwhile, since the vacuum bag 371 is fluid-tightly connected to the bag 360 , the pressurized air does not flow into the vacuum bag 371 , so that the interior of the vacuum bag 371 can be maintained as a vacuum.

[0168] At the end of the second heating, the vacuum bag 371 can be removed, for example by breaking or in any case in a manner similar to how the vacuum bag 355 is removed.

[0169] Once the vacuum bag 371 is removed, the housing 310 or, if necessary, the main unit 2 is manufactured.

[0170] The first heating is optional and can be omitted. In this case, the second heating becomes a single heating of all carbon fiber sheets 346, 358 and the separator 324 in the closed mold 340.

[0171] All the features described above for the second heating can also be applied to the single heating.Thus, the bag 360 and the vacuum bag 371 can be used as described above.

[0172] Furthermore, the motor vehicle 1 comprises a plurality of external panels, i.e. external panels visible from the outside of the motor vehicle 1, such as a bonnet 205, a windscreen 206 and, if required, a roof 207. The external panels are supported by the frame 100 in a fixed position, i.e. they are fixed relative to the frame 100.

[0173] In this particular case, the bonnet 205 is a front bonnet, depending on the direction of travel of the motor vehicle 1 .

[0174] The frame 100 also comprises a windshield frame 210 which surrounds the windshield 206. The latter is fixed to the windshield frame 210 in a region having a closed contour defined by the windshield frame 210. The windshield 206 is thus surrounded by a closed contour.

[0175] The windshield frame 210 includes a crossbar 211 that constitutes a support base for supporting the windshield 206. In other words, the crossbar 211 is arranged below the windshield 206.

[0176] Furthermore, the crossbar 211 projects relative to the windshield 206 in the direction of travel of the motor vehicle 1 , in particular relative to the front of the windshield 206 .

[0177] The crossbar 211 is at least partially or completely covered by the engine hood 205 .

[0178] The crossbar 211 comprises a beam or more precisely is a beam, in particular a box beam, more particularly having a greater width extension, namely in a direction BB orthogonal to the direction of travel and transverse to the side of the motor vehicle 1 .

[0179] Specifically, since the windshield 206 extends according to a curved and concave surface toward the passenger compartment 200, the crossbar 211 has a curved shape, in particular, a radius of curvature of a plane defined by the direction BB and the direction of travel. However, this is not required, as both the windshield 206 and the crossbar 211 may have different shapes without lack of versatility.

[0180] In addition, the windshield frame 210 includes a pair of upright posts 212 , which are respectively fixed to opposite side ends of the crossbar 211 , ie, opposite ends with respect to the direction BB.

[0181] The upright post 212 extends transversely relative to the crossbar 211 , in particular, extends upward, thereby forming the above-mentioned area with a closed contour for positioning the windshield 206 .

[0182] Optionally, the closed profile is completed by another crossbar 213 of the windscreen frame 210 , which crossbar 213 extends parallel to the axis BB. The crossbar 213 has two lateral ends, namely according to the axis BB, fixed to the uprights 212 .

[0183] In particular, the crossbar 213 also supports the roof 207. The crossbar 213 is arranged above the uprights 212 and obviously also above the crossbar 211. In the case of a motor vehicle 1 with a convertible roof 207 or without a roof 207, the crossbar 213 may not be present, without in any case changing the area for positioning the windshield 206. In fact, the closed contour may also be defined by the area for positioning the windshield 206, and not necessarily by the frame 210.

[0184] The crossbar 211 includes a plurality of walls including at least one wall 214 that faces downward or on the opposite side relative to the windshield 206 and thus toward the area for positioning the windshield 206 .

[0185] Specifically, the wall 214 is opposite to another wall 215 of the crossbar 211 , ie, away from another wall 215 of the crossbar 211 , and the wall 215 can support the windshield 206 , ie, form a base of the windshield 206 .

[0186] The crossbar 211 also comprises a wall 216 which is transverse to the two walls 214 , 215 and faces the passenger compartment 200 .

[0187] Furthermore, the crossbar 211 comprises a wall 217 which is transverse to the wall 214 and, in particular, also transverse to the wall 215 .

[0188] The wall 217 extends to be laterally connected to the wall 214 .

[0189] In particular, the wall 217 is curved, more particularly, the wall 217 is curved according to the already mentioned radius of curvature. In the embodiment shown here, the wall 217 is part of the side wall of a cylinder. The axis of the cylinder is oriented upwards or perpendicular to the floor of the frame 100.

[0190] Wall 217 is located forwardly relative to windshield 206 or wall 216 .

[0191] The frame 100 advantageously includes a tube 220 extending through the crossbar 211 .

[0192] The duct 220 extends between an opening 221 formed in the wall 217 and an opening 222 formed in the wall 214 .

[0193] More precisely, the duct 220 is defined by a chamber that is completely inside the crossbar 211 .

[0194] The chamber opens out through openings 221, 222. In particular, the wall 217 has a further opening 221, for example parallel and identical to the previous one.

[0195] The opening 221 communicates with the environment outside the motor vehicle so that air can be introduced into the duct 220. In fact, in particular, the opening 221 communicates directly with the passenger compartment of the motor vehicle 1 covered by the bonnet 205.

[0196] Optionally, the crossbar 211 may have ribs inside the chamber or duct 220, the ribs having the function of reinforcing or increasing the resistance to the stresses of the crossbar 211, which, from a structural point of view, are inevitably slightly weakened by the presence of the duct 220. In fact, the ribs are sufficient to fully compensate for the slight weakening of the resistance caused by the presence of the duct 220.

