A space (10) for a motor vehicle comprising a first hydroformed, longitudinally extending tubular lower side rail (12) and a second hydroformed, longitudinally extending tubular lower side rail (12), the lower side rails being laterally spaced from one another and extending in generally parallel relation to one another. Also included is a pair of generally parallel, hydroformed tubular upper longitudinal structures (20), each being an integrally formed structure fixed to an associated one of the lower side rails. Each upper longitudinal structure has a longitudinally extending portion (26) constructed and arranged to support a roof of the motor vehicle, each longitudinally extending portion extending longitudinally between an upper end of an A pillar (24) of the space frame and an upper end of a rearward-most pillar (28) of the space frame. The hydroformed tubular upper longitudinal structures thus define lengths between the vehicle A pillars and the rearward-most pillars of the space frame. Laterally extending connecting structure connects the lower side rails to one another.

Hydroformed space frame and method of manufacturing the same

A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member; (4) placing the end segment of the first member through the first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of the openings; and (5) welding the intermediate segment and the end segment together in the area of said abutting engagement between exterior surface portions of the end segment and the edge portions of the openings.

Hydroformed space frame and joints therefor

A reinforced hydroform member (10) having an outer structural member (12) reinforced by a structural foam (16) over an inner structural member (14). The structural foam (16) extends along at least a portion of the length of the outer structural member (14). The structural foam (16) is a heat-activated epoxy-based resin. As the foam is heated, it expands and adheres to adjacent surfaces.

Heat-activated structural foam reinforced hydroform

A vehicle frame has side rails which support the suspension system and body of the vehicle. The side rails have a rectangular cross-section with the end sections thereof having predetermined wall thicknesses and rectangular size, and a center section having a thinner wall thickness and a larger height dimension of the rectangular cross-section. A transition section connects respective end sections with the center section. The transition section has rectangular cross-sections and wall thickness at the respective junctures which matches the adjoining section. The frame side rail is manufactured by prebending a cylindrical tube of constant wall thickness into a shape consistent with the desired final shape; then hydroforming an intermediate work piece in a first die to provide wall thickness and perimeter characteristics commensurate with the final product; and then further hydroforming the intermediate work piece in a second die to provide the finished product or to provide two components which are joined to form the final frame side rail. When two intermediate work pieces are processed, each is formed with an end section and a part of the center section.

Hydroformed side rail for a vehicle frame and method of manufacture

A sub-frame structure of a motor vehicle includes a pair of side frame sections and a cross member section. The pair of side frame sections extend in the longitudinal direction of the vehicle at prescribed lateral spacing and include laterally inward bends in each section. The cross member section connects front ends of the side frame sections. The cross member section and end portions of the side frame sections connected to the cross member section are integrally formed of a deformed tube member. The remaining portions of the frame member sections including said bends are formed of a closed section member fabricated by joining a plurality of members at flanges.

Sub-frame structure of motor vehicle

A method for hydroforming a tubular structural member of generally polygonal, flat walled cross section in which the various walls in the final part do not have the same thickness. A cylindrical tubular blank is extruded in which the outer surface is round, but in which the inner surface is asymmetrical, providing several contiguous angular sectors or portions of varying width and thickness. Each individual angular portion is tailored as to thickness and width to correspond to a respective wall in the final part. The blank is oriented between in a die cavity so as to align each angular portion with a respective wall of the finished part, and hydroformed in conventional fashion.

Hydroformed structural member with varied wall thickness

A vehicle space frame is built up piece by piece into an initial or rough frame, consisting of standard, cylindrical metal tubes welded to matching cylindrical plugs of hollow, nodal joints. All weld seams are circular and, therefore, easily and quickly formed, and the initial frame need be formed only with the accuracy that plugging the ends of the tubes into the joints will achieve. The entire interior of the initial frame is then clamped between a large pair of dies with mating cavities, and hydroformed to provide a final frame with the desired non cylindrical cross section and accurate, final shape and form.

Method for hydroforming a vehicle space frame

A hydroformed vehicle body component has an attachment flange or the like-formed as an integral part of the hydroforming process. For a given flange shape, a parting plane for the dies is established relative to which the various surfaces of the flange shape, in cross section, have no significant reverse curvature. Then, a weld line is established which is on or substantially parallel to the parting plane, and which is as symmetrical to the flange as possible. A planar blank sufficient in size to produce the flange is pre welded to a cylindrical blank along the weld line, at the desired location. Shoulders bordering the die cavities and corresponding in shape to the desired flange shape simultaneously form the flange as the dies close. After the dies are closed, the tubular blank is pressurized and formed to shape as usual.

Method of forming a tubular member with separate flange

A hydroformed and roll-formed cross sill assembly for a vehicle and method of making same includes a pair of hydroformed tubular side members. The hydroformed and roll-formed cross sill assembly also includes a roll-formed beam member disposed between the tubular side members and at least one weld to secure the beam member to each of the tubular side members.

Hydroformed and roll-formed cross sill assembly for vehicles and method of making same

A hydroformed dovetail joint and method of joining tubular members includes a first hydroformed tubular member having a depression therein and a second hydroformed tubular member having an end. The end of the second hydroformed tubular member is disposed over the depression of the first hydroformed tubular member to join the first hydroformed tubular member and the second hydroformed tubular member together to form a dovetail joint between the first hydroformed tubular member and the second hydroformed tubular member.

Chi-Mou Ni

Papers

Hydroformed structural member with varied wall thickness

Method for hydroforming a vehicle space frame

Method of forming a tubular member with separate flange

Hydroformed and roll-formed cross sill assembly for vehicles and method of making same

Hydroformed dovetail joint and method of joining tubular members