Pickup Frame-to-Bed Assembly Weight Reduction
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Solution Overview
Problem
Current frame-to-bed assemblies for pickup trucks are heavy due to the use of cross-sills and metallic materials, leading to increased carbon emissions, reduced fuel economy, and noise issues, as well as a higher center of gravity.
Innovation Solution
A frame-to-bed assembly that eliminates the need for cross-sills by directly attaching the pickup bed to the truck frame using a mounting bracket and cross-members, reducing the overall mass and torsional loading, and incorporating corrugations on the bed for weight distribution and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cross-sills are used to support the pickup bed, then the bed support and weight distribution are improved, but the vehicle weight increases and fuel economy decreases
Solution Approach 1:
The patent removes the cross-sills from the frame-to-bed assembly, extracting the unnecessary supporting components that were causing excessive weight. The bed is directly attached to the frame rails, eliminating the need for separate cross-sill members while maintaining structural support functionality.
Solution Approach 2:
The patent merges the bed support function directly into the frame rails by attaching the bed longitudinally to them, combining what were previously separate components (frame rails, cross-sills, and bed supports) into a more integrated structure that reduces overall weight while maintaining strength.
2Strength
If cross-sills are used to support the pickup bed, then the bed support is improved, but the vehicle center of gravity increases
Solution Approach 1:
By removing the cross-sills that extended upward from the frame, the patent eliminates the component that was raising the vehicle's center of gravity. The bed attaches directly to the frame rails at a lower point, naturally lowering the center of gravity and improving vehicle stability.
3Strength
If cross-sills are used to support the pickup bed, then the bed support is improved, but noise from the bed increases
Solution Approach 1:
The patent removes the cross-sills that were generating noise through their interaction with the bed and frame. By eliminating these components, the source of the noise is removed, resulting in a quieter vehicle operation.
4Strength
If cross-sills and brackets are used to support the pickup bed, then the bed support is improved, but the assembly cost increases
Solution Approach 1:
The patent removes multiple components including cross-sills and separate brackets, reducing the total number of parts that need to be manufactured, stored, and assembled. This simplification directly reduces assembly cost and manufacturing complexity while maintaining adequate bed support.
Solution Approach 2:
The patent combines the support function into the frame rails themselves, eliminating the need for separate cross-sill and bracket components. This merging reduces the total component count and simplifies the assembly process, lowering overall manufacturing and assembly costs.
5Strength
If cross-sills are used to support the pickup bed, then the bed support is improved, but the material usage increases
Solution Approach 1:
The patent removes the cross-sills and separate bracket components, reducing the total quantity of material required for the frame-to-bed assembly. The bed attaches directly to the frame rails, eliminating the need for additional material in the form of separate support components.
Data Source
AI summary
The aspects of the present disclosure include an improved frame-to-bed assembly, which allows the pickup bed to be attached directly to the pickup truck frame without or with the reduced use of cross-sills. Instead, the pickup bed is directly attached to the frame cross-members via an attachment assembly to retain the pickup bed in place.