Cast aluminum node for connecting vehicle frame members and method of manufacturing same

Abstract

A vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted is manufactured by initially casting a node that includes a body portion having a plurality of mounting portions. A first structural member is secured to each of the mounting portions of the node. Second structural members are secured to the first structural members to form a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted. If desired, a plurality of nodes is initially cast that each include a body portion having a plurality of mounting portions. A plurality of structural members is secured to the plurality of nodes to form the vehicular frame assembly.

1 . A method of manufacturing a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted comprising the steps of: 
 (a) casting a node that includes a body portion having a plurality of mounting portions;    (b) securing a first structural member to each of the mounting portions of the node; and    (c) securing second structural members to the first structural members to form a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted.    
   
   
       2 . The method defined in  claim 1  wherein step (b) is performed by securing an end portion of each of the first structural members to each of the mounting portions of the node.  
   
   
       3 . The method defined in  claim 1  wherein step (b) is performed by welding each of the first structural members to each of the mounting portions of the node.  
   
   
       4 . The method defined in  claim 3  wherein step (b) is performed by laser welding each of the first structural members to each of the mounting portions of the node.  
   
   
       5 . The method defined in  claim 3  wherein step (b) is performed by magnetic pulse welding each of the first structural members to each of the mounting portions of the node.  
   
   
       6 . The method defined in  claim 1  wherein step (b) is performed by adhering each of the first structural members to each of the mounting portions of the node.  
   
   
       7 . The method defined in  claim 6  wherein step (b) is performed by providing a gap between each of the first structural members to each of the mounting portions of the node and by providing an adhesive is each of the gaps.  
   
   
       8 . The method defined in  claim 1  wherein step (b) is performed by riveting each of the first structural members to each of the mounting portions of the node.  
   
   
       9 . A method of manufacturing a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted comprising the steps of: 
 (a) casting a plurality of nodes that each include a body portion having a plurality of mounting portions; and    (b) securing a plurality of structural members to the plurality of nodes to form a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted.    
   
   
       10 . The method defined in  claim 9  wherein step (b) is performed by securing an end portion of each of the first structural members to each of the mounting portions of each of the nodes.  
   
   
       11 . The method defined in  claim 9  wherein step (b) is performed by welding each of the first structural members to each of the mounting portions of each of the nodes.  
   
   
       12 . The method defined in  claim 11  wherein step (b) is performed by laser welding each of the first structural members to each of the mounting portions of each of the nodes.  
   
   
       13 . The method defined in  claim 11  wherein step (b) is performed by magnetic pulse welding each of the first structural members to each of the mounting portions of each of the nodes.  
   
   
       14 . The method defined in  claim 9  wherein step (b) is performed by adhering each of the first structural members to each of the mounting portions of each of the nodes.  
   
   
       15 . The method defined in  claim 14  wherein step (b) is performed by providing a gap between each of the first structural members to each of the mounting portions of each of the nodes and by providing an adhesive is each of the gaps.  
   
   
       16 . The method defined in  claim 9  wherein step (b) is performed by riveting each of the first structural members to each of the mounting portions of each of the nodes.