Vehicle frame and corresponding joint structure

Abstract

The present disclosure provides a frame and a corresponding joint structure. A joint structure for a vehicle frame includes a first structural tube, a second structural tube, and a pin. The first structural tube has a first panel and a second panel opposed to each other. The first structural tube has a third panel and a fourth panel opposed to each other. The second structural tube extends through the first panel and the second panel. The second structural tube has a fifth panel and a sixth panel opposite to each other. The pin is secured to the first structural tube. The pin extends through the third panel, to the fifth panel, through the fifth panel, to the sixth panel, through the sixth panel, to the fourth panel, and through the fourth panel. The first structural tube, the second structural tube, and the pin are configured such that the first structural tube, the second structural tube, and the pin are co-operable to resist shear and bending forces between the first structural tube and the second structural tube.

Description

Technical Field

[0001] This disclosure relates to vehicle body structure and / or frame structure. Background Technology

[0002] Vehicles and automobiles include a body and / or frame, which operate as a basic support structure for other subsystems of the vehicle (e.g., powertrain, steering system, etc.). Summary of the Invention

[0003] A vehicle frame includes a front longitudinal beam, a front deflector, and a pin. The front longitudinal beam has a first side, a second side, a third side, and a fourth side; the front longitudinal beam defines a first cavity between the first side, the second side, the third side, and the fourth side. The first side and the second side are opposite to each other. The third side and the fourth side are opposite to each other. The third side and the fourth side are transverse to the first side and the second side. The front deflector extends laterally outward from the front longitudinal beam. The front deflector extends through the first side, the first cavity, and the second side. The front deflector includes a fifth side and a sixth side opposite to each other. The front deflector defines a second cavity between the fifth side and the sixth side. The fifth side and the sixth side are transverse to the first side and the second side. The pin is secured to the front longitudinal beam. The pin extends through the third side, the first cavity, the fifth side, the second cavity, the sixth side, and the fourth side, such that the front longitudinal beam, the front deflector, and the pin form a joint, the joint being operable to resist shear and bending forces between the front longitudinal beam and the front deflector.

[0004] A joint structure for a vehicle frame includes a first structural tube, a second structural tube, and a pin. The first structural tube has a first panel and a second panel opposite to each other. The first structural tube also has a third panel and a fourth panel opposite to each other. The second structural tube extends through the first panel and the second panel. The second structural tube has a fifth panel and a sixth panel opposite to each other. The pin is secured to the first structural tube. The pin extends through the third panel, reaches the fifth panel, passes through the fifth panel, reaches the sixth panel, passes through the sixth panel, reaches the fourth panel, and passes through the fourth panel, such that the first structural tube, the second structural tube, and the pin can operate together to resist shear and bending forces between the first structural tube and the second structural tube.

[0005] A vehicle includes a traction battery and a frame. The traction battery is configured to store and provide power to propel the vehicle. The frame is operable to support the traction battery. The front end of the frame includes a first structural tube, a second structural tube, and a pin. The first structural tube extends between a forward region and a rearward region of the vehicle. The first structural tube has a first top side, a first bottom side, a first lateral side, and a second lateral side. The first structural tube defines a first cavity between the first top side, the first bottom side, the first lateral side, and the second lateral side. A second structural tube is secured to the first structural tube. The second structural tube extends through the first lateral side, the first cavity, and the second lateral side. The second structural tube has a second top side and a second bottom side. The second structural tube defines a second cavity between the second top side and the second bottom side. The pin is secured to the first structural tube. The pin extends through the first top side, the first cavity, the second top side, the second cavity, the second bottom side, and the first bottom side, such that the first structural tube, the second structural tube, and the pin form a joint, the joint being operable to resist shear and bending forces between the first and second structural tubes. Attached Figure Description

[0006] Figure 1 It is a perspective top view of the lower part or lower structure of the vehicle frame, including the front frame structure and the rear underbody structure;

[0007] Figure 2 It is a right-side perspective front view of a part of the front frame structure, wherein the elements of said part of the front frame structure form structural joints;