[0197] For example, each rib may extend from any one of the walls 214, 215 to the other of the walls 214, 215, or directly connect the two walls 214, 215, thereby defining a partition. The partition may also define a chamber or duct 220, ie, a wall defining the chamber or duct 220.

[0198] Preferably, the wall 214 includes a portion 223 that is recessed downward, ie, toward the side opposite the area for positioning the windshield 206 .

[0199] In particular, the opening 222 is obtained in the portion 223 .

[0200] As explained more clearly below, portion 223 defines a recess in wall 214 that functions as a "seat" for placing an object or device therein.

[0201] The remaining portion of the wall 214 that is different from the portion 223 is identified by reference numeral 224 .

[0202] The portion 223 comprises a flat region 225 which is inclined relative to the portion 224 and in which the opening 222 is obtained.

[0203] Thus, the opening 222 extends according to an ideal surface corresponding to the ideal continuation of the flat area 225, the straight line orthogonal to the flat area 225 or the ideal surface being oriented towards one side of the motor vehicle 1. Said straight line is coplanar with the axis BB and therefore defines, together with the axis BB, a plane which in turn is orthogonal to the direction of travel. Thus, the straight line orthogonal to the flat area 225 or the ideal surface belongs to a plane orthogonal to the direction of travel.

[0204] The flat region 225 is a specific example, but it can be replaced by a corresponding non-flat region. In this case, the cutting plane still exists. The cutting plane will have the same properties as the flat region 225.

[0205] In particular, the opening 222 is in direct communication with a housing 226 defined by the frame 100 , the housing 226 including the recess having the function of a “seat” as described above.

[0206] The shell 226 is different from the passenger compartment 200. In particular, the vehicle frame 100 includes a firewall 227 that separates the shell 226 from the passenger compartment 200.

[0207] The housing 226 is provided in front of the passenger compartment 200 in terms of the traveling direction of the motor vehicle 1 .

[0208] Therefore, the shell 226 communicates with the duct 220 through the opening 222 .

[0209] The motor vehicle 1 comprises an air conditioning device 230 which is configured to condition the environment of the passenger compartment 200 , ie to cool or heat the passenger compartment 200 .

[0210] The air conditioning device 230 is known in the industry and, therefore, will not be described in further detail.

[0211] The air conditioning device 230 is arranged within the housing 226 , that is, is accommodated in the housing 226 .

[0212] The air conditioning device 230 conditions the air contained in the casing 226 and introduces it into the passenger compartment 200 .

[0213] Therefore, the firewall 227 is provided with sufficient ducts (not shown herein) to allow the air conditioning device 230 to introduce air into the passenger compartment 200 .

[0214] The motor vehicle 1 further comprises at least one, some or all typical components, such as a suspension 3 , a steering knuckle 4 , a wheel hub 5 , a half shaft 6 and a steering box 7 .

[0215] The wheel hub 5 has a fixed portion fixed relative to the steering knuckle 4 and a rotating portion rotatable about an axis A transverse to the driving direction.

[0216] The fixed part is carried by the steering knuckle 4 , while the rotating part is coupled to the half shaft 6 so that it can be driven to rotate by the half shaft 6 .

[0217] The semi-shaft 6 extends along a rectilinear axis B which is parallel to the axis A but not necessarily coincident therewith.

[0218] The steering box 7 extends along another linear axis C which is parallel to the axes A, B or transversely, more precisely perpendicularly, to the direction of travel.

[0219] The steering box 7 is a known device connected to the wheel hub 5 and has the function of steering the fixed part of the wheel hub 5 , in particular, converting the rotational movement of the steering wheel (not shown) of the motor vehicle 1 into a linear movement along the axis C for steering the fixed part of the wheel hub 5 .

[0220] In fact, more generally, the steering box 7 is part of a steering device of the motor vehicle 1 , which also includes a steering wheel and is used for fixing the steering hub 5 , for example.

[0221] Furthermore, as described below, the steering box 7 may be considered as a part of the vehicle frame 100 .

[0222] The steering box 7 includes a tie rod 40 coupled to the steering knuckle 4 or wheel hub 5 in a known manner.

[0223] Furthermore, the steering box 7 includes a steering transmission device for transmitting the rotation of the steering wheel to the tie rod 40 so that the tie rod translates in response to the turning of the steering wheel.

[0224] The steering gear comprises known but not shown gear elements, such as a rack or a worm, possibly with recirculating balls.

[0225] The transmission element is coupled to the tie rod 40 , for example, the transmission element is fixed relative to the tie rod 40 , in particular, the transmission element is fixed to the tie rod 40 .

[0226] The steering box 7 comprises a tubular casing 41 which at least partially houses the transmission elements and which extends along the axis C.

[0227] The transmission element is coupled to the tubular sleeve 41 in an axially movable or translational manner along the axis C inside the tubular sleeve 41 .

[0228] Thus, the tie rod 40 is configured to move in response to the translation of the transmission element, thereby steering the wheel hub 5, in particular, rotating the steering knuckle 4 about an axis oriented from the bottom to the top.

[0229] The transmission element can be coupled to the steering wheel via a kinematic chain of a steering transmission, for example, the transmission element includes a shaft that is coupled to the steering wheel to rotate in response to rotation of the steering wheel and terminates inside a tubular sleeve 41, a transmission member (not shown) is configured to cooperate with the transmission element to transfer the rotation of the shaft to the transmission element, and the transmission element translates in response to the rotation of the shaft.

[0230] For example, the transmission member may comprise a pinion meshing with a rack which is part of the transmission element.

