U.S. patent application number 15/811011 was filed with the patent office on 2018-03-08 for off-road recreational vehicle.
This patent application is currently assigned to Arctic Cat Inc.. The applicant listed for this patent is Arctic Cat Inc.. Invention is credited to Reid Dale Anderson, Luke Adam Baker, Thomas Robert Brausen, Stephen Tyler Deck, Robby Gordon, Cody Tove Kallock, Shane Dean Kruse, Michael Jeffrey Lupelow, Ross Leonard Nygren, Kyle Douglas Olason, Lucas Grant Purcell, Casey Leland Root, Aaron Lee Swanson, Nicholas Keegan Ward, Chadwick Allen Williams.
Application Number | 20180065465 15/811011 |
Document ID | / |
Family ID | 61282407 |
Filed Date | 2018-03-08 |
United States Patent
Application |
20180065465 |
Kind Code |
A1 |
Ward; Nicholas Keegan ; et
al. |
March 8, 2018 |
Off-Road Recreational Vehicle
Abstract
Embodiments relate to an off-road vehicle comprising a frame,
including at least one cargo box support member, a suspension
movably coupled to the frame, a passenger compartment, an engine, a
transmission operatively coupled to the engine, and a cargo box.
The cargo box includes a floor and a plurality of upwardly
extending sidewalls, wherein at least a portion of the cargo box
floor extends over the at least one cargo box support member and
wherein the cargo box is removably coupled to the at least one
cargo box support members and is removable from the off-road
vehicle via the removal of fewer than eight fasteners.
Inventors: |
Ward; Nicholas Keegan;
(Saint Joseph, MN) ; Williams; Chadwick Allen;
(Paynesville, MN) ; Baker; Luke Adam; (St. Cloud,
MN) ; Nygren; Ross Leonard; (Rogers, MN) ;
Swanson; Aaron Lee; (Kandiyohi, MN) ; Kallock; Cody
Tove; (Becker, MN) ; Olason; Kyle Douglas;
(Thief River Falls, MN) ; Purcell; Lucas Grant;
(St. Cloud, MN) ; Anderson; Reid Dale; (Maple
Lake, MN) ; Root; Casey Leland; (Big Lake, MN)
; Lupelow; Michael Jeffrey; (Maplewood, MN) ;
Brausen; Thomas Robert; (St Cloud, MN) ; Deck;
Stephen Tyler; (Augusta, GA) ; Kruse; Shane Dean;
(Hutchinson, MN) ; Gordon; Robby; (Charlotte,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Arctic Cat Inc. |
Minneapolis |
MN |
US |
|
|
Assignee: |
Arctic Cat Inc.
Minneapolis
MN
|
Family ID: |
61282407 |
Appl. No.: |
15/811011 |
Filed: |
November 13, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15244793 |
Aug 23, 2016 |
|
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|
15811011 |
|
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62208805 |
Aug 23, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B62D 21/11 20130101;
B60Y 2200/20 20130101; B60K 17/165 20130101; B62D 23/005 20130101;
B60G 3/145 20130101; B60G 2200/4622 20130101; B60K 2005/003
20130101; B60Y 2200/124 20130101; B60Y 2300/84 20130101; B60G
2204/15 20130101; B60K 5/10 20130101; B60K 17/24 20130101; B60K
17/34 20130101; B60K 11/04 20130101; B60G 2204/1242 20130101; B60G
2300/07 20130101; B60G 2204/61 20130101; B62D 5/04 20130101; B60K
5/1275 20130101; B60G 2204/129 20130101; B60G 2200/46 20130101;
B60Y 2400/802 20130101; B60G 2204/62 20130101; B60Y 2400/72
20130101; B60G 2200/1322 20130101; B60G 3/207 20130101; B60G 7/003
20130101; B60G 3/185 20130101; B60K 17/22 20130101; B60G 2200/1442
20130101; B60G 7/006 20130101; B60G 7/02 20130101; B60K 5/04
20130101; B60G 2200/18 20130101 |
International
Class: |
B60K 5/12 20060101
B60K005/12; B60K 17/34 20060101 B60K017/34; B60K 5/04 20060101
B60K005/04; B60G 7/02 20060101 B60G007/02; B60G 7/00 20060101
B60G007/00; B60G 3/20 20060101 B60G003/20; B60G 3/18 20060101
B60G003/18; B60G 3/14 20060101 B60G003/14 |
Claims
1. An off-road vehicle comprising: a frame, including at least one
cargo box support member; a suspension movably coupled to the
frame; a passenger compartment; an engine; a transmission
operatively coupled to the engine; and a cargo box, the cargo box
comprising a floor and a plurality of upwardly extending sidewalls,
wherein at least a portion of the cargo box floor extends over the
at least one cargo box support member and wherein the cargo box is
removably coupled to the at least one cargo box support members and
is removable from the off-road vehicle via the removal of fewer
than eight fasteners.
2. An off-road vehicle comprising: a frame, including at least one
cargo box support member; a suspension movably coupled to the
frame; a passenger compartment; an engine having an engine block; a
transmission operatively coupled to the engine; and an engine
cradle, the engine cradle having a first portion extending
forwardly of the engine block and a second portion extending
rearwardly of the engine block, wherein at least a portion of the
engine cradle extends under the engine block.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 15/244,793, filed Aug. 23, 2016, which claims
the benefit of and priority to U.S. Provisional Application No.
