Tab-and-slot frame members with removable stringers

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Solution Overview

Problem

Current vehicle frame designs are large, heavy, expensive, and difficult to manufacture due to the need for traditional welding methods, which do not allow for customization and are prone to warping and twisting during the assembly process.

Innovation Solution

The method involves constructing custom vehicle frames using tab-and-slot frame members, where stringers are used to stabilize sections during welding, and the members are cut or stamped from flat sheets, allowing for interlocking connections that can be welded or brazed, enabling easier and less expensive manufacturing while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional welding methods are used to construct vehicle frames, then structural strength is achieved, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The vehicle frame is divided into multiple tab-and-slot members that can be manufactured separately and then assembled through interlocking tabs and slots, reducing manufacturing complexity while maintaining structural strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Tabs and slots are pre-formed on frame members before assembly, allowing for easier and more cost-effective manufacturing by enabling pre-fabrication of individual components with integrated connection features

Inventive Principle:

Principle #10Preliminary action

2Strength

If traditional welding methods are used to construct vehicle frames, then structural integrity is maintained, but weight increases

Engineering Contradiction:

Improvestructural integrityVSAvoidvehicle frame weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The frame is segmented into multiple lightweight tab-and-slot members that can be optimized for minimal weight while maintaining integrity, replacing heavy traditional welded construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Welding is applied only at critical connection points (tabs and slots) rather than extensive welding throughout the frame, reducing overall weight while maintaining structural integrity where needed

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If customization is implemented in vehicle frame construction, then adaptability improves, but manufacturing complexity increases

Engineering Contradiction:

Improvecustomization capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The tab-and-slot design provides universal connection features that can accommodate different frame configurations and customizations through the same basic interlocking mechanism, enabling adaptability without proportionally increasing complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The modular tab-and-slot members can be selectively assembled and configured to create customized frame designs, allowing adaptability through combination of standardized components

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If tab-and-slot connections are used instead of traditional welding, then ease of manufacture improves, but structural strength may be compromised

Engineering Contradiction:

Improvemanufacturing easeVSAvoidstructural strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Tabs and slots are pre-formed with precise geometry to ensure proper fit and load distribution, maintaining structural strength while enabling easier manufacturing through pre-fabrication

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The tab-and-slot connection parameters (dimensions, tolerances, geometry) are optimized to provide sufficient structural strength for vehicle frame applications while maintaining ease of manufacture

Inventive Principle:

Principle #35Parameter changes

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 allows for the creation of customized vehicle frames that are lighter, easier to manufacture, and more cost-effective, while maintaining the ability to withstand static and dynamic loads, and supports various vehicle components without the need for extensive welding.

Implementation Method 1

the first tab-and-slot frame member may have at least one stringer portion used to position and prevent warping of the tab-and-slot member when it is welded to another tab-and-slot frame member

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

welding the first and second tab-and-slot frame members together

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

Such plates may be laser cut or stamped from larger plates

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS9802663B1Tab-and-slot frame members with a stringer

Publication Date: 2017.10.31 VANDERHALL MOTOR WORKS INC

AI summary

A frame may comprise a plurality of interlocking tab-and-slot frame members forming a three-dimensional structure. A removable stringer may be designed into one or more of the interlocking tab-and-slot frame members. The stringers may be removed after positioning and welding of tab-and slot frame members together. Notches may also be designed into and formed as additional features of a tab-and-slot frame member. Notches may serve as a guide for bending tab-and-slot frame members and in the creation of tabs and/or slots of the tab-and-slot frame members.