[0231] Thus, the steering transmission may be a typical rack-and-pinion mechanism in which a pinion coupled to the steering wheel meshes with a rack fixed to the tie rods, the rack translating along axis C in response to rotation of the pinion induced by the steering wheel through a kinematic chain.

[0232] Optionally, the steering box 7 may comprise an actuator arrangement 44 for performing a power steering function.

[0233] The actuator device 44 is carried by the tubular sleeve 41 and has, for example, a sleeve 44 a which is fixed relative to the tubular sleeve 41 .

[0234] The actuator arrangement 44 is configured to move the transmission element along the axis C, for example independently or in conjunction with the rotation of a steering wheel.

[0235] The actuator device 44 may include an electric motor within a casing 44a and another transmission device, not shown, for transmitting the output power of the electric motor to a transmission element.

[0236] Furthermore, the motor vehicle 1 comprises a braking device 113 for braking the wheel hub 5 or more precisely for braking the rotating part thereof.

[0237] The brake device 113 comprises a first brake element 114 such as a brake disc fixed relative to the rotating part of the wheel hub 5 and a second brake element 115 such as a brake caliper carried by the fixed part of the wheel hub 5 or the steering knuckle 4 .

[0238] Second brake element 115 may be operated by, for example, a known, not shown actuator to contact first brake element 114 , thereby generating a braking torque acting on the rotating portion of hub 5 due to friction generated by contact between brake elements 114 , 115 .

[0239] Furthermore, the frame 100 comprises a front frame assembly 11 which is fixed relative to the body unit 2 and has the function of supporting body elements of the motor vehicle 1 , ie outer panels or sheet metal such as bumpers 8 , fenders 9 etc., for example.

[0240] The assembly 11 includes a front suspension attachment structure 12 , alternatively referred to as a “shock tower”.

[0241] More precisely, the assembly 11 comprises two suspension attachment structures or bodies 12 arranged at the side ends of the main unit 2 according to a horizontal direction orthogonal to the direction of travel.

[0242] The structures 12 are parallel to each other along respective axes D parallel to the direction of travel.

[0243] The structure 12 protrudes relative to the body unit 2. More precisely, the structure 12 protrudes from the body unit 2 along the axis D, in particular, directly from the body unit 2.

[0244] Preferably, the structures 12 are identical to each other. For this reason, the following description will only disclose one of the structures 12 in detail, provided that each feature described for one of the structures 12 may also be applicable to the other structure 12. Therefore, the term "structure 12" may indiscriminately refer to any one of the structures 12.

[0245] If desired, the structure 12 may also be considered as a single structure 12 .

[0246] The structure 12 has an attachment portion 13 which is fixed relative to the body unit 2 , ie fixed to the body unit 2 , for example by releasable fixing means 14 , in particular comprising a threaded member, such as a bolt 128 .

[0247] The structure 12 has the function of supporting the suspension 3. In fact, the assembly 11 also comprises a plurality of attachment elements or attachments 15 for allowing the suspension 3 to be coupled to the attachment portion 13.

[0248] Some attachment elements 15 are located in the region of the attachment portion 13 , but this does not exclude that other attachment elements 15 may be located in the region of other parts of the structure 12 .

[0249] Furthermore, the attachment 15 may be part of the structure 12 .

[0250] Preferably, the structure 12 or more precisely each structure 12 can be manufactured as a single piece, for example by means of a casting technique or more precisely by means of a die-casting technique.

[0251] The suspension 3 carries the steering knuckle 4 and is coupled to the attachment portion 13 via an attachment 15, in particular connected to the attachment portion 13 in a movable manner relative to the structure 12. The steering knuckle 4 in turn is movable relative to the suspension 3.

[0252] Furthermore, the vehicle frame 100 , and more particularly the assembly 11 , comprises a steering box 7 with a tie rod 40 , a tubular sleeve 41 and a transmission element.

[0253] The tubular sleeve 41 is rigidly fixed to the structure 12 .

[0254] The term "rigidly fixed" means that the tubular sleeve 41 is fixed relative to the structure 12, in other words, the tubular sleeve 41 cannot perform relative movements relative to the structure 12 beyond negligible deformations or local vibrations of a material generally considered rigid (such as metal). In other words, the tubular sleeve 41 is not suspended relative to the structure 12 by elastic means (such as a spring or a flexible body, which may be made of rubber).

[0255] Conveniently, the structure 12 comprises a plurality of threaded holes, whereby the assembly 11 comprises a plurality of threaded members 49 , such as self-tapping screws, coupled to the threaded holes and connected to the tubular sleeve 41 , so as to rigidly secure the tubular sleeve 41 to the structure 12 .

[0256] More precisely, the threaded member 49 passes through a corresponding sleeve 45 which is fixed relative to the sleeve 41 and is arranged in a coaxial manner in the region of the threaded hole.

[0257] The sleeves 45 are part of the steering box 7 and each sleeve extends axially between two end faces, with one sleeve being arranged around one of the corresponding threaded holes and the other sleeve facing in the opposite direction.

[0258] In particular, the threaded member 49 has corresponding heads 46 which are fastened when the threaded member 49 is screwed into the threads of the threaded hole, and the heads 46 are fastened respectively on the opposite faces of the sleeve 45 with respect to the sleeve 45 arranged around the threaded hole.

[0259] The assembly 11 also comprises at least one absorbing element 16 for absorbing frontal impacts of the motor vehicle 1. The absorbing element 16 comprises or is more precisely a longitudinal member, ie a beam extending parallel to the direction of travel of the motor vehicle 1, in particular a box beam.

[0260] The absorption element 16 is distinct from the structure 12 and is fixed relative to the structure 12 , ie fixed to the structure 12 .