62/208,805, filed Aug. 23, 2015, and which application is
incorporated herein by reference. A claim of priority is made.
BACKGROUND
[0002] Off-road recreational vehicles, such as side-by-side
recreational off-highway vehicles ("ROVs") or all-terrain vehicles
("ATVs"), are quite capable in a wide variety of riding
environments and situations, whether for sport or utility purposes.
The vehicles can be easy to enter and exit and easy to operate with
controls and ergonomics somewhat similar to automobiles. However,
unlike most automobiles, off-road recreational vehicles can be
driven on harsh off-road terrain.
SUMMARY
[0003] Embodiments relate to an off-road vehicle comprising a
frame, including at least one cargo box support member, a
suspension movably coupled to the frame, a passenger compartment,
an engine, a transmission operatively coupled to the engine, and a
cargo box. The cargo box includes a floor and a plurality of
upwardly extending sidewalls, wherein at least a portion of the
cargo box floor extends over the at least one cargo box support
member and wherein the cargo box is removably coupled to the at
least one cargo box support members and is removable from the
off-road vehicle via the removal of fewer than eight fasteners.
[0004] Embodiments also relate to an off-road vehicle comprising a
frame, including at least one cargo box support member, a
suspension movably coupled to the frame, a passenger compartment,
an engine having an engine block, a transmission operatively
coupled to the engine, and an engine cradle. The engine cradle
includes a first portion extending forwardly of the engine block
and a second portion extending rearwardly of the engine block,
wherein at least a portion of the engine cradle extends under the
engine block.
BRIEF DESCRIPTION OF DRAWINGS
[0005] This written disclosure describes illustrative embodiments
that are non-limiting and non-exhaustive. Reference is made to
illustrative embodiments that are depicted in the figures, in
which:
[0006] FIGS. 1-41 illustrate perspective views of an off-road
recreational vehicle, according to some embodiments.
[0007] FIGS. 42-51 illustrate perspective views of drive train and
engine components, according to some embodiments.
[0008] FIGS. 52-53 illustrate perspective views of air handling
components, according to some embodiments.
[0009] FIGS. 54-55 illustrate perspective views of steering
components, according to some embodiments.
[0010] FIGS. 56-57 illustrate perspective views of a brake system,
according to some embodiments.
[0011] FIGS. 58-66, 91-92 illustrate perspective views of a
suspension system, according to some embodiments.
[0012] FIGS. 67-84 illustrate perspective views of body panels,
cowls, skid plates, and doors of an off-road recreational vehicle,
according to some embodiments.
[0013] FIGS. 85-90, 106, and 107 illustrate perspective views a
floor panel, a footwell panel, center console, upper dash, bridging
dash panel, corner upright panel, gauge panel, rear console member,
and cupholder member of an off-road recreational vehicle, according
to some embodiments.
[0014] FIG. 93 illustrates a perspective view of a cooling system
of an off-road recreational vehicle, according to some
embodiments.
[0015] FIGS. 94-100 illustrate perspective views a removable
subframe and associated components, according to some
embodiments.
[0016] FIGS. 101-105 illustrate perspective views of trailing arm
attachment locations formed from castings to which respective frame
tubes are welded, according to some embodiments.
DETAILED DESCRIPTION
[0017] As shown in FIG. 1 an embodiment of an off-road vehicle 10
includes a plurality of ground engaging members 50, a front
suspension assembly 72 (FIG. 3), a rear suspension assembly 38
(FIG. 3), a frame 12, and one or more body panels 200. In some
embodiments, the off-road vehicle 10 further comprises a cargo box
202 (FIG. 68).
[0018] In some embodiments, the frame 12 includes structural
members 204 (FIG. 2) which are coupled together (e.g., welded,
bolted, glued). Further, the structural members 204 can be tubular
steel or aluminum, stamped sheet metal (e.g., steel, aluminum),
hydroformed, cast, forged, or formed in any other suitable manner.
The off-road vehicle 10 can be 2-wheel or 4-wheel drive. Further,
it can have any suitable style of drive system. In some
embodiments, the off-road vehicle 10 is 4-wheel drive and includes
a differential one or both the front end and rear end of the
off-road vehicle 10. The differentials can include optional locking
differentials or they can be open differentials, which can be
manually selectable by an operator or engaged automatically in
response to terrain conditions (e.g., wheel slip). In some
embodiments, the off-road vehicle has a limited slip differential
(e.g., clutch pack, Quaife, Torsen) or any other suitable
configuration (e.g., spool).
[0019] With further regard to FIG. 2, in some embodiments, the
off-road vehicle 10 includes a seating area 206. The seating area
206 includes one or more seats 208. Further one or more of the
seats 208 can be arranged in any configuration, such as a
side-by-side configuration. Further still, the seats 208 can
include bench seats, bucket seats, or a combination of both bench
and bucket seating. In some embodiments, one or more of the seats
208, or portions thereof, are adjustable.
[0020] In some embodiments, the frame 12 includes a ROPS (roll-over
protection structure) 210. In some embodiments, the ROPS 210 is
attached to the main frame 212. As used in herein, the term "frame"
12 includes both the ROPS 210 and main frame 212.