[0008] Figure 3 It is a left-side perspective front view of the portion of the front frame structure including the elements forming the structural joint;

[0009] Figure 4 It is an exploded perspective rear view of the portion of the front frame structure including the elements forming the structural joints;

[0010] Figure 5 It is a front view of the portion of the front frame structure including the elements forming the structural joint;

[0011] Figure 6 It is an enlarged perspective bottom front view of the front frame structure, including the elements forming the structural joints, and shows the intersection between the structural tubes and pins; and

[0012] Figure 7 It is an enlarged perspective top front view of the front frame structure including the elements forming the structural joints, and shows the intersection between the structural tubes and pins. Detailed Implementation

[0013] This document describes embodiments of the present disclosure. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to adopt the embodiments in different ways. As will be understood by those skilled in the art, various features illustrated and described with reference to any of the drawings may be combined with features illustrated in one or more other drawings to produce embodiments not explicitly illustrated or described. Combinations of illustrated features provide representative embodiments for typical applications. However, for a particular application or implementation, various combinations and modifications of features consistent with the teachings of this disclosure may be desired.

[0014] refer to Figure 1 The diagram illustrates a vehicle 10 having a frame 12. More specifically, the frame 12 may be a lower portion or substructure of the frame 12. The frame 12 includes a front end or front frame structure 14 and a rear underbody structure 16, as well as additional frame sub-components forming the frame 12 or more specifically, the lower portion of the frame 12. The additional frame sub-components may include shock absorbers or strut towers 18, a first lower side beam longitudinal or side beam and a second lower side beam longitudinal or side beam 20, and a trunk support structure 22. The shock absorbers or strut towers 18 may include a pair of shock absorbers or strut towers 18 arranged along the wheel chambers of the frame 12. The first and second side beams 20 may also be referred to as a pair of lower side beam longitudinal or side beams 20. The first pair of shock absorbers or strut towers 18 may be attached to the front frame structure 14, while the second pair of shock absorbers or strut towers 18 may be attached to the rear underbody structure 16. The first side beam and the second side beam 20 extend between the forward region of the vehicle 10 or the frame 12 (e.g., the region where the front frame structure 14 is located) and the rearward region of the vehicle 10 or the frame 12 (e.g., the region where the rear underbody structure 16 is located).

[0015] The front frame structure 14 can be fixed to an additional frame sub-component along the front end of the first lower side longitudinal beam or side beam and the second lower side longitudinal beam or side beam 20, or more specifically, fixed to the first lower side longitudinal beam or side beam and the second lower side longitudinal beam or side beam 20. More specifically, the rear outer ends of the first front longitudinal beam and the second front longitudinal beam 24 of the front frame structure 14 can be fixed to the front end of the first lower side longitudinal beam or side beam and the second lower side longitudinal beam or side beam 20. The first front longitudinal beam and the second front longitudinal beam 24 can also be referred to as front flared members. The first side beam and the second side beam 24 extend in a direction between the forward region of the vehicle 10 or the frame 12 (e.g., the region where the front frame structure 14 is located) and the rearward region of the vehicle 10 or the frame 12 (e.g., the region where the rear underbody structure 16 is located).

[0016] The first and second front deflectors 25 can be fixed to the first and second front longitudinal beams 24. The first and second front deflectors 25 can be referred to as sparrow components and can be operable to absorb energy. The rear vehicle bottom structure 16 can be fixed to an additional frame component along the rear end of the first and second lower side beam longitudinal or side beams 20, or more specifically, to the first and second lower side beam longitudinal or side beams 20. More specifically, the front ends of the opposing first and second rear side members 26 can be fixed to the rear ends of the first and second lower side beam longitudinal or side beams 20.

[0017] The passenger compartment space 28 can be defined between the front frame structure 14, the rear underbody structure 16, and the first lower side longitudinal beam or side beam and the second lower side longitudinal beam or side beam 20. A crossbeam 30 can extend between the front and rear ends of the first lower side longitudinal beam or side beam and the second lower side longitudinal beam or side beam 20. At least one crossbeam 32 can extend between the first front longitudinal beam and the second front longitudinal beam 24. At least one crossbeam 34 can extend between the rear side beams 26.

