Patent ID: 12233939

DETAILED DESCRIPTION OF EMBODIMENTS

FIG.1illustrates a vehicle Body In White (BIW), which is a vehicle spaceframe structure1consisting of structural members in the form of beams connected to each other by node units at intersection/meeting areas. Each node unit has at least two designated sockets node unit, each configured to snugly receive therein a portion of a different beam, referred to herein as an engaging portion of the beam, so as to fixedly secure in place this engaging portion and thus the beam, and thereby adjoin the two different beams into a unified structure while maintaining their desired mutual orientation.

In the BIW shown inFIG.1, there is a plurality of such beams with their engaging portions received in respective node units, of which for the purpose of brevity, only one node unit which is designated as15, and only two beams which are designated as11and13, will be referred to in the description below, whilst the description is fully applicable to all other node units and beams connected thereby.

In the illustrated example, as seen inFIG.2, each beam11,13comprises engaging portions111and113, while the node unit15comprises two designated sockets17and19, each configured to snugly receive the respective engaging portion111,113. As can be understood fromFIG.2, the engaging portion111constitutes a middle engaging portion as it is disposed between side portions11aand11bof the structural member11. Suitably, as seen inFIG.1, the corresponding socket17accommodating this engaging portion111, constitutes an embracing socket as it has two opposed and aligned openings17′ and17″, which render it suitable for receiving therein the middle engaging portion111in a manner which allows the side portions of the beam11to protrude from the openings17′ and17″.

The node unit15consists of two shell members15aand15b, shown separately from each other inFIGS.3A and3B, configured to be fastened to each other to form the node unit15with the designated sockets17and19thereof. Each shell member15a,15bconstitutes one half of the node unit15, such that socket portions154aand154bform together the designated socket19, while portions155aand155bform together the designated socket17. These designated sockets are interior sockets formed between the two shell members15aand15b, as best seen inFIG.4Awith respect to the interior socket17.

In other embodiments of the presently disclosed subject matter, at least one socket can be a non-interior, independent socket, formed in one of the shell members, and more than two shell members can be required for forming a single interior socket and thus a complete node unit.

Reverting toFIG.2, the structural members11and13are initially positioned in one of the shell members, e.g. the member15asuch that their engaging portions111and113are oriented in 90 degrees with respect to each other, and the shell members15bis then fastened to the shell member15a, so as to fixedly secure the engaging portions111,113in place.

As seen inFIGS.3A and3B, the shell members15aand15bcomprise mating pairs of auxiliary flanges151aand151b, respectively. When the shell members15aand15bare assembled together to form the node unit15, the mating pairs of the auxiliary flanges contact each other.

To fixedly secure the two shell members15aand15bto each other along the above pairs of flanges, and thereby the two engaging portions111,113within the designated sockets17,19, any suitable fixation techniques can be used. One example of this is gluing the flanges to each other by an adhesive which can be applied at the contact areas thereof. In this example, the contact area between the auxiliary flanges of the two shell members constitutes a majority of the total contact area between the shell members, which allows applying a relatively large amount of adhesive thereon, so as to create a strong bond between the two shell members15aand15b.

In order to increase the integrity of the connection, the auxiliary flanges151a,151bcan be pressed against each other after the application of the adhesive, and the adhesive can also be applied between portions153aand153blocated on an inner surface of the shell member15a, and on an outer surface of shell member15b, respectively, as well as within the sockets17and19.

The above manner of connection allows the beams11and13together with their engaging portions111and113, to be made of any material including a composite material. The same is correct regarding the node15, i.e. the shell members15aand15b, which in this example can be made of pressed aluminum sheet.

Whilst the shell members15aand15bdescribed above are shown as being pre-formed to have their interior of the desired configuration, this does not need to be the case. Thus, for example, the shell members can be forced to receive the desired configuration by pressing a flat aluminum sheet against the corresponding structural members arranged in a desired disposition, at their intersection area, so that the corresponding interior sockets17and19are formed, conforming in shape to that of the engaging portions111,113.

Regarding the mutual disposition of structural members with respect to each other and, consequently, of their engaging portions with the corresponding node unit, these portions can be in contact with each other within the node unit.