[0021] As shown in FIG. 2, in some embodiments, the off-road
vehicle 10 includes a steering wheel 214 which is coupled, for
example via a steering linkage, to at least two of the ground
engaging members 50, for example front ground engaging members. The
steering wheel 84 is coupled to the front ground engaging members
(e.g., tires) in any suitable way, for example by mechanical
steering linkage, electric power steering (EPS), hydraulically
assisted power steering, electric power steering without mechanical
linkage (e.g., drive-by-wire), electric assisted power steering
((EPAS), e.g., including pull-drift compensation, active nibble
control, etc.) or in any other suitable way. Further, in some
embodiments, the steering can include variable ratio steering and
it can be programmable such that the user can set the steering
ratio (and rate-of-change of steering ration, if it is variable) to
illicit a steering response in accordance with the user's or
manufacturer's desires (e.g., exhibiting understeer
characteristics). As further shown in FIG. 2, in some embodiments,
the steering wheel 214 tilts, shown via arrow 216, and a tilt
assembly 218 includes a shock 220 to adjust the tilt configuration
of the steering wheel 214.
[0022] With regard to FIG. 3, the off-road vehicle 10 includes a
gear shift selector 222. The gear shift selector 222 is coupled to
the transmission 224 (FIG. 42), for example via a push-pull cable
226. The off-road vehicle 10 further includes a radiator 142 and
coolant lines (or coolant hoses) 156, also shown in FIG. 93. As
illustrated in FIG. 93, in some embodiments, the coolant lines 156
include a first coolant line 156a and a second coolant line 156b.
In some embodiments, coolant flows through the first coolant line
156a from the radiator 142 to the prime mover (e.g., engine 86,
FIG. 4), as shown via directional arrow 228 (FIG. 93). In some
embodiments, coolant flows through the second coolant line 156b
from the prime mover (e.g., engine 86, FIG. 4) to the radiator 142,
as shown via directional arrow 230 (FIG. 93).
[0023] As further shown in FIG. 93, in some embodiments, a shunt
line 232 extends to a coolant tank 234 which, in some embodiments,
is an overflow tank. In some embodiments, a radiator overflow line
236 extends between the radiator 142 and the coolant tank 234.
Further, in some embodiments, a coolant tank overflow line 238. In
some embodiments, the coolant tank overflow line 238 is fluidly
connected to the coolant tank cap 240. In some embodiments, the
shunt line 232 extends from the first coolant line 156a. In some
embodiments, however, the shunt line 232 extends from the second
coolant line 156b. In some embodiments, the radiator 142 has no
radiator cap and the radiator 142 is filled with coolant via the
coolant tank cap 240. In some embodiments, for example as shown in
FIG. 93, a coolant line (e.g., first coolant line 156a) extends
from a front of the radiator 142. As shown in FIG. 93, in some
embodiments, one of the coolant lines (e.g., second coolant line
156b) extends from the back of the radiator 142. Other
configurations can also be utilized. In some embodiments, one or
more fans 242 (e.g., electric fans) are used to circulate air
across the radiator fins to help cool the coolant in the radiator.
In some embodiments, one or more of the fans 242 are reversible
fans and can "pull" or "push" air across the radiator 142 as
desired.
[0024] With regard to FIGS. 4 and 31-41, in some embodiments, the
ROPS 210 comprises two detachable portions: a first detachable ROPS
portion 244 (FIGS. 40 and 41) and a second detachable ROPS portion
246. In some embodiments, the second detachable ROPS portion 246 is
rearward of the first detachable ROPS portion 244. In some
embodiments, the first and second detachable ROPS portions 244, 246
are coupled to one another via one or more disconnects 36. In some
embodiments, the disconnects 36 comprise castings that mate with
opposing disconnects. As shown in FIG. 40, for example, disconnect
36a is configured to mate with disconnect 36b.
[0025] In some embodiments, the ROPS 210 includes one or more
lengthwise ROPS members 248. In some embodiments, the ROPS 210
includes three lengthwise ROPS members 248 which are generally
parallel to one another. In some embodiments, one or more of the
lengthwise ROPS members 248 are bowed outwardly as shown in FIG.
35. As shown in FIG. 41, in some embodiments, the ROPS 210 further
includes a front transverse ROPS member 250 and a rear transverse
ROPS member 252. In some embodiments, one or both of the front
transverse ROPS member 250 and a rear transverse ROPS member 252
are bowed. As shown in FIGS. 35 and 41, in some embodiments, the
front transverse ROPS member 250 is bowed forwardly such that the
middle of the front transverse ROPS member 250 is forward of the
left and right ends of the front transverse ROPS member 250.
[0026] In some embodiments, the ROPS 210 includes an A-pillar
member 254. In some embodiments, the A-pillar member 254 is formed
form the same piece of tubing as a lengthwise ROPS member 248. In
some embodiments, the ROPS 210 includes front V-brace members 256.
In some embodiments, the front V-brace members 256 are coupled to
the front transverse ROPS member 250, for example via welding. In
some embodiments, the front V-brace members 256 are further
comprise disconnects and are removably coupled to mating
disconnects. In some embodiments, the front V-brace members 256
have a smaller diameter than the diameter of the A-pillar member(s)
254.
[0027] In some embodiments, the ROPS 210 includes an intermediate
pillar member 258 and a rear pillar member 260, as shown for
example in FIGS. 35 and 40. In some embodiment, the intermediate
pillar member 258 and rear pillar member 260 are coupled via a
pillar bracing member 262. In some embodiments, one or both of the
intermediate pillar member 258 and rear pillar member 260 include
disconnects 36 such that the second detachable ROPS portion 246 can
be removed from the main frame 212.