[0261] The absorption element 16 extends along a straight axis D parallel to the direction of travel of the motor vehicle 1 .

[0262] The absorption element 16 extends from the structure 12, ie it protrudes relative to the structure 12, in particular it protrudes towards the bumper 8. In particular, the absorption element 16 extends directly from the structure 12, ie it protrudes directly from the structure 12.

[0263] More specifically, the absorption element 16 extends towards the bumper 8 until it ends at an end 16 a opposite the structure 12 .

[0264] The structure 12 is arranged according to the axis D between the absorption element 16 and the body unit 2 .

[0265] In fact, the assembly 11 also comprises a further absorption element 17 , preferably identical to the previous absorption element and protruding parallel to the axis D from a further structure 12 not described in detail.

[0266] For the sake of brevity, with respect to absorbent elements 16 , 17 , the following description will only discuss absorbent element 16 , with the understanding that all teachings disclosed herein may also be applicable to absorbent element 17 .

[0267] Basically, the two parts of the assembly 11 defined respectively by the absorbent element 16 with associated structure 12 and the absorbent element 17 with associated structure 12 may be identical to each other, ie have the same properties. More precisely, every property of one part may be applicable to the other part.

[0268] Furthermore, the assembly 11 comprises a third absorbing element 18 for absorbing frontal impacts of the motor vehicle 1. The third absorbing element 18 comprises a crossbar or more precisely is a crossbar, i.e. a beam, in particular a box beam, in particular a horizontal beam, extending transversely, more precisely perpendicularly, to the direction of travel of the motor vehicle 1.

[0269] The third absorption element 18 has two ends 18a, 18b which are fixed to the absorption elements 16, 17 respectively.

[0270] The end portion 18a is fixed to the end portion 16a.

[0271] Elements 16 , 17 , 18 are each part of a crash box of component 11 .

[0272] Assembly 11 comprises a channel 120 extending continuously through absorption element 16 and structure 12 between an inlet opening 121 obtained at end 16a along axis D and an outlet opening 122 obtained in structure 12 along axis HH, towards the placement area of ​​suspension 3 or towards braking device 113 .

[0273] In particular, axis HH is transverse, or, more precisely, orthogonal to axis D.

[0274] The absorption element 18 or, more precisely, the end 18 a has ventilation openings 123 , in particular along the axis D, designed to convey air to the channel 120 through the inlet opening 121 .

[0275] More specifically, the vent 123 is aligned along the axis D with the opening 121 .

[0276] Basically, the vent 123 is adjacent to or matches the opening 121 .

[0277] Similarly, the bumper 8 has ventilation openings (not shown), in particular along the axis D, designed to direct air to the ventilation openings 123 .

[0278] More specifically, the vents of the bumper 8 are aligned along the axis D with the vents 123 .

[0279] Basically, the vents of the bumper 8 are adjacent to or match the vents 23 .

[0280] Channel 120 extends along direction 127 and comprises in particular at least two sections 125 , 126 , section 125 being parallel to axis D or more precisely coinciding with axis D and section 126 being, for example, a connection between axis D and axis H, ie it connects axes D, H.

[0281] More specifically, channel 120 is defined by segments 125 , 126 .

[0282] The segment 125 is a rectilinear portion of the channel 120 which extends along the axis D, in particular along a length which is equal to the length of the absorption element 16 along the axis D.

[0283] In other words, the straight line portion extends from the opening 121 to the structure 12 .

[0284] The absorbent element 16 is thus tubular and is crossed along the axis D from one side to the other by segments 125 .

[0285] Segment 126 is a curved end portion that extends completely inside structure 12 and ends in opening 122 .

[0286] Preferably, the curved end portion comprises a diverging segment, such as an end segment ending in opening 122 or an intermediate segment between the end segment and segment 125 .

[0287] This is not a strict limitation. In fact, in general, the channel 120 may include one or more diverging segments, which may be straight or curved. Each diverging segment may extend through the absorbent element 16 or through the structure 12.

[0288] In this particular case, segment 126 is fully divergent, although even its only terminal portion may diverge all the way to opening 122.

[0289] In particular, the diverging section thus ends with an opening 122 .

[0290] Preferably, the curved end is defined by walls 131 , 132 connected by a joint 129 having a radius that increases along the curved end toward the opening 122 .

[0291] Conveniently, the assembly 11 further comprises a fixing interface 130 fixed relative to the structure 12 and arranged around the opening 122 .

[0292] In particular, the fixing interface 130 includes a bracket that is fixed to the structure 12. More specifically, the bracket defines a frame that completely surrounds or defines the opening 122.

[0293] The fixing interface 130 is configured to allow a known diffuser device (not shown here) to be fixed to the structure 12. The function of the diffuser device is to direct the air flowing out of the opening 122 towards the brake device 113.

[0294] In the prior art, diffuser devices are usually used to direct the air flowing out of the outlet opening of a dedicated duct which does not pass through the absorption element 16 and the structure 12 but is completely separate from each of the structure 12 and the absorption element 16. This duct is clearly different from the channel 120 and is not present in the assembly 11 and, more generally, in the frame 100 or in the motor vehicle 1.

[0295] In particular, the diffuser device may be fixed to the structure 12 via the fixing interface 130 at a position where it communicates with the opening 122 so as to be able to perform its function.

[0296] For example, the diffuser device may be connected to the interface 130 by known fixing means (eg, threaded members).

[0297] In the same manner, the fixing interface 130 may be fixed to the structure 12 by known fixing means, such as threaded members.

[0298] Preferably, the structure 12 is hollow inside and is manufactured by casting. More particularly, the structure 12 has thicker walls, as they are subject to greater stresses in use, while the other walls are thinner, and may have a minimum nominal thickness of about 2 mm.