[0018] The trunk support structure 22 includes a first rear side beam and a second rear side beam 36, a trunk floor support member 38, and a rear support member or bumper support member 40. The first and second rear side beams 36 may also be referred to as a pair of rear side beams 36. The front ends of the first and second rear side beams 36 can be respectively fixed to the rear ends of opposing first and second rear side members 26. The bumper support member 40 can extend between and be fixed to the rearward regions of the first and second rear side beams 36. The trunk floor support member 38 can be disposed between the first and second rear side beams 36. The trunk floor support member 38 can extend between a rearward crossbeam in at least one crossbeam 34 and the bumper support member 40. The trunk floor support member 38 can be fixed to each of the rearward crossbeam in at least one crossbeam 34 and the bumper support member 40.

[0019] Vehicle 10 may include a traction battery 42 configured to store and provide power to propel vehicle 10. Frame 12 may be operable to support the traction battery 42. The traction battery 42 may be disposed between and secured to each of the first and second lower side beams. However, it should be noted that, in addition to or in place of the traction battery 42, the frame may be operable to support other powertrain components. For example, in some configurations, vehicle 10 may not include a traction battery or an electric motor powered by a battery to propel the vehicle, but may include an internal combustion engine to propel vehicle 10. In other configurations, vehicle 10 may not include an internal combustion engine and may only include a traction battery and a corresponding electric motor to propel vehicle 10. In still other configurations, the vehicle may include a traction battery, an electric motor, and an internal combustion engine.

[0020] The sub-components of the frame 12 may be fastened to each other by fasteners (e.g., screws, rivets, bolts, etc.), adhesives, welding, press fitting, or any other method known in the art. The sub-components of the frame 12 may be made of steel, aluminum, magnesium, titanium, or any other material that can serve as a support structure for other components and subsystems of the vehicle.

[0021] refer to Figures 2 to 7 This shows a portion of the front frame structure 14. Figures 2 to 7 The components of the front frame structure shown form structural joint 44. More specifically, structural joint 44 includes one of the front longitudinal beams 24 and one of the front deflectors 25. The front longitudinal beams 24 and the front deflectors 25 may be structural tubes. Figures 2 to 7 The front longitudinal beam 24 and the front deflector 25 shown can be referred to as the first structural tube and the second structural tube, respectively, or vice versa. The cross-section of each of the first structural tube and the second structural tube, including the front longitudinal beam 24 and the front deflector 25, can be rectangular.

[0022] The front longitudinal beam 24 has a first panel or side 46, a second panel or side 48, a third panel or side 50, and a fourth panel or side 52. The first side 46 and the second side 48 are opposite to each other (e.g., positioned on opposite sides of the front longitudinal beam 24). The third side 50 and the fourth side 52 are opposite to each other (e.g., positioned on opposite sides of the front longitudinal beam 24). The first side 46 and the second side 48 are transverse to the third side 50 and the fourth side 52 (e.g., the first side 46 and the second side 48 each extend between the third side 50 and the fourth side 52, the third side 50 and the fourth side 52 each extend between the first side 46 and the second side 48, the first side 46 and the second side 48 are each orthogonal to the third side 50 and the fourth side 52, etc.). The first side 46, the second side 48, the third side 50, and the fourth side 52 define a cavity 54 therebetween.

[0023] The first side 46 may be a first transverse panel or a first transverse side of the front longitudinal beam 24. The second side 48 may be a second transverse panel or a second transverse side of the front longitudinal beam 24. The third side 50 may be a top panel or a top side of the front longitudinal beam 24. The fourth side 52 may be a bottom panel or a bottom side of the front longitudinal beam 24. The front longitudinal beam 24 may be formed by two panels 56 having a C-shaped cross-section. The C-shaped cross-sections may be fixed to each other along the overlapping area of ​​the C-shaped cross-sections. The panels 56 may be fixed to each other by any method known in the art. For example, the panels 56 may be fixed to each other by adhesives, welding, fasteners (e.g., rivets, bolts, screws, clips, snaps), etc.

