Vehicle Frame Rigidity via Bending-Induced Pressure Joining

Solution Overview

Problem

Existing vehicle frame manufacturing methods face challenges in increasing the rigidity of frame members without requiring additional joining processes, particularly when using extrusion molding, as altering the cross-section profile is difficult and additional processes are needed for reinforcing members.

Innovation Solution

A method involving the placement of a reinforcing member within a frame member, followed by bending to generate a reaction force and pressure join the reinforcing member to the frame member, eliminating the need for a separate joining process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a reinforcing member is joined to a frame member using traditional methods (bolts, rivets, welding, clinching), then the rigidity of the frame member is improved, but additional separate joining processes are required

Engineering Contradiction:

ImproverigidityVSAvoidnumber of joining processes

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the reinforcing member placement with the bending process itself. The reinforcing member is placed inside the frame member before bending, and the bending operation simultaneously achieves both the desired frame shape and the joining of the reinforcing member through reaction forces generated during bending.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bending process generates reaction forces that automatically join the reinforcing member to the frame member without requiring external joining equipment or separate operations. The frame member's own bending operation serves to join the reinforcing member.

Inventive Principle:

Principle #25Self-service

2Strength

If traditional joining methods are used to attach a reinforcing member, then the rigidity is improved, but surface accuracy may be lost or material properties changed

Engineering Contradiction:

ImproverigidityVSAvoidsurface accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The bending process generates reaction forces that automatically join the reinforcing member to the frame member without requiring external joining equipment or separate operations. The frame member's own bending operation serves to join the reinforcing member.

Inventive Principle:

Principle #25Self-service

3Strength

If the cross-section profile of an extrusion-molded frame member is enlarged to increase rigidity, then the rigidity is improved, but the cross-section profile cannot be easily changed

Engineering Contradiction:

ImproverigidityVSAvoidcross-section profile modification

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent separates the frame member into two functional components: the main extrusion-molded frame member that maintains its original cross-section profile, and a separate reinforcing member that can be independently designed and placed inside to provide the necessary rigidity enhancement without modifying the main frame's extrusion profile.

Inventive Principle:

Principle #1Segmentation

4Strength

If additional joining processes are provided to attach reinforcing members, then the rigidity is improved, but productivity decreases due to more process steps

Engineering Contradiction:

ImproverigidityVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent combines the reinforcing member placement with the bending process itself. The reinforcing member is placed inside the frame member before bending, and the bending operation simultaneously achieves both the desired frame shape and the joining of the reinforcing member through reaction forces generated during bending.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bending process generates reaction forces that automatically join the reinforcing member to the frame member without requiring external joining equipment or separate operations. The frame member's own bending operation serves to join the reinforcing member.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances the rigidity of the frame member by integrating the reinforcing member without additional processing steps, improving productivity and avoiding issues like surface accuracy loss or material changes associated with traditional joining methods.

Implementation Method 1

causing reaction force to be generated by the reinforcing member against the frame member which undergoes cross-sectional deformation

Methodology Applied

Scientific EffectReaction force: Reaction (physics)

Implementation Method 2

pressure joining the reinforcing member to the frame member

Methodology Applied

Scientific EffectPressure joining: Compression

Data Source

PatentUS10479414B2Vehicle frame body manufacturing method and vehicle frame structure

Publication Date: 2019.11.19 TOYOTA JIDOSHA KK

AI summary

A method of manufacturing a vehicle frame body, the method includes: a placement process of placing a reinforcing member at a portion of a frame member, the portion being located in a length direction of the frame member and within the frame member, the frame member being a single member having an elongated shape and configuring a chamber structure; and, after the placement process, a bending process of bending the frame member at a placement region of the reinforcing member, causing reaction force to be generated by the reinforcing member against the frame member undergoing cross-sectional deformation, and pressure joining the reinforcing member to the frame member.