Extruded Metal Frame With Pierced Bars And Tabs

Solution Overview

Problem

Metal automobile frames with extruded members face a challenge in maintaining mechanical strength while minimizing weight, as forming openings in the linear bars to accommodate component parts reduces strength, necessitating increased thickness and weight.

Innovation Solution

The design incorporates hollow, extruded linear bars with controlled-strain sections and strategically placed tabs and varying thicknesses to absorb collision energy and accommodate suspension components, maintaining performance with reduced weight by optimizing the structural nodes and cross-sectional geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If openings are formed in linear bars to accommodate suspension components, then the frame can house necessary component parts, but the mechanical strength of the bar is locally reduced

Engineering Contradiction:

Improveability to accommodate suspension componentsVSAvoidmechanical strength of linear bar

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent applies local quality by varying the thickness of the linear bar specifically at the corners where openings are formed. The bar maintains its original thickness in non-critical areas but increases thickness at corners to compensate for strength loss. This localized reinforcement allows the opening to accommodate suspension components while maintaining overall structural integrity without requiring the entire bar to be thicker.

Inventive Principle:

Principle #3Local quality

2Strength

If the thickness of linear bars is increased to compensate for strength loss from openings, then mechanical strength is maintained, but the weight of the frame greatly increases

Engineering Contradiction:

Improvemechanical strength of linear barVSAvoidweight of frame

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent resolves this contradiction by applying thickness increases only locally at corner regions where openings are present, rather than uniformly throughout the entire bar. This selective reinforcement provides the necessary strength compensation at critical stress points while minimizing additional material usage and weight increase across the entire frame structure.

Inventive Principle:

Principle #3Local quality

3Strength

If the thickness of linear bars is increased to compensate for strength loss from openings, then mechanical strength is maintained, but the frame becomes heavier

Engineering Contradiction:

Improvemechanical strength of linear barVSAvoidweight of frame

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent resolves this contradiction by applying thickness increases only locally at corner regions where openings are present, rather than uniformly throughout the entire bar. This selective reinforcement provides the necessary strength compensation at critical stress points while minimizing additional material usage and weight increase across the entire frame structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8029051B2Metal automobile frame of extruded members

Publication Date: 2011.10.04 FERRARI SPA

AI summary

A metal automobile frame including a number of extruded, constant-section linear bars welded to one another at structural nodes defined by connecting bodies with pockets for housing the linear bars. A pierced linear bar includes a number of tabs, each of which is located inside the pierced linear bar, extends perpendicularly from a side of the pierced linear bar, and is sized so as not to interfere with the opening in the pierced linear bar.