[0024] The front deflector 25 extends laterally outward from the front longitudinal beam 24 along the vehicle 10 or along the frame 12 (e.g., the front deflector 25 extends outward from the front longitudinal beam 24 in a direction orthogonal to the direction extending between the forward and rearward regions of the vehicle 10 or frame 12). The front deflector 25 also extends through a first side 46 of the front longitudinal beam 24, a cavity 54 defined by the elements of the front longitudinal beam 24, and a second side 48 of the front longitudinal beam 24.

[0025] The front deflector 25 has a first panel or side 58, a second panel or side 60, a third panel or side 62, and a fourth panel or side 64. To distinguish it from the panels or sides of the front longitudinal beam 24, the first panel or side 58 may be referred to as the fifth panel or side, the second panel or side 60 may be referred to as the sixth panel or side, the third panel or side 62 may be referred to as the seventh panel or side, and the fourth panel or side 64 may be referred to as the eighth panel or side.

[0026] First side 58 and second side 60 are opposite to each other (e.g., positioned on opposite sides of the front deflector 25). Third side 62 and fourth side 64 are opposite to each other (e.g., positioned on opposite sides of the front deflector 25). First side 58 and second side 60 are transverse to third side 62 and fourth side 64 (e.g., first side 58 and second side 60 each extend between third side 62 and fourth side 64, third side 62 and fourth side 64 each extend between first side 58 and second side 60, first side 58 and second side 60 each are orthogonal to third side 62 and fourth side 64, etc.). First side 58, second side 60, third side 62 and fourth side 64 define a cavity 66 between them.

[0027] The first side 58 can be the top panel or top side of the front deflector 25. The second side 60 can be the bottom panel or bottom side of the front deflector 25. Therefore, the first side 58 and the second side 60 of the front deflector 25 can be transverse to (e.g., orthogonal to) the first side 46 and the second side 48 of the front longitudinal beam. The third side 62 can be the first transverse panel or the first transverse side of the front deflector 25. The fourth side 64 can be the second transverse panel or the second transverse side of the front deflector 25. Therefore, the third side 62 and the fourth side 64 of the front deflector 25 can be transverse to (e.g., orthogonal to) the third side 50 and the fourth side 52 of the front longitudinal beam 24.

[0028] The front deflector 25 may be formed of two panels 68 having a C-shaped cross-section and being secured to each other along the overlapping area of ​​the C-shaped cross-section. The panels 68 may be secured to each other by any method known in the art. For example, the panels 68 may be secured to each other by adhesives, welding, fasteners (e.g., rivets, bolts, screws, clips, snaps), etc.

[0029] Pin 70 is secured to front longitudinal beam 24. Pin 70 may comprise a solid or hollow element, such as a shaft or tube, respectively. Pin 70 extends through a third side 50 of front longitudinal beam 24, through a first portion of a cavity 54 defined by elements of front longitudinal beam 24, to a first side 58 of front deflector 25, through the first side 58 of front deflector 25, through a cavity 66 defined by elements of front deflector 25, to a second side 60 of front deflector, through the second side 60 of front deflector, through a second portion of a cavity 54 defined by elements of front longitudinal beam 24, to a fourth side 52 of front longitudinal beam 24, and through the fourth side 52 of front longitudinal beam 24, such that front longitudinal beam 24, front deflector 25, and pin 70 form a structural joint 44 operable to resist shear and bending forces between front longitudinal beam 24 and front deflector 25. In other words, the front longitudinal beam 24, the front deflector 25, and the pin 70 can work together to resist the shear and bending forces between the front longitudinal beam 24 and the front deflector 25.