[0299] To manufacture the structure 12, low pressure sand casting is used, therefore first a model 404 of the structure 12 (usually made of resin) is manufactured which reproduces the appearance of the structure 12 and is divided into two halves 405 and 406 (lower half 405 and upper half 406).

[0300] The mold half 405 has (at least has) a protrusion 407 which will form a casting channel 408 through which molten metal 414 will be supplied in the manner described below.

[0301] Using the two halves 405 and 406 of the model 404 , two halves 409 and 410 of a mold 411 are obtained by lost sand casting (which reproduces in negative the shape of the model 404 and thus the shape of the structure 12 ).

[0302] The lower half 409 of the sand casting mold 411 has a casting channel 408 through which molten metal will be supplied in the manner described below.

[0303] In particular, the two halves 409 and 410 are joined together to form a sand casting mold 411 into which one or more inner cores 412 are inserted.

[0304] In other words, a lost core 412 is arranged inside the two halves 409 and 410 (and will be destroyed and eliminated after the components are cured), preferably also made of sand with an inorganic binder added.

[0305] The sand casting mold 411 is then placed in a feeding system 413 for supplying molten metal 414 (liquid aluminum alloy) under pressure, wherein the molten metal 414 is cast into the sand casting mold 411, and at the end of the process, when the molten metal 414 has solidified, the sand casting mold 411 will be destroyed to extract the component.

[0306] The feeding system 413 feeds the molten metal 414 into the sand casting mold 411 at a pressure of about 1.2 bar to allow the molten metal 414 to penetrate the sand casting mold 411 by completely filling the entire sand casting mold 411 .

[0307] In particular, the feed system 413 causes the molten metal to flow upward through a casting tube 415 immersed in a bath of molten metal 414 (contained in a crucible 416), preferably with a low pressure (about 1.2 bar) applied on its surface.

[0308] The feed system 413 comprises a watertight chamber 417 in which an overpressure is obtained by a pressurizing device 418. The watertight chamber 417 houses a crucible 416 containing a bath of molten metal 414 and in which a casting tube 415 is inserted, which ends in the casting channel 408 of the sand casting mold 411; in use, the overpressure in the watertight chamber 417 causes the molten metal 414 to flow upwards along the casting tube 415, which enters the sand casting mold 411.

[0309] For example, the molten metal is an aluminum alloy.

[0310] The manner in which the structure 12 ("shock tower") may be manufactured by low pressure sand casting as described above may be applicable to any other hollow component of the frame 100, particularly when the component has very thin walls (ie, having a minimum nominal thickness approaching 2 mm or between 2 mm and 3 mm).

[0311] The structure 12 also comprises a collapsible portion 20 which is situated according to the axis D between the absorbent element 16 and the attachment portion 13 .

[0312] More precisely, the foldable portion 20 extends in a direction orthogonal to the axis D and the axis C, ie from top to bottom, for the entire extension of the structure 12 in the same direction. In other words, the extension of the foldable portion 20 in the latter direction is equal to the extension of the structure 12 in the same direction.

[0313] Furthermore, in particular, the foldable portion 20 is adjacent to the absorption element 16 with respect to the axis D. In other words, the absorption element 16 protrudes from the foldable portion 20 , more in particular directly from the foldable portion 20 .

[0314] Optionally, a plurality of attachment elements 15 are arranged in the region of the foldable portion 20 .

[0315] Preferably, the structure 12 comprises the parts 13 , 20 and possibly also the attachment 15 .

[0316] The foldable portion 20 is less rigid to compression than the attachment portion 13. In other words, the compression rigidity of the foldable portion 20 is less than the compression rigidity of the attachment portion 13.

[0317] Furthermore, the compressive stiffness of the foldable portion 20 is equal to or greater than the compressive stiffness of the absorbent element 16, although this is not strictly necessary. In fact, according to alternative embodiments, the compressive stiffness of the foldable portion 20 may be less than the compressive stiffness of the absorbent element 16.

[0318] In particular, the foldable portion 20 has a compressive strength defined by a compressive stress at break value equal to any value within a range between 140 kN and 200 kN, more preferably between 160 kN and 180 kN.

[0319] Furthermore, and in more detail, the extension of the foldable portion 20 according to the axis D is less than half of the total extension of the structure 12 along the axis D, ie the distance between the absorbent element 16 and the body unit 2 .

[0320] More precisely, the extension of the foldable portion 20 according to the axis D is less than three fifths of the total extension of the structure 12 along the axis D.

[0321] In particular, the foldable portion 20 enables the maximum deceleration of the motor vehicle 1 along the axis D to be equal to any value within the range between 15G and 25G.

[0322] Preferably, the housing 41 is fixed in the region of the foldable part 20 and extends transversely with respect to the axis D, ie along the axis C. In this case, the term “in the region” means that the actual fixing point of the tubular sleeve 41 to the structure 12 belongs to the foldable part 20 .

[0323] More specifically, a threaded hole is formed in the foldable portion 20 .

[0324] In particular, according to the axis C, threaded holes are obtained on the inner sides of the absorption elements 16 , 17 or between the absorption elements 16 , 17 .

[0325] Advantageously, the tubular sleeve 41 is the only beam element or beam fixed in the region of the foldable portion 20 and extending transversely to the axis D.

[0326] In other words, the assembly 11 lacks a beam element or beam, different from the tubular sleeve 41 , which is fixed in the region of the foldable portion 20 and extends transversely to the axis D.

[0327] Thus, there are no beams or crossbars connecting the foldable portions 20 of the structure 12 extending parallel to the axis C or transverse to the axis D.

