U.S. patent application number 15/876551 was filed with the patent office on 2019-07-25 for vehicle frame and vehicle having same.
The applicant listed for this patent is Honda Motor Co., Ltd.. Invention is credited to Dakota D. KIRTLAND, Daniel T. SELLARS, Matthew L. TARACKO, Luke M. UPAH.
Application Number | 20190225270 15/876551 |
Document ID | / |
Family ID | 67069274 |
Filed Date | 2019-07-25 |
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United States Patent
Application |
20190225270 |
Kind Code |
A1 |
UPAH; Luke M. ; et
al. |
July 25, 2019 |
VEHICLE FRAME AND VEHICLE HAVING SAME
Abstract
A frame assembly for a vehicle can include a main frame assembly
defining a passenger compartment, and a front frame assembly. The
front frame assembly can include a pair of front frame members
extending upwardly, and a pair of intermediate frame members spaced
apart from each other in the transverse direction of the vehicle.
Each of the intermediate frame members can be connected to a
respective one of the front frame members. Each of the intermediate
frame members also can be connected to a cross member of the main
frame assembly, and can include a bend such that each of the
intermediate frame members buckles in the longitudinal direction of
the vehicle if a load or kinetic energy applied to each of the
intermediate frame members in the longitudinal direction of the
vehicle exceeds a predetermined threshold.
Inventors: |
UPAH; Luke M.;
(Williamsburg, IA) ; SELLARS; Daniel T.; (West
Liberty, OH) ; KIRTLAND; Dakota D.; (Dublin, OH)
; TARACKO; Matthew L.; (Marysville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Honda Motor Co., Ltd. |
Tokyo |
|
JP |
|
|
Family ID: |
67069274 |
Appl. No.: |
15/876551 |
Filed: |
January 22, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60G 2200/144 20130101;
B60R 21/13 20130101; B60G 3/20 20130101; B60G 2300/07 20130101;
B60G 3/00 20130101; B62D 23/005 20130101; B62D 21/15 20130101; B60G
2300/08 20130101; B60G 2200/17 20130101; B60R 16/0207 20130101;
B60R 16/0215 20130101; B62D 21/02 20130101; B62D 25/088 20130101;
B60R 19/26 20130101 |
International
Class: |
B62D 21/15 20060101
B62D021/15; B62D 21/02 20060101 B62D021/02; B60R 19/26 20060101
B60R019/26; B60R 16/02 20060101 B60R016/02; B62D 25/08 20060101
B62D025/08; B60R 21/13 20060101 B60R021/13 |
Claims
1. A frame assembly for a vehicle comprising: a main frame assembly
defining a passenger compartment, and including, a pair of side
frame members extending upwardly along a vertical direction of the
vehicle, and a cross frame member extending in the transverse
direction from one of the side frame members to a different one of
the side frame members; and a front frame assembly including, a
pair of front frame members, and a pair of intermediate frame
members spaced apart from each other in the transverse direction of
the vehicle, each of the intermediate frame members is connected to
and extends from a respective one of the front frame members, each
of the intermediate frame members is also connected to the cross
member, and each of the pair of intermediate frame members includes
a bend such that each of the intermediate frame members buckles in
the longitudinal direction of the vehicle if a load or kinetic
energy applied to each of the intermediate frame members in the
longitudinal direction of the vehicle exceeds a predetermined
threshold; wherein the bend of each of the intermediate frame
members is oriented to be convex toward a traveling surface on
which the vehicle travels.
2. The frame assembly according to claim 1, further comprising: a
front bumper assembly connected to the front frame assembly such
that the front frame assembly is located between the front bumper
assembly and the main frame assembly, the front bumper assembly is
configured to collapse if a load or kinetic energy is input to the
front bumper assembly that exceeds a second predetermined
threshold, wherein the intermediate frame members are configured to
resist deformation when subjected to a load or kinetic energy input
via the front bumper assembly until the front bumper assembly
initially collapses in a direction toward the main frame assembly,
and the intermediate frame members are further configured to
collapse in the direction toward the main frame assembly if the
load or the energy input continues to be applied to the front frame
members via the front bumper assembly after the front bumper
assembly initially collapses.