[0028] In some embodiments, the ROPS 210 includes rear V-brace
members 264 (FIG. 40). In some embodiments, the rear V-brace
members 264 are coupled (e.g., welded) to rear pillar members 260
and rear transverse ROPS member 250. In some embodiments, the ROPS
210 includes one or more gussets 266 (FIG. 37). In some
embodiments, the gussets 266 are welded to adjacent ROPS members,
as shown for example in FIG. 37.
[0029] In some embodiments, for example as shown in FIG. 32, the
main frame 212 includes outer lower frame member(s) 268, front
lateral lower frame member(s) 270, rear outer lateral lower frame
member(s) 272, rear inner lateral lower frame member 274 (FIG. 34),
inner lower frame member(s) 276, joining lower frame member(s) 278,
rear outer upstanding support member(s) 280, front outer upstanding
support member(s) 282, intermediate outer upstanding support
member(s) 284 (FIGS. 35 and 41), diagonal outer support member(s)
286, rear inner upstanding lower support member(s) 288, rear
intermediate lateral frame member 290 (FIG. 41), rear upper lateral
frame member 292 (FIG. 41), rear inner upstanding intermediate
support member(s) 294 (FIG. 41), rear outer lengthwise frame
member(s) 296, rear outer lateral frame member(s) 298, rear inner
lengthwise frame member(s) 300, upper lateral dash support member
302 (FIG. 40), lower lateral dash support member 304 (FIG. 40),
front upper lengthwise frame member(s) 306 (FIG. 35), front upper
lateral frame member 308 (FIG. 34), front upper intermediate
lateral frame member 310 (FIG. 41), front upstanding frame
member(s) 312 (FIG. 32), upper lengthwise dash support member(s)
314 (FIG. 41), front lengthwise bridging member(s) 316 (FIG. 35),
front intermediate support member(s) 318 (FIG. 35), front
intermediate bridging member(s) 320 (FIG. 35), front upper bridging
member(s) 322, front intermediate dash support member 324 (FIG.
35), steering support member 326 (FIG. 41).
[0030] In some embodiments, the frame 12 includes a removable front
subframe 100 (FIG. 41). In some embodiments, the removable front
subframe 100 includes coupling locations for the lower A-arms 78,
as shown in FIG. 5. In some embodiments, the removable front
subframe 100, shown in greater detail in FIGS. 94, 97, and 98. In
some embodiments, the removable subframe 100 is coupled (e.g., via
fasteners such as bolts) to the front lateral lower frame member
270 via lower front subframe casting 328 (FIGS. 95 and 96). The
lower front subframe casting 328 is coupled to the front lateral
lower frame member 270, for example, via welding.
[0031] In some embodiments, the removable subframe 100 is coupled
to the front upper A-arm support member 330 (FIGS. 97 and 98) and
the front upstanding frame members 312 via upper front subframe
casting 332 (FIGS. 97-100). In some embodiments, the upper front
subframe casting 332 has one or more casting features to locate the
front upstanding frame members 312 thereon for attachment thereto
(e.g., welding). In some embodiments, the casting features 334 fit
inside the inner diameter of the respective front upstanding frame
member 312 to locate the front upstanding frame member 312 relative
to the upper front subframe casting 332.
[0032] With further regard to FIG. 40, in some embodiments, the
frame 12 includes a removable rear subframe 118. In some
embodiments, the rear subframe 118 includes disconnects 36 which
couple the rear subframe 118 to the rear outer lateral frame member
298, for example via tube segments 336 extending downwardly from
the rear outer lateral frame member 298. In some embodiments, the
rear subframe 118 is further coupled to the rear inner lateral
lower frame member 274, for example via lengthwise tube segments
338. In some embodiments, the rear subframe 118 comprises one or
more laterally extending tube connection members 340. In some
embodiments, the rear subframe 118 includes one or more rear
subframe panels 342 (e.g., stampings), as shown in FIG. 41, to join
adjacent rear subframe members 344.
[0033] As shown for example in FIGS. 4-11, 42, and 43, the off-road
vehicle 10 includes a driveline 350 (FIG. 12). Referring to FIGS.
42 and 43, in some embodiments, the off-road vehicle 10 includes a
longitudinally extending driveshaft 92. In some embodiments, the
driveshaft 92 is a two-piece driveshaft, for example having a first
section 92a and a second section 92b, as shown in FIGS. 42 and 43,
however, it can also be a single piece driveshaft, three piece
driveshaft, etc. Where a two-piece driveshaft 92 is utilized, a
bearing mount 352, including a bearing such as a ball bearing, can
be located at the joint between the first section 92a and the
second section 92b. Further, the bearing mount 352 can be used to
secure the driveshaft 92 to the frame 12, while permitting rotation
of the driveshaft 92. In some embodiments, one or more portions of
the driveshaft 92 extend beneath a portion of the engine 86, as
shown in FIG. 42.
[0034] In some embodiments, the driveshaft 92 is selectively
coupled to a front differential 98. In some embodiments, the front
differential 98 can include a locker, for example as disclosed in
U.S. Pat. No. 7,018,317, the contents of which are herein
incorporated by reference.
[0035] As further shown in FIGS. 42 and 43, in some embodiments,
the off-road vehicle 10 includes a continuously variable
transmission ("CVT") 354, which includes a drive clutch 356 and a
driven clutch 358. The drive clutch 356 and driven clutch 358 have
a belt 360 extending therebetween. In some embodiments, the driven
clutch 358 is coupled to a transaxle 90. In some embodiments, the
transaxle 90 has: one or more forward gears, one or more reverse
gears, and neutral. Further, in some embodiments, the transaxle 90
has a park setting. Each of the gear settings can be selected by an
operator, for example via gear shift selector 222 (FIG. 24).