[0030] The front deflector 25 tapers along the cross-section 72 of the portion or region 74 of the front deflector 25 disposed within the cavity 54 defined by the elements of the front longitudinal beam 24 in a direction 76 extending from the first side 46 and toward the second side 48 of the front longitudinal beam 24 (e.g., in a direction laterally across the front longitudinal beam 24). The first side 46 and the second side 48 of the front longitudinal beam 24 define aligned openings 78. The front deflector 25 extends through the aligned openings 78. The aligned openings 78 are sized differently to accommodate the taper of the front deflector 25 along the cross-section 72 of the portion or region 74 of the front deflector 25 disposed within the cavity 54.

[0031] The front deflector 25 can be secured to the front longitudinal beam 24 by any method known in the art. For example, the front deflector 25 can be attached to the front longitudinal beam 24 via an adhesive within or along the aligned opening 78; the front deflector 25 can be press-fitted into the aligned opening 78; the front deflector 25 can be welded to the front longitudinal beam 24 along the aligned opening 78; and so on. More specifically, the front deflector 25 and the front longitudinal beam 24 can each be welded to a bridging plate 80, which is disposed along the outside of the front longitudinal beam 24 and around the outer periphery of the aligned opening 78. The bridging plate 80 is located in… Figure 2 and Figure 3 As shown in the image, but for ease of explanation, it has been removed from the original text. Figures 4 to 7 Excluded from the list.

[0032] The third side 50, the fourth side 52, the first side 58, and the second side 60 of the front deflector 25 may define aligned orifices 82. A pin 70 extends through each of the aligned orifices 82. The aligned orifices 82 defined by the first side 58 and the second side 60 of the front deflector 25 provide clearance for the pin 70, such that the pin 70 does not contact the front deflector 25 within the aligned orifices 82 defined by the first side 58 and the second side 60 of the front deflector 25. In an alternative configuration, the pin 70 may be attached to the front deflector 25 via adhesive, welding, press fitting, etc., along the aligned orifices 82 defined by the first side 58 and the second side 60 of the front deflector 25. The pin 70 may be connected to the front longitudinal beam 24 within the aligned orifices 82 defined by the third side 50 and the fourth side 52 of the front longitudinal beam 24.

[0033] Pin 70 can be attached to the front longitudinal beam 24 by any method known in the art. For example, pin 70 can be attached to the front longitudinal beam 24 via an adhesive within or along said aligned aperture 82 defined by the front longitudinal beam 24, pin 70 can be press-fitted into said aligned aperture 82 defined by the front longitudinal beam 24, pin 70 can be welded to the front longitudinal beam along said aligned aperture 82, etc. Furthermore, or in addition to the attachment methods described herein, pin 70 and front longitudinal beam 24 can each be welded to a reinforcing plate or support plate 84. Such a reinforcing plate or support plate 84 can be disposed on a third side 50 of the front longitudinal beam 24 and surround the outer periphery of said aligned aperture 82 defined by the third side 50 of the front longitudinal beam 24. Support plate 84 can define additional apertures in said aligned aperture 82, said additional apertures being further operable to receive pin 70.

[0034] The first side 46, the second side 48, the third side 50, and the fourth side 52 of the front longitudinal beam 24 form a first outer wall 86. The first side 58, the second side 60, the third side 62, and the fourth side 64 of the front deflector 25 form a second outer wall 88. When the pin 70 is in the form of a hollow tube instead of a solid shaft, the pin can form a third outer wall 90. The ratio of the thickness of the third outer wall 90 of the pin 70 to the thickness of the first outer wall 86 of the front longitudinal beam 24 can be in the range of 1.25 to 1.75. The ratio of the thickness of the third outer wall 90 of the pin 70 to the thickness of the second outer wall 88 of the front deflector 25 can be in the range of 0.6 to 0.95. The ratio of the thickness of the second outer wall 88 of the front deflector 25 to the thickness of the first outer wall 86 of the front longitudinal beam 24 can be in the range of 1.5 to 2.0.

[0035] Vehicle 10 or frame 12 may include two structural joints 44 (including front longitudinal beam 24, front deflector 25, and pin 70) on opposite lateral sides of vehicle 10 or frame 12. The two joints 44 may be mirror images of each other. The pin 70 is positioned within the joint 44 to resist shear and bending forces that may exist between the front longitudinal beam 24 and the front deflector 25.

