Patent EA-001477-B1 (EA)
Title: Hydroformed space frame and methodof manufacturing the same
Inventor: JAEKEL FRED G
IPC: B62D23/00
Filed: 1998-10-16
Abstract: 1. A space frame (10) for a motor vehicle, comprising: first and second longitudinally extending laterally spaced lower side rails (12); laterally extending connecting structure (44, 46, 48, 50) constructed and arranged to space said lower rails from one another in generally parallel relation to one another; and a pair of hydroformed tubular upper longitudinal members (20) each being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration, characterized by each upper longitudinal member being connected to an associated one of said lower side rails, each upper longitudinal member having an upright portion (22, 24) extending upwardly from said associated lower side rail so as to form an A pillar of said space frame, each upper longitudinal member having a longitudinally extending portion (26) extending rearwardly from said A pillar forming upright portion, each upper longitudinal member extending downwardly to said associated lower side rail to form a rearward-most pillar (28) of said space frame, the longitudinally extending portions of said hydroformed tubular upper longitudinal members thus defining lengths between said A pillars and said rearward-most pillars of said space frame. 2. A space frame according to claim 1, further comprising an inverted U-shaped hydroformed tubular cross member (50) defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration, said tubular cross member being connected at a free end of a first leg portion (56) thereof to said first lower side rail (12) and connected at a free end of a second leg portion (56) thereof to said second lower side rail (12), said first leg portion extending upwardly from the free end thereof to form a first B pillar, said hydroformed cross member having a cross portion (54) between said leg portions extending across said vehicle frame from said first B pillar, said second leg portion extending downwardly from said cross portion towards the free end thereof so as to form a second B pillar, the cross portion of said hydroformed tubular cross member thus defining a length between said B pillars of said space frame. 3. A space frame according to claim 2, wherein said lower side rails comprise first and second hydroformed tubular side rail members (12) each being defined by an irregularly outwardly deformed tubular mteallic wall fixed into a predetermined irregular exterior surface configuration. 4. A space frame according to claim 3, wherein said hydroformed tubular cross member (50) is disposed in abutting lapped relation with said longitudinally extending portion (26) of each of said hydroformed tubular upper longitudinal members (20), said longitudinally extending portion of each of said hydroformed tubular upper longitudinal members being provided with a recess (100), and wherein said hydroformed tubular cross member (50) includes junctures (58) between said leg portions and said cross portion disposed within said recesses. 5. A space frame for a motor vehicle according to claim 4, wherein said laterally extending connecting structure comprises a hydroformed tubular connecting member (52) extending perpendicularly with respect to said lower side rails, said connecting member being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration. 6. A space frame according to claim 5, said laterally extending connecting structure further comprising a plurality of hydroformed forward connecting members (44, 46, 48), each of said hydroformed forward connecting members being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration and extending laterally between said upper longitudinal members and connecting said upper longitudinal members to one another. 7. A space frame according to claim 1, further comprising a door structure (90), said door structure being pivotally connected with one of said upper longitudinal members at the upright portion thereof that extends upwardly from a forward end portion (14) of said associated lower side rail. 8. A space frame according to claim 7, wherein said door structure comprises a plurality of hydroformed tubular door members (92, 98) each being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration, said hydroformed tubular door members being connected end-to-end to form a periphery of said door structure. 9. A space frame according to claim 8, wherein said plurality of hydroformed tubular door members comprises a first U-shaped hydroformed tubular door member (92) and a second hydroformed U-shaped tubular door member (98), said second U-shaped hydroformed tubular door member being inverted relative to said first U-shaped hydroformed tubular door member and having opposite ends connected to respective opposite ends of said first U-shaped hydroformed tubular door member. 10. A space frame (10, 200) for a motor vehicle, comprising: first and second laterally spaced, generally parallel hydroformed, longitudinally extending tubular lower side rail members (12, 212), each rail member being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration; laterally extending connecting structure (44, 46, 48, 50, 244, 246) constructed and arranged to connect said first and second hydroformed lower side rail members to one another; and a pair of generally parallel, hydroformed tubular upper longitudinal members (20, 220), each being defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration, characterized by each of said hydroformed tubular upper longitudinal members being fixed to an associated one of said hydroformed lower side rail members, each hydroformed upper longitudinal member having a longitudinally extending portion (26, 226) constructed and arranged to support a side of a roof of said motor vehicle, each longitudinally extending portion extending longitudinally between an upper end of an A pillar of said space frame and an upper end of a rearwardmost pillar of said space frame, said hydroformed tubular upper longitudinal members thus defining lengths between said vehicle A pillars and said rearward-most pillars of said space frame. 11. A space frame according to claim 10, wherein each said hydroformed upper longitudinal member includes a vertically extending portion (22, 24, 222, 224) connecting said longitudinally extending portion thereof with the associated hydroformed side rail member thereof, each said vertically extending portion constituting an A pillar of said space frame. 12. A space frame according to claim 11, further comprising a pair of vertically extending structures (28, 241, 243) connecting rearward ends of said longitudinally extending portions with rearward ends of the associated hydroformed side rail members, said vertically extending structures constituting the rearward-most pillars of said space frame. 13. A space frame according to claim 12, wherein said vertically extending structures are integrally formed as part of said hydroformed upper longitudinal members. 14. A method of forming a space frame (10) for a motor vehicle, said method comprising: hydroforming a first upper longitudinal member (20) defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration; hydroforming a second upper longitudinal member (20) defined by an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration; providing first and second lower side rails (12); positioning said first and second lower side rails in laterally spaced, generally parallel relation to one another; connecting said first and second lower side rails to one another with laterally extending connecting structure (44, 46, 48, 50); connecting said first upper longitudinal member to opposite end portions (14, 18) of a first of said spaced lower side rails; and connecting said second upper longitudinal member to opposite end portions (14, 18) of a second of said spaced lower side rails. 15. A method according to claim 14, further comprising: mounting body panels (375) to said first and second upper longitudinal members. 16. A method according to claim 14, wherein said connecting structure is provided by a hydroformed connecting member and so that said step of connecting said first and second lower side rails to one another with laterally extending connecting structure comprises: hydroforming said a connecting member (50) to have a U-shape and having an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration; connecting a first end of a first leg portion (56) of said connecting member to said first lower side rail; and connecting a second end of a second leg portion (56) of said connecting member to said second lower side rail. 17. A method of forming a space frame (10, 200) for a motor vehicle, said method comprising: hydroforming a first and a second upper longitudinal member (20, 220) so that each has an irregularly outwardly deformed tubular metallic wall fixed into a predetermined irregular exterior surface configuration and so that each has a tubular. pillar forming portion (22, 24, 28, 222, 224) and an integral longitudinally extending length defining portion (26, 226) extending integrally from said pillar forming portion; providing first and second lower side structures (12, 212); connecting said first upper longitudinal member to the first lower side structure such that said pillar forming portion of said first upper longitudinal