3. The frame assembly according to claim 1, wherein the front frame
assembly further includes a pair of lower frame members connected
to and extending from the main frame assembly in the longitudinal
direction of the vehicle, each of the front frame members is
connected to and extends upwardly from a respective one of the
lower frame members, and the bend of each of the intermediate frame
members is oriented to be convex toward a respective one of the
lower frame members.
4. The frame assembly according to claim 1, wherein the bend of
each of the intermediate frame members includes a concave portion
and a tuning hole in the concave portion.
5. The frame assembly according to claim 4, wherein the front frame
assembly further includes a pair of lower frame members connected
to and extending from the main frame assembly in the longitudinal
direction of the vehicle, each of the front frame members is
connected to and extends upwardly from a respective one of the
lower frame members, and each of the intermediate frame members
includes a bottom portion that is a portion of the intermediate
frame member that is closest to a respective one of the lower frame
members in the vertical direction of the vehicle, and a drain hole
is located in the bottom portion.
6. The frame assembly according to claim 1, wherein each of the
intermediate frame members is a hollow tube.
7. The frame assembly according to claim 1, wherein the front frame
assembly further includes: a pair of lower frame members connected
to and extending from the main frame assembly in the longitudinal
direction of the vehicle, and a pair of first front frame members,
each of the first front frame members is connected to and extends
upwardly from a respective one of the lower frame members, each of
the front frame members includes a first end connected to a
respective one of the lower frame members and a second end
connected to a respective one of the first front frame members such
that each of the front frame members extends from the respective
one of the lower frame members to the respective one of the first
front frame members, and each of the intermediate frame members is
connected to a respective one of the front frame members at a
location that is between the first end and the second end.
8. The frame assembly according to claim 7, wherein the location on
the respective one of the frame members is closer to the second end
than to the first end.
9. The frame assembly according to claim 1, wherein each of the
intermediate frame members is welded to the cross member and the
respective one of the front frame members.
10. The frame assembly according to claim 1, wherein each of the
intermediate frame members includes a pair of straight portions and
the bend is located between the straight portions.
11. The frame assembly according to claim 1, further comprising: a
wire harness extending from the cross member to the front frame
members, and the wire harness is connected to at least one of the
intermediate frame members.
12. The frame assembly according to claim 11, wherein each of the
intermediate frame members includes a clip hole adjacent to the
bend, and the wire harness includes a clip that is mounted in the
clip hole.
13. A vehicle comprising: a main frame assembly defining a
passenger compartment of the vehicle, and including, a pair of main
frame members extending in a longitudinal direction of the vehicle,
and spaced apart in a transverse direction of the vehicle, a pair
of side frame members, each of the side frame members is connected
to and extends upwardly along a vertical direction of the vehicle
from a front end portion of a respective one of each of the main
frame members, and a cross frame member extending in the transverse
direction of the vehicle from one of the side frame members to a
different one of the side frame members; a rear frame assembly
connected to and extending from a rear end portion of the main
frame members in a longitudinal direction of the vehicle, the rear
frame assembly is configured to mount a rear suspension and wheel
assembly; and a front frame assembly connected to and extending
from a front end portion of the main frame assembly of the vehicle
such that the main frame assembly extends between the front frame
assembly and the rear frame assembly in a longitudinal direction of
the vehicle, the front frame assembly is configured to mount a
front suspension and wheel assembly, the front frame assembly
including, a pair of lower frame members connected to the main
frame assembly, the pair of lower frame members extending from the
main frame assembly in the longitudinal direction of the vehicle,
and the lower frame members are spaced apart from each other in the
transverse direction of the vehicle, a pair of front frame members,
each of the front frame members is connected to and extends
upwardly from a respective one of the lower frame members, and a
pair of intermediate frame members spaced apart from each other in
the transverse direction of the vehicle, each of the intermediate
frame members is connected to and extends from a respective one of
the front frame members, each of the intermediate frame members is
also connected to the cross member, and each of the pair of
intermediate frame members includes a bend such that each of the
intermediate frame members buckles in the longitudinal direction of
the vehicle if a load or kinetic energy applied to each of the
intermediate frame members in the longitudinal direction of the
vehicle exceeds a predetermined threshold, wherein the bend of each
of the intermediate frame members includes a concave portion and a
tuning hole in the concave portion.