[0036] The front longitudinal beam 24, front deflector 25, pin 70, bridge plate 80, support plate 84, and any other components of the frame 12 can be made of any desired structural material, such as metal or composite material. For example, the front longitudinal beam 24, front deflector 25, pin 70, bridge plate 80, support plate 84, and other components of the frame 12 can be made of steel, aluminum, magnesium, titanium, etc. As another example, the front longitudinal beam 24, front deflector 25, pin 70, bridge plate 80, support plate 84, and other components of the frame 12 can be made of fiber-reinforced plastic. Fiber-reinforced plastic (also known as fiber-reinforced polymer) is a composite material made of a polymer matrix reinforced with fibers. The fibers can be glass fibers, carbon fibers, basalt fibers, aramid fibers, or other suitable reinforcing materials. The polymer can be epoxy resin, vinyl ester resin, polyester thermosetting plastic, phenolic resin, or other suitable polymers or plastics. Fiber-reinforced plastics can also be thermosetting and / or pressure-cured.

[0037] It should be understood that the designations of first, second, third, fourth, etc., for any component, state, or condition described herein may be rearranged in the claims such that they are arranged chronologically with respect to the claims. Furthermore, it should be understood that if one or more specific components, states, or conditions are claimed, any component, state, or condition without a numerical name described herein may be given the names first, second, third, fourth, etc., in the claims.

[0038] The terms used in this specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of the various embodiments may be combined to form other embodiments that may not be explicitly described or illustrated. While various embodiments may have been described as providing advantages or preference over other embodiments or prior art implementations in terms of one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system properties, depending on the specific application and implementation. Thus, embodiments described as less desirable than other embodiments or prior art implementations in terms of one or more characteristics are within the scope of this disclosure and may be desirable for a particular application.

[0039] According to the present invention, a vehicle frame is provided, the vehicle frame having: a front longitudinal beam having a first side, a second side, a third side, and a fourth side, and defining a first cavity between the first side, the second side, the third side, and the fourth side, wherein (i) the first side and the second side are opposite to each other, (ii) the third side and the fourth side are opposite to each other, and (iii) the third side and the fourth side are transverse to the first side and the second side; a front deflector extending transversely outward from the front longitudinal beam, wherein the front deflector (i) extends through the first side, the first cavity, and the second side. The front longitudinal beam (i) includes a fifth side and a sixth side, which are opposite to each other, and (iii) defines a second cavity between the fifth side and the sixth side, wherein the fifth side and the sixth side are transverse to the first side and the second side; and a pin (i) secured to the front longitudinal beam, and (ii) extending through the third side, the first cavity, the fifth side, the second cavity, the sixth side, and the fourth side, such that the front longitudinal beam, the front deflector, and the pin form a joint operable to resist shear and bending forces between the front longitudinal beam and the front deflector.

[0040] According to one embodiment, the cross-section of the portion of the front deflector disposed within the first cavity tapers in a direction extending from the first side of the front longitudinal beam toward the second side.

[0041] According to one embodiment, the first and second sides of the front longitudinal beam define aligned openings through which the front deflector extends, and the aligned openings are of different sizes to accommodate the taper along the cross-section of the portion of the front deflector.

[0042] According to one embodiment, the third side of the front longitudinal beam, the fourth side of the front longitudinal beam, the fifth side of the front deflector, and the sixth side of the front deflector define aligned orifices, and wherein the pin extends through each of the aligned orifices.

[0043] According to one embodiment, the aligned aperture defined by the fifth side and the sixth side of the front deflector provides a clearance for the pin, such that the pin does not contact the front deflector within the aligned aperture.

[0044] According to an embodiment, the invention is further characterized by a support plate disposed on the third side of the front longitudinal beam, wherein the pin is fixed to the support plate.