[0036] Turning to FIGS. 44-51, in some embodiments, the engine 86,
transmission 224, intake assembly 362, and exhaust assembly 364 can
be removed from the off-road vehicle as an assembly. In some
embodiments, the intake assembly 362 includes an air filter housing
366, having therein one or more air filters such as paper filters,
an air intake conduit 368 extending between the filter housing 366
and the intake manifold 370. In some embodiments, the intake
manifold 370 has one or more intake runners 140. As show in FIG.
50, for example, in some embodiments, the intake manifold 370 has
three intake runners 140. In some embodiments, the intake manifold
370 has a manifold housing 372, shown in FIGS. 48 and 50. In some
embodiments, the cross-sectional area of the manifold housing 372
is greater nearer the throttle valve 374 than at a distal end
portion of the manifold housing 372. As shown in FIG. 48, in some
embodiments, the intake manifold 370 and filter housing 366 overlap
and the filter housing 366 is positioned above the intake manifold
370. In some embodiments, a filter housing support bracket 376
(FIG. 44) is coupled to the intake manifold 370 and filter housing
366.
[0037] In some embodiments, the intake assembly 362 further
includes an intake isolator 384. The intake isolator 384 mates with
a portion of the inner cowl 386 (FIGS. 53, 82, and 83). In some
embodiments, the intake isolator 384 interfaces with an underside
of the inner cowl 386, for example the right port 388 (FIG. 83) of
the inner cowl 386. In some embodiments, the intake isolator 384
has a toroidal cross section. In some embodiments, the intake
isolator 384 is formed from an elastomeric material in order to
permit the engine/transmission assembly to move a limited amount
relative to the inner cowl 386 while a portion of the intake
isolator 384 maintains contact with the inner cowl 386. In some
embodiments, the intake isolator is formed from a rubber material
and, in some embodiments, the intake isolator 384 includes a
bellows portion 410.
[0038] Returning to FIGS. 44-48, and with regard to FIG. 52, in
some embodiments, the clutches of the CVT 354 are surrounded by an
inner CVT cover 390 and an outer CVT cover 392. In some
embodiments, a CVT gasket 394 provides a seal between the inner CVT
cover 390 and outer CVT cover 392. In some embodiments, the outer
CVT cover 392 is releasably coupled to the inner CVT cover 390 with
one or more CVT cover fasteners 396, for example spring-type
retainers. In this way, the outer CVT cover 390 is removable from
the inner CVT cover 390 without the use of tools (i.e. with hands
only).
[0039] In some embodiments, the CVT has one or more CVT air
intakes. For example, as shown in FIG. 52, a first CVT air intake
assembly 398 and a second CVT air intake assembly 400 route air
into the space defined by the CVT covers to facilitate cooling of
the CVT. In some embodiments, the first CVT air intake assembly 398
routes air into the CVT via the outer CVT cover 392. Further, as
shown in FIG. 52, the second CVT air intake assembly 400 routes air
into the CVT via the inner CVT cover 390. The CVT includes a CVT
exhaust assembly 402, including a CVT exhaust port 404 and a CVT
exhaust duct 406. In some embodiments, the CVT exhaust port 404 is
located on the inner CVT cover 390, however, it can be located on
the outer CVT cover 392 or both inner and outer CVT covers.
[0040] As further shown in FIG. 52, in some embodiments, the first
air intake assembly 398 includes a first CVT intake duct 408, a
removable outer CVT cover plate 412, and a sealing member 414. In
some embodiments, the removable outer CVT cover plate 412 includes
a first intake port 416. In some embodiments, the removable outer
CVT cover plate 412 can be removed from the outer CVT cover 392 by
rotating the removable outer CVT cover plate 412 in the direction
of arrow 418. Further, the removable outer CVT cover plate 412 can
be locked into place in rotating the removable outer CVT cover
plate 412 in the direction opposite arrow 418. The removable outer
CVT cover plate 412 includes one or more tabs 420 that interface
with ramps 422 on the outer CVT cover 392 to lock/unlock the
removable outer CVT cover plate 412 relative to the outer CVT cover
392. The tabs 420 can be located on either the removable outer CVT
cover plate 412 or the outer CVT cover 392 and the ramps 422 can
also be located on either the removable outer CVT cover plate 412
or the outer CVT cover 392. In some embodiments, the first CVT
intake duct 408 interacts with the inner cowl 386 (FIG. 79). In
some embodiments, the first CVT intake duct 408 interacts with the
left port 424 (FIG. 83) of the inner cowl 386.
[0041] In some embodiments, the second CVT air intake assembly 400
includes a second CVT intake duct 426, an intake elbow 428, a
second CVT intake sealing member 430, and a second intake port 432.
In some embodiments, the intake elbow 428 and second intake port
432 have a rectangular cross-section, as shown in FIG. 52. In some
embodiments, the second CVT intake duct 426 interacts with the
inner cowl 385 (FIG. 83) and, in some embodiments, with the middle
port 434 of the inner cowl 386. With further reference to FIG. 83,
in some embodiments, the engine 86 receives combustion air and the
CVT receives cooling air from a space between by the inner cowl 386
and outer cowl 436. Air enters the space between the inner cowl 386
and outer cowl 436 via a grate 438, which is rearwardly facing in
some embodiments. In some embodiments, a cowl divider 440 divides
the air between the right port 388 on one side and the middle port
434 and left port 424 on the other side.