14. The vehicle according to claim 13, further comprising a front
bumper assembly connected to the front frame assembly such that the
front frame assembly is located between the front bumper assembly
and the main frame assembly, the front bumper assembly is
configured to collapse if a load or kinetic energy is input to the
front bumper assembly that exceeds another predetermined threshold,
wherein the intermediate frame members are configured to resist
deformation when subjected to a load or kinetic energy input via
the front bumper assembly until the front bumper assembly initially
collapses in a direction toward the main frame assembly, and the
intermediate frame members are further configured to collapse in
the direction toward the main frame assembly if the load or the
energy input continues to be applied to the front frame members via
the front bumper assembly after the front bumper assembly initially
collapses.
15. The frame assembly according to claim 13, wherein the bend of
each of the intermediate frame members is oriented to be convex
toward a traveling surface on which the vehicle travels.
16. (canceled)
17. The frame assembly according to claim 13, wherein each of the
intermediate frame members includes a pair of straight portions and
the bend is located between the straight portions.
18. The frame assembly according to claim 13, further comprising a
wire harness extending from the cross member to the front frame
members, and the wire harness is connected to at least one of the
intermediate frame members.
19. An all-terrain vehicle comprising: a main frame assembly
including, a pair of main frame members extending in a longitudinal
direction of the vehicle, and spaced apart in a transverse
direction of the vehicle, a roll cage connected to each of the main
frame members at locations on each of the main frame members that
are spaced apart in the longitudinal direction of the vehicle, the
roll cage is configured to define a passenger compartment, and the
roll cage includes a pair of cage side members, each of the cage
side members is connected to and extends upwardly along a vertical
direction of the vehicle from a front end portion of a respective
one of each of the main frame members, and a cross frame member
extending in the transverse direction of the vehicle from one of
the cage side members to a different one of the cage side members;
an instrument panel assembly connected to the cross frame member
and extending in the transverse direction of the vehicle between
the cage side members; a rear frame assembly connected to and
extending from a rear end portion of the main frame members in a
longitudinal direction of the vehicle, and connected to and
extending from a rear end portion of the roll cage, and the rear
frame assembly is configured to mount a rear suspension and wheel
assembly; and a front frame assembly connected to and extending
from a front end portion of the main frame assembly of the vehicle
such that the main frame assembly extends between the front frame
assembly and the rear frame assembly in a longitudinal direction of
the vehicle, the front frame assembly is configured to mount a
front suspension and wheel assembly, the front frame assembly
including, a pair of lower frame members connected to the main
frame assembly, the pair of lower frame members extending from the
main frame assembly in the longitudinal direction of the vehicle,
and the lower frame members are spaced apart from each other in the
transverse direction of the vehicle, a pair of front frame members,
each of the front frame members is connected to and extends
upwardly from a respective one of the lower frame members, a pair
of intermediate frame members spaced apart from each other in the
transverse direction of the vehicle, each of the intermediate frame
members is connected to and extends from a respective one of the
front frame members, each of the intermediate frame members is also
connected to the cross member, and each of the pair of intermediate
frame members includes a bend such that each of the intermediate
frame members buckles in the longitudinal direction of the vehicle
if a load or kinetic energy applied to each of the intermediate
frame members in the longitudinal direction of the vehicle exceeds
a predetermined threshold, and each of the front frame members
includes a first end connected to a respective one of the lower
frame members and a second end, and each of the intermediate frame
members is connected to a respective one of the front frame members
at a location that is between the first end and the second end.