[0328] Similarly, there are no beams or crossbars connecting the foldable portion 20 of one of the structures 12 to the attachment portion 13 of another of the structures 12 .

[0329] In the embodiment shown here, the assembly 11 comprises a beam or crossbar 48 fixed to the structure 12 in the region of the attachment portion 13 .

[0330] The crossbar 48 extends transversely to the axis D or parallel to the axis C. Furthermore, preferably, the crossbar 48 is arranged between the structures 12 and, more precisely, connects the two structures 12 by being fixed to them in the region of its attachment portion 13 .

[0331] Preferably, the foldable portion 20 has a through hole along the axis C. The steering box 7 passes through the foldable portion 20 through the through hole. That is, the steering box 7 passes through the through hole along the axis C. In particular, the tie rod 40 passes through the through hole along the axis C.

[0332] More precisely, the foldable portion 20 has an end 21 , in particular an upper end, which is according to a vertical axis H, ie orthogonal to the axes D and C. The end 21 has a recess 22 which extends along the axis H towards the depth.

[0333] The recess 22 accommodates the steering box 7, or more precisely the tie rod 40. In other words, the steering box 7, or more precisely the tie rod 40, traverses the structure 12 through the recess 22, ie it traverses or extends through the recess 22 along the axis C.

[0334] The tubular sleeve 41 extends relative to the structure 12 , in particular on the side opposite to the suspension attachment 15 .

[0335] In other words, the tubular sleeve 41 extends between the structures 12 .

[0336] The tie rod 40 projects relative to the tubular sleeve 41 or, according to the axis C, extends out of the tubular sleeve 41 .

[0337] The recess 22 is open along the axis H, in particular upwardly open. In other words, the recess 22 has a mouth opening extending transversely to the axis H, ie, an upper end.

[0338] The recess 22 has a U-shape or a concave shape relative to the axis H, in particular pointing upwards.

[0339] According to the axis C, the recess 22 extends along the axis C over the entire extension or width of the foldable part 20 , ie in the region of the recess 22 itself.

[0340] Preferably, the depth of the recess 22 along the axis H is greater than at least one third of the entire extension of the foldable portion 20 along the axis H.

[0341] Furthermore, conveniently, the recess 22 has an extension parallel to the axis D that is greater than at least one third of the total extension of the foldable portion 20 along the axis D, or more preferably, at least half.

[0342] Alternatively, the ratio between the maximum extension of the recess 22 parallel to the axis D and the entire extension of the structure 12 along the axis D is equal to any value between 1 / 15 and 1 / 3.

[0343] Thus, due to the recess 22 and in the region of the recess 22 , the foldable portion 20 has a cross section relative to the axis D that is weakened compared to any cross section of the attachment portion 13 relative to the same axis D.

[0344] Therefore, in this sense, the foldable portion 20 is generally weakened relative to the attachment portion 13. This is why the compression stiffness of the foldable portion 20 is smaller than that of the attachment portion 13.

[0345] Conveniently, the foldable portion 20 may be further weakened, for example in that it comprises one or more holes 23 extending transversely to the two axes D, H, for example parallel to the axis C. In other words, the holes 23 extend transversely to the two axes D, H or parallel to the axis C in respective directions.

[0346] Optionally, the holes 23 are substantially aligned with the recesses 22 according to the axis H. Here, the term “substantially” means that at least one axis parallel to the axis H extends inside the recess 22 and at the same time intersects or is tangential to one of the holes 23 .

[0347] Each hole 33 may be a through hole of the foldable portion 20 .

[0348] Preferably, the recess 22 is aligned with the first axis D. That is, the axis D extends inside the recess 22 . For the sake of clarity, the axis D is here the axis of the beam or longitudinal member defining the absorption element 16 .

[0349] Advantageously, the assembly 11 also comprises an absorbent body 24 and releasable fixing means 25 which fix the absorbent body 24 to the foldable portion 20 in a releasable manner.

[0350] In more detail, the releasable fixing device 25 comprises a threaded element or a fixing interface, which is connected to the foldable part 20 in a fixed manner relative to the foldable part 20. In particular, the threaded element comprises a threaded hole formed in the foldable part 20 and a corresponding screw that can be screwed into the threaded hole. In particular, the threaded hole extends parallel to the axis H.

[0351] The absorption body 24 comprises or rather is preferably a plate having a thickness of less than 20 mm, more preferably less than 10 mm.

[0352] The absorbent body 24 is fixed to the foldable part 20 in the region of the recess 22 .

[0353] More precisely, the absorbent body 24 covers or defines a cover for the mouth opening of the recess 22 in the direction of the axis H.

[0354] The absorbent body 24 is provided substantially above the recessed portion 22 .

[0355] The absorption body 24 extends parallel to the axis D and its extension according to the same axis D is greater than the extension of the recess 22 .

[0356] In particular, the absorption body 24 completely covers the depression 22 or its mouth opening, in particular from above.

[0357] The thickness of the plate of the absorber 24 or the orientation of the absorber 24 along the axis H is defined.

[0358] In practice, the assembly 11 may preferably comprise a plurality of absorbent bodies which, if desired, comprise or are defined by respective panels, all differing from one another, for example, by their thickness or shape.

[0359] The plurality of absorbent bodies includes or comprises absorbent body 24, while other absorbent bodies in the plurality of absorbent bodies are not shown.

[0360] The securing means 25 is configured to releasably secure each of the plurality of absorbent bodies to the foldable portion 20 in the same position where the absorbent body was secured after the absorbent body 24 has been released and removed from its position, ie, detached from the structure 12 .