[0045] According to the present invention, a joint structure for a vehicle frame is provided, the joint structure comprising: a first structural tube having a first panel and a second panel opposite to each other and having a third panel and a fourth panel opposite to each other; a second structural tube extending through the first panel and the second panel, wherein the second structural tube has a fifth panel and a sixth panel opposite to each other; and a pin secured to the first structural tube, wherein the pin extends through the third panel, to the fifth panel, through the fifth panel, to the sixth panel, through the sixth panel, to the fourth panel, and through the fourth panel, such that the first structural tube, the second structural tube, and the pin are operable together to resist shear and bending forces between the first structural tube and the second structural tube.

[0046] According to one embodiment, the cross-section of a portion of the second structural tube tapers in a direction extending from the first panel of the first structural tube toward the second panel.

[0047] According to one embodiment, the first panel and the second panel of the first structural tube define aligned openings through which the second structural tube extends, and the aligned openings are of different sizes to accommodate the taper along the cross-section of the portion of the second structural tube.

[0048] According to one embodiment, the third panel of the first structural tube, the fourth panel of the first structural tube, the fifth panel of the second structural tube, and the sixth panel of the second structural tube define aligned orifices, and wherein the pin extends into each of the aligned orifices.

[0049] According to one embodiment, the aligned aperture defined by the fifth panel and the sixth panel of the second structural tube provides a gap for the pin, such that the pin does not contact the second structural tube within the aligned aperture.

[0050] According to an embodiment, the invention is further characterized by a support plate disposed on the third panel of the first structural tube, wherein the pin is fixed to the support plate.

[0051] According to one embodiment, the first structural tube is a front longitudinal beam.

[0052] According to one embodiment, the second structural tube is a front deflector.

[0053] According to the present invention, a vehicle is provided comprising: a traction battery configured to store and provide power to propel the vehicle; and a frame operable to support the traction battery, wherein a front end of the frame includes a first structural tube extending between a forward region and a rearward region of the vehicle, wherein the first structural tube has a first top side, a first bottom side, a first lateral side, and a second lateral side, and defines a first cavity between the first top side, the first bottom side, the first lateral side, and the second lateral side; a second structural tube fixed to the first structural tube, wherein the second structural tube extends through the first lateral side, the first cavity, and the second lateral side, and wherein the second structural tube has a second top side and a second bottom side and defines a second cavity between the second top side and the second bottom side; and a pin fixed to the first structural tube, wherein the pin extends through the first top side, the first cavity, the second top side, the second cavity, the second bottom side, and the first bottom side, such that the first structural tube, the second structural tube, and the pin form a joint, the joint operable to resist shear and bending forces between the first structural tube and the second structural tube.

[0054] According to one embodiment, the cross-section of a portion of the second structural tube tapers in a direction extending from the first lateral side of the first structural tube toward the second lateral side.

[0055] According to one embodiment, the first lateral side and the second lateral side of the first structural tube define aligned openings, the second structural tube extending through the aligned openings, and the aligned openings being of different sizes to accommodate the taper along the cross-section of the portion of the second structural tube.

[0056] According to one embodiment, the first top side of the first structural tube, the first bottom side of the first structural tube, the second top side of the second structural tube, and the second bottom side of the second structural tube define aligned orifices, and wherein the pin extends into each of the aligned orifices.

[0057] According to one embodiment, the aligned orifice defined by the second top side and the second bottom side of the second structural tube provides a gap for the pin, such that the pin does not contact the second structural tube within the aligned orifice.

[0058] According to one embodiment, the first structural tube is a front longitudinal beam, and the second structural tube is a front deflector.

Claims

1. A frame comprising: A front longitudinal beam having a first side, a second side, a third side and a fourth side, and defining a first cavity between the first side, the second side, the third side and the fourth side, wherein (i) the first side and the second side are opposite to each other, (ii) the third side and the fourth side are opposite to each other, and (iii) the third side and the fourth side are transverse to the first side and the second side; A front deflector extending laterally outward from the front longitudinal beam, wherein the front deflector (i) extends through the first side, the first cavity and the second side, (ii) includes a fifth side and a sixth side opposite to each other, and (iii) defines a second cavity between the fifth side and the sixth side, wherein the fifth side and the sixth side are transverse to the first side and the second side; as well as A pin (i) is fixed to the front longitudinal beam and (ii) extends through the third side, the first cavity, the fifth side, the second cavity, the sixth side, and the fourth side, such that the front longitudinal beam, the front deflector, and the pin form a joint that is operable to resist shear and bending forces between the front longitudinal beam and the front deflector.