20. The all-terrain vehicle according to claim 19, further
comprising a front bumper assembly connected to the front frame
assembly such that the front frame assembly is located between the
front bumper assembly and the main frame assembly, the front bumper
assembly is configured to collapse if a load or kinetic energy is
input to the front bumper assembly that exceeds another
predetermined threshold, wherein the intermediate frame members are
configured to resist deformation when subjected to a load or
kinetic energy input via the front bumper assembly until the front
bumper assembly initially collapses in a direction toward the main
frame assembly, and the intermediate frame members are further
configured to collapse in the direction toward the main frame
assembly if the load or the energy input continues to be applied to
the front frame members via the front bumper assembly after the
front bumper assembly initially collapses.
21. The all-terrain vehicle according to claim 19, wherein the
front frame assembly further includes: a pair of first front frame
members, each of the first front frame members is connected to and
extends upwardly from a respective one of the lower frame members,
and the second end of each of the front frame members is connected
to a respective one of the first front frame members such that each
of the front frame members extends from the respective one of the
lower frame members to the respective one of the first front frame
members.
Description
BACKGROUND
[0001] The disclosed subject matter relates to a vehicle and a
frame assembly for the vehicle. More particularly, the disclosed
subject matter relates to methods and apparatus that enhance load
and energy management performance upon application of external
loads and stresses, such as may occur during off-road travel over
uneven terrain.
[0002] Vehicles, such as but not limited to all-terrain vehicles,
can be subjected to relatively large load and/or energy inputs to
the frame assembly due to the unevenness of the terrain across
which the vehicle is travelling. The all-terrain vehicle can
include a generally rigid frame assembly that is designed to
withstand the load and energy inputs transmitted from the wheels
and through the suspension components during travel over the uneven
terrain. For example, space constraints and off-road durability may
make it beneficial to provide very stiff portions of the vehicle
frame that are spaced from the passenger area, such as but not
limited to frame structures around the front suspension components,
rear suspension components and/or powertrain components.
SUMMARY
[0003] Some embodiments are directed to a frame assembly for a
vehicle that can include a main frame assembly and a front frame
assembly. The main frame assembly can define a passenger
compartment, and can include a pair of side frame members extending
upwardly along a vertical direction of the vehicle from a
respective one of each of the main frame members, and a cross frame
member extending in the transverse direction from one of the side
frame members to a different one of the side frame members. The
front frame assembly can include a pair of front frame members, and
a pair of intermediate frame members that can be spaced apart from
each other in the transverse direction of the vehicle. Each of the
intermediate frame members can be connected to and can extend from
a respective one of the front frame members. Each of the
intermediate frame members also can be connected to the cross
member. Each of the pair of intermediate frame members can include
a bend such that each of the intermediate frame members buckles in
the longitudinal direction of the vehicle if a load or kinetic
energy applied to each of the intermediate frame members in the
longitudinal direction of the vehicle exceeds a predetermined
threshold.
[0004] Some embodiments are directed to a vehicle that can include
a main frame assembly, a rear frame assembly, and a front frame
assembly. The main frame assembly can define a passenger
compartment of the vehicle, and can include a pair of main frame
members, a pair of side frame members, and a cross frame member.
The main frame members can extend in a longitudinal direction of
the vehicle, and can be spaced apart in a transverse direction of
the vehicle. Each of the side frame members can be connected to and
can extend upwardly along a vertical direction of the vehicle from
a front end portion of a respective one of each of the main frame
members. The cross frame member can extend in the transverse
direction of the vehicle from one of the side frame members to a
different one of the side frame members. The rear frame assembly
can be connected to and can extend from a rear end portion of the
main frame members in a longitudinal direction of the vehicle. The
rear frame assembly can be configured to mount a rear suspension
and wheel assembly. The front frame assembly can be connected to
and can extend from a front end portion of the main frame assembly
of the vehicle such that the main frame assembly extends between
the front frame assembly and the rear frame assembly in a
longitudinal direction of the vehicle. The front frame assembly can
be configured to mount a front suspension and wheel assembly. The
front frame assembly can include a pair of lower frame members, a
pair of front frame members, and a pair of intermediate frame
members. The lower frame members can be connected to the main frame
assembly. The lower frame members can extend from the main frame
assembly in the longitudinal direction of the vehicle. The lower
frame members can be spaced apart from each other in the transverse
direction of the vehicle. Each of the front frame members can be
connected to and can extend upwardly from a respective one of the
lower frame members. The intermediate frame members can be spaced
apart from each other in the transverse direction of the vehicle.