[0361] However, this is not restrictive, since other fixing means than the fixing means 25 may be used to fix each of the other absorption bodies not shown here.

[0362] The absorber 24 can therefore be replaced by any other absorber which may not actually be mounted on the motor vehicle 1 or fixed to the structure 12 .

[0363] The plurality of absorbent bodies forms a set of interchangeable components or absorbent bodies having different stiffnesses and deformability.

[0364] Alternatively, the absorbent bodies may be provided in sets and / or may be identified by different identifying markings (eg abbreviations or colors).

[0365] The frame 100 also comprises a rear frame assembly 501 which is in particular fixed relative to the body unit 2 and has a similar function to the assembly 11 , for example.

[0366] The assembly 501 comprises a structure 502 defining an engine compartment designed to house an engine for propelling the motor vehicle 1 .

[0367] The structure 502 comprises a lower portion 503 for supporting the engine and an upper portion 504 arranged to cover or protect the nacelle or the engine from above.

[0368] The upper part 504 may be considered as a part of the main body unit 2 and, in particular, forms a single body with the main body unit 2. Thus, the upper part 504 may comprise or be made of carbon fibers.

[0369] On the other hand, the lower part 503 is made of a more ductile material than the upper part 504 , ie in particular aluminum.

[0370] In addition, assembly 501 includes a rear suspension attachment structure 505 ("shock tower"), which has a similar function to structure 12. For example, structure 505 is hollow inside and can be manufactured in the same way as described for structure 12.

[0371] The upper part 504 and the lower part 503 , ie the structure 502 , are connected and more particularly fixed to a structure 505 which is arranged directly behind the structure 502 according to the direction of travel of the motor vehicle 1 .

[0372] In other words, structure 502 is arranged between passenger cabin 200 and structure 505 .

[0373] Like structure 12 , structure 505 also has a plurality of attachments 15 , which may be part of structure 505 .

[0374] Behind the structure 12, the main unit 100 or component 501 also includes another collision box, this time a rear collision box, which in turn includes absorption elements 516, 517, and 518, and the function and arrangement of the absorption elements relative to the structure 505 are basically similar to the function and arrangement of the absorption elements 16, 17, and 18 relative to the structure 12.

[0375] The elements 516 , 517 are fixed relative to the structure 505 and extend from the structure 505 protruding relative to the structure 505 towards the rear of the motor vehicle 1 .

[0376] Structure 505 is arranged between element 516 and structure 502 .

[0377] The element 518 comprises or is more precisely a crossbar, ie a beam, in particular a box beam, which extends transversely and more precisely perpendicularly to the direction of travel of the motor vehicle 1 .

[0378] The element 518 has two ends fixed to the elements 516, 517 respectively.

[0379] In summary, depending on the direction of travel of the motor vehicle 1, the frame 100 has, i.e. is arranged in order, a crash box comprising absorbing elements 16, 17, 18, preferably comprising aluminum or being made of aluminum; a structure 12, preferably comprising aluminum or being made of aluminum; a main body unit 2 (particularly comprising an upper part 504), preferably comprising carbon fiber or being made of carbon fiber; a lower part 503, preferably comprising aluminum or being made of aluminum and being arranged below the upper part 504; a structure 505, preferably comprising aluminum or being made of aluminum; and a crash box comprising elements 516, 517, 518, preferably comprising aluminum or being made of aluminum.

[0380] Due to the above reasons, the advantages of the frame 100 according to the present invention are obvious.

[0381] The material selection of each of the components of the frame 100 is optimized to minimize the overall weight of the frame 100 and, therefore, the overall weight of the motor vehicle 1 .

[0382] This selection is the result of extensive research and optimization by the applicant, including simulations and experiments on the frame 100 .

[0383] Furthermore, the production process of the described component is particularly simple, effective and inexpensive.

[0384] The arrangement and materials of the components of the frame 100 allow the overall dimensions to be optimized, facilitating the installation of devices useful for the operation of the motor vehicle 1 .

[0385] Furthermore, although the frame 100 is lighter than other known frames, the frame 100 is extremely durable and safe.

[0386] Finally, although the frame 100 according to the present invention may be subjected to changes and modifications, these changes and modifications do not depart from the scope of protection set forth in the appended claims.

[0387] In particular, the number and shapes of components described and shown herein may be different.

[0388] In addition, each described range is to be interpreted as a plurality of alternative individual values. Each individual numerical value within the range should be considered to be specifically described even if not explicitly mentioned.

[0389] Finally, the term "foldable" refers to a relative manner with respect to the attachment portion 13, and in particular refers to being more foldable than the attachment portion, provided that the preferred material of the foldable portion 20 is a ductile material, such as aluminum.

