Vehicle Support Frames with Interlocking Features for Joining Members of Dissimiliar Materials

Abstract

The present disclosure relates to various vehicle cross-member assemblies and methods of manufacturing the same. The various vehicle cross-member assemblies have rails composed of dissimilar materials.

1 . A method of manufacturing a vehicle cross-member assembly, comprising:
 journaling an interconnecting member composed of a first material onto a first rail composed of a second material; and   welding the interconnecting member to a second rail composed of a different material than the first rail.   
     
     
         2 . The method of  claim 1 , further comprising
 adhering the interconnecting member to the first rail.   
     
     
         3 . The method of  claim 1 , further comprising:
 press-fitting the interconnecting member and the first rail together.   
     
     
         4 . The method of  claim 3 , wherein the press-fitting includes:
 forming at least one set of crimps in the interconnecting member and first rail.   
     
     
         5 . The method of  claim 4 , wherein the forming at least one set of crimps includes forming the crimps so that a longitudinal center line of the crimps extends parallel to a lateral axis of a vehicle. 
     
     
         6 . The method of  claim 4 , wherein the forming at least one set of crimps includes forming the crimps so that a longitudinal center line of the crimps extends parallel to a longitudinal axis of a vehicle. 
     
     
         7 . A vehicle cross-member assembly, comprising:
 a first rail composed of a first material;   a second rail composed of a second material; and   an interconnecting member composed of the second material adhered to the first rail and journaled onto the first rail;   wherein the interconnecting member is welded to the second rail.   
     
     
         8 . The assembly of  claim 7 , further comprising:
 at least one set of crimps commonly formed in the interconnecting member and first rail.   
     
     
         9 . The assembly of  claim 8 , wherein a longitudinal center line of the crimps extends along a lateral axis of a vehicle. 
     
     
         10 . The assembly of  claim 9 , wherein a longitudinal center line of the crimps extends along a longitudinal axis of a vehicle. 
     
     
         11 . A method of manufacturing a vehicle cross-member assembly, comprising:
 forming a hem-lock between a first rail having a first material composition and an interconnecting member having a second material composition; and   welding the interconnecting member to a second rail having a different material composition than the first rail.   
     
     
         12 . The method of  claim 11 , wherein the forming a hem-lock includes:
 forming a plurality of flanges in one of the interconnecting member or first rail; and   folding the flanges over an edge of the other of the interconnecting member or first rail.   
     
     
         13 . The method of  claim 12 , wherein the forming a plurality of flanges includes removing material from a corner of the interconnecting member or first rail. 
     
     
         14 . The method of  claim 12 , further comprising:
 applying adhesive between the interconnecting member and first rail.   
     
     
         15 . A vehicle frame assembly, comprising:
 a first rail having a first material composition;   a second rail having a second material composition; and   an interconnecting member hem-locked to the first rail and welded to the second rail.   
     
     
         16 . The vehicle frame assembly of  claim 15 , wherein the first rail is configured to extend longitudinally with respect to the assembly; and wherein the second rail is configured to extend laterally with respect to the assembly. 
     
     
         17 . The vehicle frame assembly of  claim 16 , wherein the interconnecting member or first rail comprises a plurality of flanges. 
     
     
         18 . The vehicle frame assembly of  claim 17 , further comprising a notch formed between at last two of the plurality of flanges. 
     
     
         19 . The vehicle frame assembly of  claim 17 , wherein the plurality of flanges are formed in the interconnecting member and fold into the first rail. 
     
     
         20 . The vehicle frame assembly of  claim 17 , wherein the plurality of flanges are formed in the first rail are fold onto the interconnecting member.