Space frame cross member with integrated door seal feature

#The present invention is generally related to motor vehicle space frames and more particularly to a door seal interface structure for providing a door seal-engagable surface between a pair of space frame members in the vicinity of a joint therebetween.

#Space frame architecture is increasingly being used in vehicle construction. Space frames are cage-like structures constructed of a plurality of elongated structural components connected together at joints. The vehicle is assembled by mounting other vehicle components, such as vehicle body panels, on the space frame.

#Vehicle doors are usually mounted on each side of the vehicle for pivotal movement between open and closed positions with respect to a door opening. Each door of a contemporary vehicle has a continuous peripheral door seal typically constructed of a resilient rubber-like material that sealingly engages a corresponding surface or surfaces surrounding the associated door opening when the door is closed. The door seal acts as a barrier which seals the vehicle passenger compartment when the door is closed, thereby protecting the vehicle occupants and the vehicle interior from outside weather conditions, noise, pollution and so on.

#FIG. 1 is a perspective view of a conventional vehicle space frame;

#FIG. 2 is a perspective view of a vehicle space frame incorporating the interface structure according to this invention;

#FIG. 3 is a partial perspective view showing the interface structure of a longitudinally extending hydroformed rail portion, a hydroformed pillar portion and a roof cross member as illustrated in FIG. 2.

#FIG. 1 is a perspective view of a conventional vehicle space frame 10. The space frame 10 generally includes a forward frame portion 12, a middle frame portion 16 and a rearward frame portion 18. A pair of laterally spaced, longitudinally extending lower side rail structures 22 are disposed on each side of the space frame 10 and extend the length thereof.

#The lower side rail structures 22 are preferably constructed of three tubular hydroformed members fixed together at joints. Specifically, each side rail structure 22 includes a hydroformed forward lower side rail member 26, 28, respectively, a hydroformed intermediate lower side rail member 30, 32, respectively, and a hydroformed rearward lower side rail member 34, 36, respectively. The pairs of hydroformed members 26, 28; 30, 32; and 34, 36 are of mirror image construction. Only one member 26, 30, and 34 of each pair will be discussed in detail, but the discussion applies to both pair members.

#Each forward lower side rail member 26 is connected to the associated intermediate lower side rail member 30 at a joint 38. Similarly, each intermediate lower side rail member 30 is connected to the associated rear lower side rail member 34 at a joint 42.