# US 12,005,957 B2 · Variable gauge cradle > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,957 B2 - Document ID: US12005957B2 - Status: Granted - Kind: B2 - Application number: 17/607,542 - Filed: 2020-05-01 - Published: 2022-08-04 - Granted: 2024-06-11 - Earliest claimed: 2019-05-02 - Assignees: Magna International Inc. - Applicants: Magna International Inc.; Darren Womack; Nikhil Kripasagar Bolar - Inventors: Darren Womack; Nikhil Kripasagar Bolar - Web page: https://patentgrep.com/patent/US12005957B2 ## CPC - B62D 21/11: with resilient means for suspension {, e.g. of wheels or engine; sub-frames for mounting engine or suspensions} - B32B 15/011: {all layers being formed of iron alloys or steels} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A cradle for being used in automotive vehicles for supporting various automotive components includes a structure with variable thickness, defining a variable gauge cradle. The variable gauge cradle has a minimum thickness and maximum thickness, with various other thicknesses therebetween. The minimum thickness is less than an original thickness of a reference cradle in which the thickness is the same. The variable gauge cradle allows specific locations to be locally increased in thickness to achieve the desired stiffness at the areas requiring the increased stiffness, while leaving areas requiring a lower stiffness at a lesser thickness. The variable gauge cradle therefore may have a lower mass than the reference cradle. The thickness may be increased relative to the minimum thickness using patches that are bonded to a base layer or panel of the cradle. The patches may be distributed at different locations to create different thicknesses. ## Claims ### Claim 1 A structural frame for a vehicle, the structural frame comprising: a plurality of interconnected panel portions defining a shape of the frame; wherein each panel portion has a variable thickness; wherein the panel portions include a first thickness at a first zone and a second thickness at a second zone; wherein the first thickness defines a minimum thickness of the panel portion; wherein the second thickness defines a maximum thickness of the panel portion; wherein the first thickness is defined by a first sheet of material; wherein the second thickness is defined by the first sheet of a material and at least one patch attached to the first sheet of material; wherein the panel portions define a curved cross-section profile. ### Claim 2 (depends on 1) The frame of claim 1, wherein the second thickness is defined by a plurality of patches stacked together on the first sheet. ### Claim 3 (depends on 1) The frame of claim 1, wherein the panel portions include a third thickness in a third zone, wherein the third thickness is between the minimum thickness and the maximum thickness. ### Claim 4 (depends on 3) The frame of claim 3, wherein the third thickness is defined by fewer patches than the second thickness. ### Claim 5 (depends on 1) The frame of claim 1, wherein the panels combine to define one or more hollow structures. ### Claim 6 (depends on 5) The frame of claim 5, wherein the hollow structure includes an upper portion attached to a lower portion, wherein the upper portion and lower portion are defined at least by a sheet of material. ### Claim 7 (depends on 1) The frame of claim 1, wherein the at least one patch defines a curved profile corresponding to the curved profile of the panel portion to which it is attached. ### Claim 8 (depends on 1) The frame of claim 1, wherein the at least one patch is attached to the panel portion via a full surface bond. ### Claim 9 (depends on 3) The frame of claim 3, wherein the second zone is disposed within a perimeter of the third zone. ### Claim 10 (depends on 1) The frame of claim 1, wherein the frame is a perimeter cradle or a k-frame. ### Claim 11 A method of manufacturing a variable gauge structural component for a vehicle, the method comprising the steps of: providing a panel portion of the structural component, the panel portion including at least a first sheet of metal having a first thickness, wherein the first thickness is a minimum thickness of the panel portion; attaching at least one patch of additional metal material to the first sheet and defining a second thickness of the panel portion, wherein the first thickness is disposed in a first zone of the panel portion and the second thickness is disposed in a second zone of the panel portion; wherein the second zone has a greater stiffness than the first zone; wherein the panel portion defines one or more hollow structures, wherein the hollow structure includes an upper portion attached to a lower portion, wherein the upper portion and the lower portion are defined at least by a second sheet of metal attached to the first sheet of metal and defining the hollow structure therebetween. ### Claim 12 (depends on 11) The method of claim 11, wherein the at least one patch is in the form of a sheet of metal material. ### Claim 13 (depends on 11) The method of claim 11, wherein the at least one patch is deposited and attached via metal deposition onto the panel portion. ### Claim 14 (depends on 11) The method of claim 11, wherein the at least one patch includes a first patch and a second patch, wherein the first patch is overlaid on the panel portion, and the second patch is overlaid on the first patch. ### Claim 15 (depends on 14) The method of claim 14, wherein the second patch has a smaller footprint than the first patch. ### Claim 16 A vehicle subframe for mounting vehicle components thereto, the vehicle subframe comprising: a plurality of interconnected frame portions defined by a plurality of sheets of material, the frame portions including an upper portion attached to a lower portion and defining a hollow space therebetween, wherein the upper portion and the lower portion are defined at least by a sheet of material of the plurality of sheets of material; wherein at least one of the upper portion or the lower portion has a variable thickness; wherein the variable thickness includes at least a first thickness and a second thickness; wherein the first thickness defines a base thickness corresponding to a thickness of a first sheet of material of the plurality of sheets of material; wherein the second thickness includes the first sheet of material and an additional layer of material of the plurality of sheets of material attached thereto. ### Claim 17 (depends on 16) The vehicle subframe of claim 16, wherein the second thickness includes multiple layers of material overlaid on the first sheet of material, wherein successive layers of material have a smaller surface area than the layer upon which they are disposed. ### Claim 18 (depends on 16) The vehicle subframe of claim 16, wherein the frame portions define a curved cross-section profile. ### Claim 19 (depends on 11) The method of claim 11, wherein the panel portion defines a curved cross-section profile. ### Claim 20 A method of manufacturing a variable gauge structural component for a vehicle, the method comprising the steps of: providing a panel portion of the structural component, the panel portion including at least a first sheet of metal having a first thickness, wherein the first thickness is a minimum thickness of the panel portion; attaching at least one patch of additional metal material to the first sheet and defining a second thickness of the panel portion, wherein the first thickness is disposed in a first zone of the panel portion and the second thickness is disposed in a second zone of the panel portion; wherein the second zone has a greater stiffness than the first zone; wherein the panel portion defines a curved cross-section profile. ### Claim 21 (depends on 20) The method of claim 20, wherein the at least one patch includes a first patch and a second patch, wherein the first patch is overlaid on the panel portion, and the second patch is overlaid on the first patch.