[0042] In some embodiments, one or both of the CVT covers includes
a drain hole 442 and drain plug 444.
[0043] Returning to FIG. 44, in some embodiments, an outer
alternator shroud 446 protects the alternator 448 (FIG. 15),
alternator drive belt 450, and associated pulleys. In some
embodiments, an inner alternator shroud 452 (FIG. 46) is provided
on the engine side of the alternator 448. In some embodiments, the
alternator drive belt 450 is coupled to the engine crankshaft (not
shown) via a pulley.
[0044] With further regard to FIG. 44, in some embodiments, a
muffler 378 is coupled to a muffler support bracket 380 (FIG. 44),
for example via fasteners which are fastened to muffler weldment
382, as also shown in FIG. 11. In turn, the muffler weldment 382
is, in some embodiments, welded to the muffler 378.
[0045] As shown in FIGS. 49-51, in some embodiments, the
engine/transmission assembly includes an engine cradle member 454,
a cradle support 456, cradle bridging member 458, cradle bridging
bracket 460, rear transmission support member 462, and transmission
support bracket 464. In some embodiments, the cradle support 456 is
vibration isolated via front isolators 466 and the transmission
support bracket 464 is vibration isolated via rear isolators 468.
In some embodiments, the muffler support bracket 380 is coupled
(e.g., welded) to the transmission support bracket 464. Further, in
some embodiments, the transaxle 90 (FIG. 44) is coupled to the
transmission support bracket 464, for example via one or more
fasteners extending through support bracket tabs 470. In some
embodiments, one or more heat shields 472, 474 provide shielding
for exhaust pipes 476 (FIG. 48). As shown in FIG. 49, in some
embodiments, the engine 86 is coupled to the engine cradle member
454 in front of the engine 86 and to the cradle bridging member 458
behind the engine 86. In some embodiments, the engine cradle member
454 has two cradle legs 478; the cradle legs 478 extend under
portions of the engine 86. In some embodiments, the cradle legs 478
are each welded to the cradle uprights 480. In some embodiments,
the engine cradle member 454 includes hoop member 482. Intake
support tabs 484 are, in turn, supported by hoop member 482. In
some embodiments an oil filter 486 (FIG. 49) is disposed between
the engine 86 and the cradle bridging member 458.
[0046] As shown in FIG. 17, in some embodiments, the rear
transmission support member 462 is coupled to rear inner lengthwise
frame member(s) 300 (FIG. 40) via lengthwise frame member brackets
488 (FIG. 17).
[0047] In some embodiments, the cradle support 456 (FIG. 51) is
coupled to mount member(s) 490 (FIGS. 24 and 26) via front
isolators 466 (FIG. 51). In some embodiments, the mount member(s)
490 are welded to the main frame 212.
[0048] Turning to FIG. 21, in some embodiments, the off-road
vehicle 10 includes a fuel tank 492. In some embodiments, a portion
of the fuel tank 492 extends rearwardly of a portion of the rear
outer upstanding support member 280. In some embodiments, a portion
of the fuel tank 492 extends forwardly to the gear shift selector
222; in some embodiments, a portion of the fuel tank 492 extends
forwardly of the bearing mount 352.
[0049] Turning to FIGS. 54 and 55, in some embodiments, a steering
assembly 494 includes a steering wheel 214, a first steering shaft
496, a second steering shaft 498, and a third steering shaft 500.
In some embodiments, the steering shafts are connected together via
universal joints (u-joints) 502. In some embodiments, the steering
assembly 494 further includes a steering rack 152 and power
steering unit 154 (e.g., electric power steering or EPS). The
steering assembly 494 includes tie rods 504 which, in turn, are
respectively coupled to front knuckles 506 (FIG. 56).
[0050] In some embodiments, the steering rack 152 is coupled to a
steering rack bracket 502. As shown in the partially exploded view
in FIG. 54, the steering rack bracket 502 is coupled to the front
subframe 100 and the front upper A-arm support member 330.
[0051] With regard to FIGS. 56 and 57, in some embodiments, a brake
system 508 includes a first fluid reservoir 510 and a second fluid
reservoir 512. In some embodiments, the second fluid reservoir 512
is a remote fluid fill reservoir. In some embodiments, the first
fluid reservoir 510 is positioned above the master cylinder 514. In
some embodiments, brake fluid is supplied to brake calipers,
including front brake calipers 516 and rear brake calipers 518. In
some embodiments, the front calipers 516 are each two-piston
calipers and the rear calipers 518 are each single-piston calipers,
however, the calipers (front and/or rear) can be of any suitable
size and have any suitable number of pistons. Further, in some
embodiments, the calipers can be integrated with anti-lock brake
sensors.
