Pickup Bed Cross Member With Reinforced Flange Holes
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Solution Overview
Problem
The challenge in designing a pickup truck bed is to reduce weight while maintaining durability and fuel efficiency, as aluminum alloys offer a higher strength-to-weight ratio than steel but require different fabrication techniques and joining methods, and existing designs do not effectively address the unique properties of aluminum alloys.
Innovation Solution
The design incorporates a beaded sheet metal floorpan with cross members featuring roll-formed channels and reinforced flanges, including a hole for efficient load distribution and attachment of aftermarket accessories, using aluminum alloys like 6xxx series, with stiffeners riveted to the cross members for added rigidity and minimal deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel alloys are used for the pickup bed structure, then strength and durability are maintained, but vehicle weight increases reducing fuel efficiency
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, which has a different strength-to-weight ratio. This material substitution allows weight reduction while maintaining structural integrity through careful design of the aluminum components including the cross member, floorpan, and stiffener system.
Solution Approach 2:
The patent employs composite construction by combining aluminum alloy components (cross member, floorpan, stiffeners) with appropriate joining methods (welding, riveting). This composite approach optimizes the overall structure to achieve both weight reduction and required strength characteristics.
2Weight of moving object
If aluminum alloys are used to reduce weight, then fuel efficiency improves, but structural durability and load-bearing capacity may be compromised
Solution Approach 1:
The patent applies local quality enhancement by adding stiffeners at specific locations where structural support is needed. The cross member includes reinforced flanges and strategically positioned stiffeners that provide localized strength enhancement without requiring the entire structure to be heavier, thus maintaining durability while preserving weight advantages.
Solution Approach 2:
The patent incorporates bead patterns in the floorpan and curved geometries in the cross member design. These curved and beaded features increase the moment of inertia and structural rigidity of the aluminum components, improving load-bearing capacity and durability while maintaining the weight benefits of aluminum alloy construction.
3Ease of operation
If cross members are designed with holes for accessory attachment, then versatility and ease of operation improve, but structural strength and rigidity may be reduced
Solution Approach 1:
The patent incorporates pre-formed holes in the cross member flanges during the roll-forming process. These holes are strategically positioned to align with common accessory mounting requirements, allowing customers to easily install accessories without drilling. The holes are designed in advance to minimize structural impact while maximizing utility.
Solution Approach 2:
The patent reinforces the areas around the holes with additional material or stiffening features in the flanges. This local reinforcement maintains the structural integrity and load-bearing capacity of the cross member while providing the necessary openings for accessory attachment, thus resolving the contradiction between versatility and strength.
4Adaptability or versatility
If flanges are designed with holes for fasteners, then ease of accessory attachment improves, but bearing area and structural integrity are reduced
Solution Approach 1:
The patent designs the flanges with variable width, making them wider in the regions where fastener bearing is required. This local width enhancement provides increased bearing area to compensate for the presence of holes, ensuring that the flanges can adequately support accessory loads while still providing attachment capability.
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 design effectively transmits loads to the frame rails with minimal deflection and stress, allowing for efficient attachment of accessories while maintaining structural integrity and weight reduction, thus addressing the need for a durable and fuel-efficient pickup truck bed.
Implementation Method 1
The cross member includes front and rear flanges welded to the floorpan between the beads
Implementation Method 2
the cross member is fabricated by roll forming which results in a cross member with a constant cross section
Implementation Method 3
A stiffener may be riveted to the cross member to stiffen the cross member near the point at which the cross member is bolted to frame rails
Data Source
AI summary
One of more cross members of a pickup bed structure include a hole in a flange in a location that is advantageous for installation of aftermarket accessories. The hole does not extend through the floorpan itself. When customers install aftermarket accessories that require holes through the floorpan, the customers are encouraged to align the new holes with the holes in the cross members. Consequently, loads applied by the aftermarket accessories are efficiently transferred to the frame rails.