2. The frame according to claim 1, wherein the cross-section of the portion of the front deflector disposed within the first cavity tapers in a direction extending from the first side of the front longitudinal beam toward the second side.

3. The frame of claim 2, wherein the first and second sides of the front longitudinal beam define aligned openings, the front deflector extends through the aligned openings, and the aligned openings are sized differently to accommodate the taper along the cross-section of the portion of the front deflector.

4. The frame of claim 1, wherein the third side of the front longitudinal beam, the fourth side of the front longitudinal beam, the fifth side of the front deflector, and the sixth side of the front deflector define aligned orifices, and wherein the pin extends through each of the aligned orifices.

5. The frame of claim 4, wherein the aligned aperture defined by the fifth side and the sixth side of the front deflector provides clearance for the pin such that the pin does not contact the front deflector within the aligned aperture.

6. The frame according to claim 1, further comprising a support plate disposed on the third side of the front longitudinal beam, wherein the pin is fixed to the support plate.

7. A joint structure for a vehicle frame, comprising: The first structural tube has a first panel and a second panel facing each other, and a third panel and a fourth panel facing each other; A second structural tube extends through the first panel and the second panel, wherein the second structural tube has a fifth panel and a sixth panel opposite to each other; as well as A pin, which is fixed to the first structural tube, extends through the third panel, to the fifth panel, through the fifth panel, to the sixth panel, through the sixth panel, to the fourth panel, and through the fourth panel, such that the first structural tube, the second structural tube, and the pin can operate together to resist shear and bending forces between the first structural tube and the second structural tube.

8. The joint structure according to claim 7, wherein the cross-section along a portion of the second structural tube tapers in a direction extending from the first panel of the first structural tube toward the second panel.

9. The connector structure of claim 8, wherein the first panel and the second panel of the first structural tube define aligned openings, the second structural tube extending through the aligned openings, and the aligned openings are sized differently to accommodate the taper along the cross-section of the portion of the second structural tube.

10. The connector structure of claim 7, wherein the third panel of the first structural tube, the fourth panel of the first structural tube, the fifth panel of the second structural tube, and the sixth panel of the second structural tube define aligned orifices, and wherein the pin extends into each of the aligned orifices.

11. The connector structure of claim 10, wherein the aligned orifice defined by the fifth panel and the sixth panel of the second structural tube provides a clearance for the pin such that the pin does not contact the second structural tube within the aligned orifice.

12. The joint structure according to claim 7, further comprising a support plate disposed on the third panel of the first structural tube, wherein the pin is fixed to the support plate.

13. The joint structure according to claim 7, wherein the first structural tube is a front longitudinal beam.

14. The connector structure according to claim 7, wherein the second structural tube is a front deflector.

15. A vehicle comprising: A traction battery, configured to store and provide power to propel the vehicle; as well as A frame operable to support the traction battery, wherein the front end of the frame includes: A first structural tube extending between the forward and rearward regions of the vehicle, wherein the first structural tube has a first top side, a first bottom side, a first lateral side and a second lateral side, and defines a first inner cavity between the first top side, the first bottom side, the first lateral side and the second lateral side; A second structural tube, the second structural tube being fixed to the first structural tube, wherein the second structural tube extends through the first lateral side, the first inner cavity, and the second lateral side, and wherein the second structural tube has a second top side and a second bottom side and defines a second inner cavity between the second top side and the second bottom side; and A pin is fixed to the first structural tube, wherein the pin extends through the first top side, the first inner cavity, the second top side, the second inner cavity, the second bottom side, and the first bottom side, such that the first structural tube, the second structural tube, and the pin form a joint, the joint being operable to resist shear and bending forces between the first structural tube and the second structural tube.

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