Tab and Slot Vehicle Frame Construction
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Solution Overview
Problem
Traditional vehicle frame designs are large, heavy, expensive, and difficult to manufacture, and do not allow for customization during the initial build based on specific component selections, with welding increasing complexity and weight.
Innovation Solution
A method using tab and slot members to construct a custom vehicle frame, where a tab and slot panel is placed in proximity to unconstrained components, measuring distances to create interlocking frame members that are welded together, allowing for customizable and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to attach vehicle components to the frame, then structural strength is improved, but manufacturing complexity and weight increase
Solution Approach 1:
The vehicle frame is divided into multiple modular frame members, each with integrated tab and slot features. These segmented members can be independently manufactured and then assembled together through mechanical interlocking, reducing manufacturing complexity while maintaining structural integrity through the distributed connection points throughout the frame structure.
Solution Approach 2:
The tab and slot connection features are integrally formed as part of the frame members themselves during the initial build process. This merging of the connection features into the frame structure eliminates the need for separate attachment operations, reducing manufacturing steps and complexity while providing consistent structural strength through the integrated design.
2Strength
If traditional welding is used to attach components to the frame, then structural integrity is maintained, but vehicle weight increases
Solution Approach 1:
The frame structure uses multiple distributed tab and slot connections across various frame members to collectively support vehicle components. This segmentation of the load path across multiple lightweight mechanical connections achieves the required structural integrity without concentrating weight in heavy welded joints.
Solution Approach 2:
The connection method transitions from permanent welding to mechanical tab and slot interlocking, changing the structural parameter from fused joints to discrete mechanical connections. This parameter change enables lighter frame members while maintaining structural integrity through the geometric interlocking and distributed connection architecture.
3Adaptability or versatility
If custom vehicle frames are designed to accommodate specific component selections, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The tab and slot frame members are designed with universal connection features that can accommodate various vehicle components through the same basic attachment mechanism. The standardized tab and slot geometry provides multi-functionality, allowing the same frame member design to support different components based on configuration rather than requiring custom manufacturing for each component type.
Solution Approach 2:
The tab and slot connection features are integrally formed into the frame members during the initial manufacturing process, before component selection and assembly. This preliminary action of pre-forming the connection features enables later customization and component selection without requiring additional manufacturing complexity, as the adaptive capability is built into the base frame structure.
4Strength
If traditional large and heavy frame designs are used, then load-bearing capacity is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The load-bearing capacity is achieved through multiple distributed tab and slot connections across numerous frame members rather than through large, heavy monolithic structures. This segmentation allows each frame member to be smaller and easier to manufacture, while the collective arrangement of connections provides the required load-bearing capacity through distributed structural support.
Solution Approach 2:
The frame structure utilizes a composite architecture combining multiple frame members with tab and slot connection features, creating a composite structural system. This composite design achieves superior load-bearing capacity compared to individual members while maintaining manufacturing ease, as each component can be manufactured using standard processes and then assembled into the high-performance composite structure.
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
Enables the creation of customized vehicle frames that are lighter and less expensive to manufacture, while maintaining structural integrity to withstand various loads, and allows for easier assembly and integration of vehicle components.
Implementation Method 1
constructing a vehicle frame by welding together a plurality of tabs and slots of the plurality of tab and slot frame members
Data Source
AI summary
A vehicle frame may comprise a plurality of interlocking tab and slot frame members forming a three-dimensional structure. A custom vehicle frame construction may be specified, designed and built based on a purchaser's selection. The three-dimensional structure may comprise a tab and slot panel to which additional tab and slot frame members are attached. The tab and slot frame members may have an attachment device disposed thereon for attachment of a vehicle component selected by the purchaser of the vehicle frame.