[0052] Regarding FIGS. 58-62, 91, and 92, in some embodiments, a
front suspension assembly 72 includes upper A-arms 80, lower A-arms
78, coil-over springs 68, and front anti-roll bar (ARB) 348. In
some embodiments, the upper A-arms 80 are movably coupled to the
front upper A-arm support member 330 (FIG. 97), for example via
upper A-arm mount(s) 346 (FIG. 16). In some embodiments, the front
anti-roll bar 348 is coupled to the lower A-arms 78. Further, the
coil-over springs 68 are coupled to the lower A-arms rearwardly of
the upper A-arms 80. In some embodiments, the front anti-roll bar
348 is rotatably coupled to front ARB support member 520 (FIGS. 16
and 29), via front ARB hangar(s) 522 (FIGS. 16, 58, 60 and 61). In
some embodiments, the lower A-arms 78 are coupled to the anti-roll
bar 348 via front ARB links 524. In some embodiments, the front ARB
links 524 include spherical joints 526 at one or both ends thereof,
as shown in FIG. 62, for example. As also shown in FIG. 62, in some
embodiments, the spherical joints 526 each have a nominal axis
(528, 530) though which a fastener is inserted. In some
embodiments, the nominal axes 528 and 530 are non-parallel and, in
some embodiments, are perpendicular to one another.
[0053] In some embodiments, for example as shown in FIG. 61, the
front ARB links 524 are coupled to a central support 532 which
extends intermediate the forward and rearward arms of the lower
A-arm 78. In some embodiments, respective coil-over springs 68 are
further coupled to the central support 532 outwardly of the
location where the front ARB links 524 couple to the central
support 532.
[0054] With regard to FIG. 62, in some embodiments, a front
half-shaft 82 is coupled to a wheel hub 534 such that external
splines on the front half-shaft 82 interact with internal splines
on the wheel hub 534 to thereby drive the wheel hub 534. In some
embodiments, a front knuckle 506 includes an inner bearing 536; an
inner portion 538 of the wheel hub 534 rides on the inner bearing
536. In some embodiments, a brake rotor 540 is coupled to the wheel
hub 534 inwardly of the flange portions of wheel hub 534.
[0055] In some embodiments, the lower A-arms 78 and upper A-arms 80
include spherical bearings at ends thereof. In some embodiments,
the spherical bearings at the ends of the respective A-arms fit
between opposing knuckle arms. In particular, as shown in FIGS. 62,
91, and 92, the spherical bearings of the upper A-arms 80 fit
between upper knuckle arms 542 and the spherical bearings of the
lower A-arms 78 fit between lower knuckle arms 544. In some
embodiments, the inside surfaces of the upper knuckle arms 542 and
the inside surfaces of the lower knuckle arms 544 are machined
surfaces in order to maintain tolerances and permit the desired fit
with the knuckle's interface with the spherical bearings, as shown
in FIG. 92. As shown in FIG. 92, the knuckle arms (542, 544)
utilize fasteners that are in "double shear". As further shown in
FIG. 92, the tie rod arms 546 utilize fasteners that are also in
"double shear". With further regard to FIG. 92, in some
embodiments, the spherical bearings at the end of the respective
A-arms have thereover rubber boots 548. The rubber boots help
prevent foreign material (e.g., dirt) from intruding into the
bearing surface.
[0056] Turning to FIGS. 67-84, in some embodiments, the off-road
vehicle 10 includes one or more body panels, cowls, skid plates,
doors. As shown, in some embodiments, the off-road vehicle includes
a front bumper panel 600, a front grill panel 602, front grill
insert 604, central hood panel 606, hood insert 608, cornering hood
panel 610, front outer fender panel 612, front bridging panel 614,
rocker panel 616, rear outer fender panel 618, firewall panel 620,
rear outer fender panel 622, rear bumper panel 624, rear ROPS panel
626, rear lower body panel 628, and rear subframe panel 630. In
some embodiments, the off-road vehicle 10 further includes an
underside panel 632, as shown in FIG. 69.
[0057] With additional reference to FIG. 84, in some embodiments,
the cargo box 202 is removable from the frame 12 (e.g., main frame
212) without tools. As shown in FIG. 84, in some embodiments, the
cargo box 202 has a plurality of sidewalls and a floor 634. In some
embodiments, the floor 634 includes one or more ridges or
corrugations 636 to provide strength to the cargo box 202. In some
embodiments, the cargo box 202 is coupled, for example via
fasteners 638 (e.g., large wing screws) which can be screwed in and
out with one's hand to secure the cargo box 202 to cargo box frame
members 640. In some embodiments, for example as shown in FIG. 30,
the cargo box frame members 640 extend generally laterally between
opposing rear outer lengthwise frame members 296. In some
embodiments, the cargo box frame members 640 have cargo box frame
tabs 642 into which the fasteners 638 are screwed (e.g., the cargo
box frame tabs include nut plates, etc.).
[0058] In some embodiments, the cargo box 202 includes one or more
tie-downs 644 to which cargo can be secured.
[0059] With regard to FIGS. 85-90, 106, and 107, in some
embodiments, the off-road vehicle 10 comprises a floor panel 646, a
footwell panel 648, center console 650, upper dash 652, bridging
dash panel 654, corner upright panel 656, gauge panel 658, rear
console member 660, and cupholder member 662.
[0060] Referring to FIG. 86, in some embodiments, a passenger grab
handle 664 is coupled at a first end to the upper dash 652 and at a
second end to a portion of the frame 12, such as handle support
hoop 666, as shown in FIG. 3. In some embodiments, the second end
of the passenger grab handle 664 is coupled, via fasteners 670, to
through-holes 668 (FIG. 3). The fasteners 670, in turn, are further
secured to mating portion of grab handle portion 664, as shown in
FIG. 86. In this way, the passenger grab handle 664 is secured, in
some embodiments to one or more plastic panels and, additional, to
a portion of the frame 12. In some embodiments, the grab handle 664
is formed in two halves and both halves are formed from a polymeric
material.
