A connection member includes a first side and a second side opposite the first side. The connection member also includes a third side connecting the first and second sides, the third side including a first portion, a second portion, and a third portion, a first edge separating the first portion from the second portion and a second edge separating the second portion from the third portion. A first flange extends along the first edge and a second flange extends along the second edge such that the first and second flanges are separated by the second portion.

INTRODUCTION

The present disclosure relates generally to a multi-flange tubular connection member for coupling two or more parts together.

Typically, an extruded member for connecting two components includes flanges specific to the components to be coupled. Significant cost savings could be realized with a coupling member having multiple flanges that may be configured for multiple part coupling scenarios.

SUMMARY

Embodiments according to the present disclosure provide a number of advantages. For example, embodiments according to the present disclosure enable a customizable connection between a plurality of components. The integrated flanges of a connection member may be machined to the desired length and position to enable coupling of a plurality of components, such as vehicle body components.

In an exemplary embodiment of the disclosure, a system for coupling multiple components includes a generally tubular connection member defining a longitudinal axis, the connection member having a first side, a second side opposite the first side, a third side connecting the first and second sides, and a fourth side connecting the first and second sides. The third side includes a first portion defining a first plane, a second portion defining a second plane, and a third portion defining a third plane. The third side also includes a first edge and a second edge. A first flange extends from the first edge and a second flange extends from the second edge. The first edge is separated from the first side by the first portion, the second edge is separated from the second side by the third portion, and the first edge is separated from the second edge by the second portion. The fourth side is separated from the third side by the first and second sides.

In some embodiments, the first flange includes a first flange portion and a second flange portion separated by a first gap.

In some embodiments, the second flange includes a third flange portion and a fourth flange portion separated by a second gap.

In some embodiments, a lateral axis of the connection member passes through the first and second sides and the first flange and the second flange are parallel to the longitudinal axis and laterally spaced from one another.

In some embodiments, the second portion separates the first flange from the second flange.

In some embodiments, the first portion forms a first angle with the first flange and the third portion forms a second angle with the second flange and the first and second angles are different.

In some embodiments, the connection member further includes a support member connecting an interior surface of the first side with an interior surface of the second side.

In an exemplary embodiment of the disclosure, a tubular member includes a first side, a second side opposite the first side, and a third side connecting the first and second sides. The third side includes a first portion defining a first plane, a second portion defining a second plane, and a third portion defining a third plane. The third side also includes a first edge separating the first plane from the second plane and a second edge separating the second plane from the third plane. A first flange extends along the first edge and a second flange extends along the second edge such that the first and second flanges are separated by the second portion. The first, second, and third planes are non-coplanar.

In some embodiments, the first flange includes a first flange portion and a second flange portion separated by a first gap.

In some embodiments, the second flange includes a third flange portion and a fourth flange portion separated by a second gap.

In some embodiments, the tubular member defines a longitudinal axis and the first flange and the second flange are parallel to the longitudinal axis.

In some embodiments, the first portion forms a first angle with the first flange and the third portion forms a second angle with the second flange and the first and second angles are different.

In some embodiments, the tubular member further includes a support member connecting an interior surface of the first side with an interior surface of the second side.

In an exemplary embodiment of the disclosure, a method for coupling vehicle body components includes providing a tubular connection member, the connection member defining a longitudinal axis and having a first side, a second side opposite the first side, a third side connecting the first and second sides, and a fourth side connecting the first and second sides. The third side includes a first portion defining a first plane, a second portion defining a second plane, and a third portion defining a third plane. The third side also includes a first edge and a second edge, the first edge separating the first plane from the second plane and the second edge separating the second plane from the third plane. The connection member also includes a first flange extending from the first edge and a second flange extending from the second edge. The method further includes providing a first vehicle body component and coupling the first vehicle body component to the first flange and providing a second vehicle body component and coupling the second vehicle body component to the second flange such that the first and second vehicle body components are laterally spaced from each other.

In some embodiments, the first flange includes a first flange portion and a second flange portion separated by a first gap and the method includes coupling the first vehicle body component to the first flange portion, providing a third vehicle body component, and coupling the third vehicle body component to the second flange portion such that the first and third vehicle body components are longitudinally spaced from each other.

The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through the use of the accompanying drawings. Any dimensions disclosed in the drawings or elsewhere herein are for the purpose of illustration only.

DETAILED DESCRIPTION

Referring toFIGS. 1 and 2, a connection member10is schematically illustrated. In various embodiments, the connection member10is a generally tubular, hollow member having a longitudinal axis A. The connection member10is used to couple multiple components, such as vehicle body components in a vehicle body assembly. The connection member10has a first end22and a second end24opposite the first end22. The connection member10also has a top26and an underside or bottom28. The connection member10includes a first side12, a second side14opposite and approximately parallel to the first side, and a third side13adjacent to each of the first and second sides12,14and connecting the first and second sides12,14. A fourth side11extends the length of the connection member10from the first end22to the second end24and is adjacent to and connects the first and second sides12,14. The fourth side11is separated from the third side13by the first and second sides12,14. In various embodiments, the fourth side11includes one or more cutouts or connection points to couple the connection member10to a vehicle chassis component, for example and without limitation.