In example shown inFIG.2, the engaging portions111and113of the respective beams11and13are received within the respective designated sockets17and19so that they contact each other at an interface area12. In this case the interface12is a load bearing interface, allowing the load transfer between the beams11and13within the node unit15. However, when such load transfer between two structural members connected by a node unit is not desired, the can be spaced from each other, e.g. by the body of the node unit.

The description above exemplifies how two structural members can be adjoined, at a mutually perpendicular orientation, by a node unit assembled of two shell members. However, the number of structural members connected by a single node unit in accordance with the presently disclosed subject matter can be any desired and they can have any desired mutual orientation. One example this option is a ‘star like’ configuration wherein structural members extend radially from a common central area disposed within a node unit. Also, node units according to the presently disclosed subject matter can be assembled from any number of shell members and/or can be connected to each other to form a combined node structure. node unit

One example of such combined node structure is shown inFIG.5illustrating two connected node units25and35, the former configured to connect engaging portions of two beams21and22of the vehicle BIW shown inFIG.1, and the latter configured to connect engaging portions of two beams23and24. The connection between the two node units can be performed by welding or otherwise fixing them to each other at a zone30.

Node units according to the presently disclosed subject matter can be connected or constitute a part of a component of a vehicle, which does not necessarily has to constitute a part of its BIW.

One example of such an option is shown inFIG.6, which illustrates a BIW of a vehicle50together with a side wall52of the vehicle. The side wall52is integrally connected with a shell member [not seen], which is formed as a mate to shell member51, in the node unit45. The two shell members are configured to be fastened to each other over the structural members56a,56band56c, and thereby form the node unit45.

Having a shell member integrally connected to the wall52of the vehicle, allows the vehicle BIW to be assembled in layers together with the wall52. The first layer includes the wall52together with the node integral therewith [not seen], the second layer includes the structural members56a,56band56c, and the third layer includes the shell member51. The layers can be assembled to each other, for example, by means of an adhesive being applied between at least some of their contact areas.

A node unit with its shell members according to the presently disclosed subject matter can have, in addition to at least one interior socket such as those described above, which is formed by the assembly of the shell members, at least one exterior socket constituting a part of one of the shell members independently of any other shell member. A structural member received within such exterior socket or at least its engaging portion can be made of a material different from that of which the structural members received in the interior sockets or at least their engaging portions can be made. For example, the latter material can be a metal or an allow and the latter can be a composite material.

FIG.7Aillustrates one example of such node unit55having two shell members55aand55b, and three designated sockets56,57, and58, each snugly receiving an engaging portion of a beam60,61and62, respectively. The sockets57and58are interior sockets defined between the shell members55aand55b, whereas the socket56is an exterior, independent socket formed merely in the shell member55a.

To assemble such connection of the beams60,61and62, the shell members55aand55bcan firstly be assembled and fastened to each other over the engaging portions of the beams60and62, so as to fixedly secure these beams within the interior sockets57and58, while the beam61can be subsequently inserted into, and be fixed within, the socket56.

As seen inFIG.7Bthe beam62is disposed along a vertical plane and appears to be leaning on the beam61via an interface60′, while the beam61is disposed on a horizontal plane and appears to be leaning merely on the body of the node unit55. In this example, the node unit55should have such integrity which allows it to support the beam61.

In the above structure, the beam61or at least its engaging portion can be made of metal, e.g. aluminum, while the beams60and62or at least their engaging portions can be made of composite material.

Though as mentioned above, shell members of node units of the presently disclosed subject matter can be fixed to each together by an adhesive, other fastening techniques can be used as well, instead or in combination with an adhesive. One example of this option is shown inFIG.8which illustrates a node unit65assembled of two shell members65aand65b, fastened to each other by two fasteners66and68, at their auxiliary flanges, fixedly securing them to each other.

It can also be appreciated that shell members according to the presently disclosed subject matter can be connected to each other at one side thereof prior to their being assembled to form a node unit. Such connection can be a result of the shell members being formed as a unitary body in which two shell members are constituted by two shell portions of the body connected at along a folding line.

FIG.9shows one example of such option, in which a unitary node unit body75comprises two shell portions75aand75bconnected along75′. The node unit body75is shown in its unfolded state inFIG.9. When folded, the shell portions75aand75bform designated sockets in a similar manner to that described above for the node unit15.