[0061] With reference to FIG. 87, in some embodiments, a glovebox
672 has a glovebox door 674, which is openably coupled, for example
with a hinge, to the upper dash 652. In some embodiments, a filler
panel 676 can be coupled to the upper dash 652, however, the filler
panel 676 can be removed in favor of one or more accessories, such
as GPS navigation, audio system, etc.
[0062] Turning now to FIGS. 106 and 107, in some embodiments, a
power supply plug 678 is positioned within the glovebox 672. In
some embodiments, the power supply plug is a 12-volt direct current
plug; in some embodiments, the power supply plug is a 120-volt
alternating current plug, such as a wall-plug.
[0063] In some embodiments, one or more USB (universal serial bus)
plugs 680 are positioned within the glovebox 672. In some
embodiments, the USB plugs 680 can provide power for charging
cellular phones, etc. In some embodiments, however the USB plugs
can permit the operator the ability to interface with an onboard
GPS, modify shock settings or other vehicle characteristics,
download ride statistics (range, fuel economy, maximum cornering
g's, straight line acceleration, lap times, etc.).
[0064] With regard to FIGS. 101-105, in some embodiments, the
trailing arm attachment locations are formed from castings to which
respective frame tubes are welded. In some embodiments, an outer
suspension support casting 700 is coupled (e.g., welded) to rear
outer lateral lower frame member 272, rear outer upstanding support
member 280, outer lower frame member 268, and lower diagonal outer
support member 704.
[0065] As shown in FIGS. 104 and 105, in some embodiments, the
inner suspension support casting 702 is coupled (e.g., welded) to
the rear outer lateral lower frame member 272, rear inner
upstanding lower support member 288, and joining lower frame member
278. As discussed above with respect to other castings, the outer
suspension support casting 700 and inner suspension support casting
702 include features which facilitate easy alignment of frame tubes
to be welded thereto.
[0066] U.S. Pat. No. 8,764,039, titled "Suspension for Vehicle,"
filed Apr. 24, 2012, having inventors Keller and Seal is hereby
incorporated by reference in its entirety. Further, the contents of
U.S. Provisional application titled "Camber Adjusting Assembly,"
having inventor Robby Gordon, and Application No. 62/208,537, filed
Aug. 21, 2015, is herein incorporated by reference. Additionally,
the contents of U.S. Provisional application titled "Universal
Wishbone Trailing Arm," having inventor Robby Gordon, and
Application No. 62/208,531, filed Aug. 21, 2015, is also
incorporated by reference herein. Additionally, the contents of
U.S. application Ser. No. 15/242,320, titled "Universal Wishbone
Trailing Arm," and U.S. application Ser. No. 15/242,380, titled
"Camber Adjusting Assembly," both having first named inventor Robby
Gordon are incorporated by reference herein. U.S. Provisional
application titled "Off Road Vehicle," having inventor Robby
Gordon, and Application No. 62/208,805, filed Aug. 23, 2015, is
herein incorporated by reference. Further, the immediate
application claims the benefit of and priority to Application
62/208,805, titled "Off Road Vehicle," having inventor Robby
Gordon, and filed Aug. 23, 2015. Finally, U.S. 62/474,562, filed
Mar. 21, 2017, having first named inventor Devin Joseph Danielson
is incorporated herein by reference.
[0067] Other embodiments of the present disclosure are possible.
Although the description above contains much specificity, these
should not be construed as limiting the scope of the disclosure,
but as merely providing illustrations of some of the presently
preferred embodiments of this disclosure. It is also contemplated
that various combinations or sub-combinations of the specific
features and aspects of the embodiments may be made and still fall
within the scope of this disclosure. It should be understood that
various features and aspects of the disclosed embodiments can be
combined with or substituted for one another in order to form
various embodiments. Thus, it is intended that the scope of at
least some of the present disclosure should not be limited by the
particular disclosed embodiments described above.
[0068] Thus the scope of this disclosure should be determined by
the appended claims and their legal equivalents. Therefore, it will
be appreciated that the scope of the present disclosure fully
encompasses other embodiments which may become obvious to those
skilled in the art, and that the scope of the present disclosure is
accordingly to be limited by nothing other than the appended
claims, in which reference to an element in the singular is not
intended to mean "one and only one" unless explicitly so stated,
but rather "one or more." All structural, chemical, and functional
equivalents to the elements of the above-described preferred
embodiment that are known to those of ordinary skill in the art are
expressly incorporated herein by reference and are intended to be
encompassed by the present claims. Moreover, it is not necessary
for a device or method to address each and every problem sought to
be solved by the present disclosure, for it to be encompassed by
the present claims. Furthermore, no element, component, or method
step in the present disclosure is intended to be dedicated to the
public regardless of whether the element, component, or method step
is explicitly recited in the claims.
[0069] The foregoing description of various preferred embodiments
of the disclosure have been presented for purposes of illustration
and description. It is not intended to be exhaustive or to limit
the disclosure to the precise embodiments, and obviously many
modifications and variations are possible in light of the above
teaching. The example embodiments, as described above, were chosen
and described in order to best explain the principles of the
disclosure and its practical application to thereby enable others
skilled in the art to best utilize the disclosure in various
embodiments and with various modifications as are suited to the
particular use contemplated. It is intended that the scope of the
disclosure be defined by the claims appended hereto
[0070] Various examples have been described. These and other
examples are within the scope of the following claims.
* * * * *