The first, second, third, and fourth sides12,14,13,11define an interior space21of the connection member10. In various embodiments, a support member18extends through at least a portion of the interior space21. The support member18is adjacent to and connects the first and second sides12,14, as best shown inFIG. 1. In various embodiments, the support member18is approximately parallel to the fourth side11. The support member18provides rigidity and support to the connection member10. In various embodiments, the support member18extends along a lateral axis B of the connection member10such that the lateral axis B passes through each of the first and second sides12,14.

In various embodiments, the third side13includes a plurality of adjacent surfaces connected by edge members. Each of the plurality of adjacent surfaces defines a plane and each plane is oriented at a different angle (that is, each plane is non-coplanar) depending on the intended connection between the connection member10and the coupled component. As shown inFIG. 2, the third side13includes a first portion23defining a first plane, a second portion25defining a second plane, and a third portion27defining a third plane. The first, second, and third planes are non-coplanar. A first edge15separates the first portion23from the second portion25and a second edge17separates the second portion25from the third portion27. A plurality of flanges extends from each of the first and second edges15,17to enable connection of multiple components using the connection member10.

In the exemplary embodiment shown inFIGS. 1 and 2, a first flange32extends from the first edge15at the first end22of the connection member10. A second flange34also extends from the first edge15at the second end24of the connection member10. A third flange36extends from the second edge17of the connection member10. The first, second, and third flanges32,34,36are arranged to allow connection with multiple other components. In various embodiments, one or more portions of one or more of the flanges may be cut away or removed where not needed for coupling to other components. The third flange36includes a first portion37and a second portion38defining a gap39. The first, second, and third flanges32,34,36extend longitudinally along the connection member10parallel to the longitudinal axis A.

In various embodiments, including the embodiment shown inFIGS. 1 and 2, the first portion23slopes away from the first flange32at a first angle and the third portion27slopes away from the third flange36at a second angle. The angle of slope of the first portion23may be the same as or different from the angle of slope of the third portion27. The angle of slope of each of the first and third portions23,27is determined based on the intended components to be coupled using the connection member10such that the shape of the connection member10does not impede the connection between the intended components and the one or more of the flanges of the connection member10.

In various embodiments, the connection member10is extruded with multiple flanges that run the length of the connection member10, that is, a first flange extends along at least a portion of the length of the connection member10and a second flange extends along at least a portion of the length of the connection member10. In various embodiments, the first flange extends along the first edge15and the second flange extends along the second edge17. The flanges can be machined or cut away to the desired configuration based on the intended components to be coupled together. Thus, the connection member10with multiple flanges can be customized through machining to obtain the desired configuration, length, and number of flanges.

As best shown inFIG. 1, the flanges32,34do not extend the full length of the connection member10. Furthermore, in some embodiments, the flanges32,34,36do not overlap, that is, the flanges extending along one edge do not overlap with flanges on the other edge. However, in other configurations, one or more flanges along one edge may overlap with one or more flanges along the other edge. In various embodiments, the one or more flanges extending from the first edge15are “inner” flanges configured to mate with components arranged inward of the connection member10. In various embodiments, the one or more flanges extending from the second edge17are “outer” flanges configured to mate with outboard components including structural components such as a B-pillar of a vehicle body assembly. However, it should be understood that the terms “inner” and “outer” are used to generally indicate a direction and the connection member10may be manufactured with any number of and position of flanges to facilitate the mating of one or more components.

FIG. 3schematically illustrates the connection member10coupling together two components52and54in an exemplary method of coupling vehicle components. In various embodiments, the components52,54are vehicle body components. The position and length of each flange of the connection member10can be customized depending on the intended configuration of the coupled components. As shown inFIG. 3, the tubular connection member10defines a longitudinal axis and has a first side, a second side opposite the first side, a third side connecting the first and second sides, and a fourth side connecting the first and second sides. The third side includes a first portion defining a first plane, a second portion defining a second plane, and a third portion defining a third plane. The third side also includes a first edge and a second edge, the first edge separating the first plane from the second plane and the second edge separating the second plane from the third plane. The first vehicle body component52is coupled to the first flange and the second vehicle body component54is coupled to the second flange such that the first and second vehicle body components are laterally spaced from each other.

WhileFIG. 3illustrates two components coupled to the connection member10, it is understood that three, four, or more components may be coupled to the first, second, third, or more flanges of the connection member10, depending on the length and position of the flanges.

WhileFIGS. 1-3illustrate a connection member10having a three-flange configuration, it is understood that other embodiments may include more or fewer flanges arranged on the connection member10to accommodate and couple a multitude of components.

In various embodiments, the connection member10, including each of the flanges, is formed as an extrusion. The flanges can be machined or otherwise cutaway to produce the desired length and configuration of flange(s). In various embodiments, the connection member10may also be formed via any other manufacturing method such as casting, 3D printing, welding, etc. as known to those skilled in the art.

It should be emphasized that many variations and modifications may be made to the herein-described embodiments, the elements of which are to be understood as being among other acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. Moreover, any of the steps described herein can be performed simultaneously or in an order different from the steps as ordered herein. Moreover, as should be apparent, the features and attributes of the specific embodiments disclosed herein may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.