Claims

1. A frame (100) of a motor vehicle (1), comprising: a main body unit (2) defining a passenger compartment (200) of the motor vehicle (1); a front suspension attachment structure (12) comprising an attachment portion (13) fixed to the main body unit (2); an engine compartment structure (502) fixed relative to the main body unit (2) and defining an engine compartment for accommodating an engine for propelling the motor vehicle (1), the engine compartment structure (502) comprising a lower portion (503) for supporting the engine and an upper portion (504) for covering the engine compartment from the top; a rear suspension attachment structure (505) fixed to the engine compartment structure (502), the engine compartment structure (502) being arranged between the passenger compartment (200) and the rear suspension attachment structure (505) according to a first straight axis (D); one or more attachment elements (15) which are fixed relative to the front suspension attachment structure (12) and / or the rear suspension attachment structure (505) and are used to allow the suspension (3) of the motor vehicle (1) to be coupled to the frame (100) in the area for arranging the suspension (3); a front absorbing element (16) for absorbing a front collision of the motor vehicle (1), the front absorbing element (16) being different from the front suspension attachment structure (12), being fixed relative to the front suspension attachment structure (12), and extending from the front suspension attachment structure (12) along the first straight axis (D) to an end (16a) opposite to the front suspension attachment structure (12), the front suspension attachment structure (12) being arranged between the front absorbing element (16) and the main body unit (2) according to the first straight axis (D); and a rear absorbing element (516) for absorbing a rear impact of the motor vehicle (1), the rear absorbing element (516) being different from the rear suspension attachment structure (505), being fixed relative to the rear suspension attachment structure (505) and extending from the rear suspension attachment structure (505) along the first straight axis (D), the rear suspension attachment structure (505) being arranged between the rear absorbing element (516) and the engine compartment structure (502) according to the first straight axis (D); in, The front absorbent element (16) and the rear absorbent element (516) comprise aluminum; The front suspension attachment structure (12) and the rear suspension attachment structure (505) comprise aluminum; The lower portion (503) comprises aluminum, and The upper portion (504) comprises carbon fibers; Wherein, the main unit (2) comprises: at least one shell (310) comprising carbon fibers and at least two first walls (311, 312) facing each other so as to define a cavity (313) between the first walls (311, 312); and One or more carbon fiber-containing baffles (324) are arranged inside the cavity (313) according to an arrangement, and each baffle (324) extends transversely to the first wall (311, 312) between two first ends seamlessly connected to the first wall (311, 312) respectively.

2. A frame according to claim 1, wherein the channel (120) extends continuously through the front absorption element (16) and the front suspension attachment structure (12) between an inlet opening (121) obtained at the end (16a) along a first straight axis (D) and an outlet opening (122) obtained in the front suspension attachment structure (12) along a fourth axis (H) transverse to the first straight axis (D) and towards the area where the suspension (3) is placed.

3. The vehicle frame according to claim 2, wherein the front suspension attachment structure (12) further includes a foldable portion (20) located between the front absorbing element (16) and the attachment portion (13) according to the first straight axis (D), the foldable portion (20) having a first compressive stiffness that is equal to or greater than a second compressive stiffness of the front absorbing element (16) and less than a third compressive stiffness of the attachment portion (13).

4. The frame according to claim 3 further comprises a steering box (7), the steering box (7) comprising a steering tie rod (40) for steering a wheel hub (5) of the motor vehicle (1); a tubular sleeve (41) extending along a second straight axis (C); and a transmission element coupled to the steering tie rod (40) and the tubular sleeve (41) to move axially along the second straight axis (C) within the tubular sleeve (41), wherein, The tubular sleeve (41) is rigidly fixed to the front suspension attachment structure (12).

5. The frame according to claim 4, wherein: The foldable portion (20) has an end portion (21) according to a third axis (H) orthogonal to the first straight axis (D) and the second straight axis (C), and the end portion (21) has a recess (22) extending in depth along the third axis (H) and intersects with the steering box (7) along the second straight axis (C).

6. The frame according to claim 5, further comprising an absorbent body (24) and releasable fixing means (25) for releasably fixing the absorbent body (24) to the foldable portion (20) at the recess (22).

7. The frame according to claim 6, further comprising: a crossbar (211) constituting a supporting base for a windshield (206) of the motor vehicle (1); and A pair of upright posts (212) are respectively fixed at two ends of the cross bar (211) to form an area with a closed outline for placing the windshield (206); wherein the crossbar (211) comprises a first wall (214) away from the region having a closed contour; The frame further includes a pipe (220) extending through the crossbar (211) between a first opening (221) obtained on a second wall (217) of the crossbar (211) and a second opening (222) obtained on the first wall (214), wherein the first wall includes a recessed portion (223) recessed toward an opposite side relative to the region having a closed contour, and the second opening (222) is formed on the recessed portion (223).

8. A method for manufacturing a vehicle frame (100) according to any one of the preceding claims, the method comprising the following steps: a. providing a first mold (340) having an inner mold wall (343, 344) for defining the cavity (313); b. fixing the pre-cured partition (324) to the first mold (340) and the first inner wall (343) of the inner walls (343, 344) according to the arrangement inside the cavity (313); c. placing a plurality of raw carbon fiber sheets (358) on a second inner wall (344) of the inner walls (343, 344) at a position suitable for forming at least one of the first walls (311, 312); d. baking the raw carbon fiber sheet (358) disposed inside the first mold (340) together with the separator (324) in an autoclave; e. forming a second sand casting mold (411) which reproduces the front suspension attachment structure (12) or the rear suspension attachment structure (505) which is hollow inside and contains at least one lost inner core (412); f. Supplying molten metal (414) into the second sand casting mold (411) under low pressure.

9. The method according to claim 8, wherein the partition (324) is arranged inside the first mold (340) to divide the cavity (313) into a plurality of separate compartments (332).

10. The method according to claim 9, wherein the first mold (340) has a plurality of through holes (361), and the through holes (361) respectively establish connections between the corresponding compartments (332) and the outside of the first mold (340), and the method further comprises the following steps: A corresponding bag (360) is placed inside the compartment (332) in the first mold (340) so that the bag (360) has a corresponding air inlet (363) passing through the through hole (361) on the outside of the first mold (340), and the air inlet (363) is suitable for allowing pressurized air to flow into the bag (360), wherein during step d, the first mold (340) contains the bag (360) located inside the compartment (332), so that the pressurized air of the autoclave causes the bag (360) to expand during the baking process, thereby pressing the raw carbon fiber sheet (358) against the second inner wall (344) during the baking process.

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