Body-on-Frame Front End Structure with Extruded Aluminum Tubes
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Solution Overview
Problem
The typical front end structure of body on frame vehicles is limited by manufacturing processes, usable space under the hood, and headlight placement due to the constraints of hydroforming and geometric limitations.
Innovation Solution
A revised front end structure featuring left and right front tubes, a lower support with riser portions, and optional gussets and an upper bolster, utilizing extruded or roll-formed aluminum materials to enhance structural strength and flexibility, allowing for improved headlight placement and manufacturing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hydroforming process is used to create front structural members, then structural strength is achieved, but manufacturing flexibility and design freedom are limited due to minimum curvature and geometric constraints
Solution Approach 1:
The patent changes the manufacturing process from hydroforming to extrusion or roll-forming, which allows for different geometric parameters and design flexibility while maintaining structural strength through alternative cross-sectional configurations and material properties
Solution Approach 2:
The front subframe is divided into multiple separate members (left upper tube, right upper tube, lower support tie bar) that can be manufactured independently using extrusion or roll-forming processes, then assembled together, providing manufacturing flexibility and design freedom not possible with monolithic hydroformed structures
2Strength
If hydroformed single unitary bodies are used for upper tubes, then structural integrity is maintained, but usable space under the hood is reduced due to geometric limitations
Solution Approach 1:
The upper tubes are segmented into separate left and right unitary members with optimized individual paths, allowing each to follow the most efficient structural route while minimizing encroachment on engine compartment space
Solution Approach 2:
The patent optimizes the three-dimensional routing of the extruded or roll-formed tube members, utilizing vertical and lateral spacing to achieve structural integrity while maximizing horizontal clearance for engine components
3Strength
If traditional hydroformed front end structure is used, then structural strength is achieved, but placement options for headlights and other components are limited
Solution Approach 1:
Changing from hydroforming to extrusion/roll-forming processes allows for different cross-sectional shapes and member configurations that can be optimized to accommodate various component placements including headlights, while maintaining structural strength
Solution Approach 2:
The extruded or roll-formed front subframe members are designed to serve multiple functions: structural support, component mounting platforms, and spatial organizers, providing versatility for accommodating different component placements across various vehicle configurations
Data Source
AI summary
A body on frame vehicle includes left and right front tubes and a lower support. The left front tube extends above a left front wheel well of the body on frame vehicle and terminates in a forward direction at a left forward end. The right front tube extends above a right front wheel well of the body on frame vehicle and terminates in the forward direction at a right forward end. The lower support includes a lateral portion, left riser portion, and right riser portion. A left end of the lower support extends upward from the lateral portion to form the left riser portion and a right end of the lower support extends upward from the lateral portion to form the right riser portion. The left and right riser portions are affixed to the left and right front tube proximate the left forward end and the right forward end, respectively.