Universal Angular Structural Joint for Automotive Frames
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Solution Overview
Problem
Existing automotive frame joint configurations are inadequate in withstanding crush loads, leading to frame collapse, and increasing frame size to meet newer safety requirements adds weight and cost, creating a 'Catch 22' situation.
Innovation Solution
A universal joint configuration that allows frame members to be bent into any angle and shape, sharing loads among multiple members, using various materials and manufacturing processes, and secured through welding or adhesives, enhancing load distribution and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If frame size is increased to meet newer safety requirements, then load carrying capability is improved, but vehicle weight increases
Solution Approach 1:
The joint is divided into multiple legs (typically three) that can be formed from separate frame members, allowing the load to be segmented and distributed across multiple members rather than requiring a single oversized member. Each leg can be optimized independently for its specific load path requirements.
Solution Approach 2:
The joint configuration transitions from simple linear connections to three-dimensional angular arrangements. By forming legs at angles (e.g., 90 degrees) relative to each other in multiple dimensions, the joint creates a spatial structure that distributes loads more effectively, increasing load carrying capability without proportionally increasing weight.
2Reliability
If traditional joint configurations are used, then assembly is simpler, but frame integrity fails under crush loading
Solution Approach 1:
Multiple frame members are merged into a single integrated joint structure through welding or bonding at angular configurations. This merging creates a unified structural element that maintains integrity under crush loading, eliminating the need for separate joint components and simplifying the overall assembly process.
Solution Approach 2:
The frame members are pre-formed into the required angular configurations and positions before final assembly. By preparing the members in advance with the correct geometry and alignment, the actual assembly process is simplified, and the joint achieves proper structural integrity without complex on-site adjustments.
3Strength
If joints are made more robust to withstand crush loads, then load carrying capability is improved, but device complexity increases
Solution Approach 1:
The joint configuration uses universal angular connections that can accommodate various frame member orientations and load directions. The same basic angular joint design serves multiple functions - connecting members at different angles, distributing loads in multiple directions, and maintaining structural integrity - without requiring complex specialized components for each specific application.
Data Source
AI summary
A structural joint configuration is formed in an automotive frame in which the frame members are bent into an angular orientation and joined together to form a structural joint in the automotive frame in which loads imposed on any of the frame members forming the joint will be transferred to and shared with the other frame members in the joint. The structural joint can be configured with as many legs as needed to conform to the number of frame members entering the joint. The frame members can be formed with any cross-sectional shape and from any conventional material or combination of materials. Joining the frame members at the structural joint can be accomplished by welding or by applying adhesives. Load distribution through the frame members forming the structural joint enables the joint to withstand an application of high loads without major cracks or bending at the structural joint.