Dana Corporation

Andrew R Simboli

Richard A Marando

Kenneth J Bonnville

Stephen M Lapic

Jason A Poirier

Scott M McGill

A method of manufacturing a node for joining a plurality of structural members together, such as in a vehicular body and frame assembly, is well suited for joining structural members that are formed from differing materials. An insert is provided having a node securing portion and a mounting portion that is adapted to have a structural member secured thereto. A node is formed about the node securing portion of the insert for joining a plurality of structural members together. The insert can be formed from a first material, while the node can be formed from a second material that is different from the first material. The insert can be provided with a node securing portion having at least one aperture or protrusion formed therein, and the node can be formed within or about the aperture or protrusion. A plurality of inserts can be provided, each having a node securing portion and a mounting portion, and the node can be formed about each of the node securing portions of the inserts. The structural members can be secured to the mounting portions of the inserts before the node is formed.

Method of manufacturing a node for connecting vehicle frame members

A weld between a tube yoke and a driveshaft tube can accommodate a greater amount of torsional shear stresses and, therefore, increase the load carrying capacity of a driveshaft assembly. The driveshaft assembly includes a yoke having a sleeve portion and a driveshaft tube having an end that extends about the sleeve portion of the yoke. The end of the tube is secured to the sleeve portion of the yoke by a weld having a shape that traverses multiple planes, such as a sinusoidal, saw-tooth, or square tooth shape. The weld occupies a greater area and, thus, has a greater surface contact between the sleeve portion of the yoke and the end of the driveshaft tube. The force vectors of the torsional shear stress sustained by the weld are in multiple planes. As a result, the force vectors of the torsional shear stress impinge the welds at different angles, and the weld has a greater load carrying capacity.

Vehicular driveshaft assembly

A closed channel structural member, such as a side rail or a cross member, for use in such a vehicle body and frame assembly that includes an internal reinforcing structure to increase the strength and rigidity thereof. The side rail can be generally rectangular in cross sectional shape, including first and second side rail sections having generally C-shaped cross sectional shapes. The reinforcing structure can be generally hat-shaped or W-shaped in cross sectional shape, including a central reinforcing portion extending between a pair of base portions. The central reinforcing portion can either be laterally spaced apart from or directly abut a central web portion of one of the side rail sections. The base portions can be generally L-shaped in cross sectional shape, including legs that terminate adjacent to the ends of the other of the side rail sections to facilitate the assembly process. A pair of such reinforcing structures can be disposed within the side rail and abut one another in end-to-end fashion. Alternatively, tabs extending from each of the reinforcing structures can is partially overlap one another to provide additional strength and rigidity.

Closed channel structural member having internal reinforcement for vehicle body and frame assembly

A closed channel structural member, such as a side rail or a cross member, for use in a vehicle body and frame assembly, includes an internal reinforcing structure to increase the strength and rigidity thereof. Portions of the side rail are removed so as to provide an opening. This can be accomplished by forming two flanges that can be bent inwardly within the side rail to form the opening. A combined internal reinforcing member and mounting bracket is assembled to the side rail by moving it laterally such that a pair of side walls and an upper wall are inserted through the opening formed through the side rail until tabs provided on the side walls and the upper wall of the reinforcement member and mounting bracket abut the outer surface of the side rail. Then, portions of the reinforcing member and bracket are secured to the side rail by welding. When assembled with and secured to the side rail, the reinforcing member and bracket functions as a dual purpose member, providing structural reinforcement for the side rail and simultaneously providing a mounting point for an ancillary component of the vehicle, such as a shock absorber, body portion, and the like. If desired, the reinforcing member can function as a single purpose member, solely providing structural reinforcement for the side rail.

A vehicle frame assembly has an energy absorbing structure including a first portion having a first generally uniform dimension. A second portion extends from the first portion and has a second generally uniform dimension that is greater than the first generally uniform dimension of the first portion, thereby defining a first shoulder between the first portion and the second portion. A third portion extends from the second portion and has a third generally uniform dimension that is less than the first generally uniform dimension of the first portion, thereby defining a second shoulder between the second portion and the third portion. The second portion has at least one stiffening rib formed therein. The third portion has at least one stiffening rib formed therein that is discontinuous with the stiffening rib formed in the second portion. The energy absorbing structure is adapted to be deformed during a collision such that the third portion is moved within the second portion to absorb energy.

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Coatesville, PA, United States of America

Andrew R Simboli