Each of the intermediate frame members can be connected to and can
extend from a respective one of the front frame members. Each of
the intermediate frame members also can be connected to the cross
member. Each of the pair of intermediate frame members can include
a bend such that each of the intermediate frame members buckles in
the longitudinal direction of the vehicle if a load or kinetic
energy applied to each of the intermediate frame members in the
longitudinal direction of the vehicle exceeds a predetermined
threshold.
[0005] Some embodiments are directed to an all-terrain vehicle that
can include a main frame assembly, an instrument panel assembly, a
rear frame assembly, and a front frame assembly. The main frame
assembly can include a pair of main frame members, a roll cage, and
a cross frame member. The main frame members can extend in a
longitudinal direction of the vehicle, and can be spaced apart in a
transverse direction of the vehicle. The roll cage can be connected
to each of the main frame members at locations on each of the main
frame members that are spaced apart in the longitudinal direction
of the vehicle. The roll cage can be configured to define a
passenger compartment. The roll cage can include a pair of cage
side members, and each of the cage side members can be connected to
and can extend upwardly along a vertical direction of the vehicle
from a front end portion of a respective one of each of the main
frame members. The cross frame member can extend in the transverse
direction of the vehicle from one of the cage side members to a
different one of the cage side members. The instrument panel
assembly can be connected to the cross frame member and can extend
in the transverse direction of the vehicle between the cage side
members. The rear frame assembly can be connected to and can extend
from a rear end portion of the main frame members in a longitudinal
direction of the vehicle. The rear frame assembly can be connected
to and can extend from a rear end portion of the roll cage. The
rear frame assembly can be configured to mount a rear suspension
and wheel assembly. The front frame assembly can be connected to
and can extend from a front end portion of the main frame assembly
of the vehicle such that the main frame assembly extends between
the front frame assembly and the rear frame assembly in a
longitudinal direction of the vehicle. The front frame assembly can
be configured to mount a front suspension and wheel assembly. The
front frame assembly can include a pair of lower frame members, a
pair of front frame members, and a pair of intermediate frame
members. The lower frame members can be connected to the main frame
assembly. The lower frame members can extend from the main frame
assembly in the longitudinal direction of the vehicle, The lower
frame members can be spaced apart from each other in the transverse
direction of the vehicle. Each of the front frame members can be
connected to and can extend upwardly from a respective one of the
lower frame members. The intermediate frame members can be spaced
apart from each other in the transverse direction of the vehicle.
Each of the intermediate frame members can be connected to and can
extend from a respective one of the front frame members. Each of
the intermediate frame members also can be connected to the cross
member. Each of the pair of intermediate frame members can include
a bend such that each of the intermediate frame members buckles in
the longitudinal direction of the vehicle if a load or kinetic
energy applied to each of the intermediate frame members in the
longitudinal direction of the vehicle exceeds a predetermined
threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The disclosed subject matter of the present application will
now be described in more detail with reference to exemplary
embodiments of the apparatus and method, given by way of example,
and with reference to the accompanying drawings, in which:
[0007] FIG. 1 is a perspective view of a vehicle made in accordance
with principles of the disclosed subject matter.
[0008] FIG. 2 is perspective view of a frame assembly of the
vehicle of FIG. 1.
[0009] FIG. 3 is a partial perspective view of the frame assembly
of FIG. 2 and attached components of the vehicle of FIG. 1.
[0010] FIG. 4 is a perspective view of the front portion of the
frame assembly of FIG. 2.
[0011] FIG. 5 is an enlarged perspective view of a portion of a
front portion of the frame assembly of FIG. 2.
[0012] FIG. 6 is a side view of a front portion of the frame
assembly of FIG. 2.
[0013] FIG. 7 is a top plan view of a front portion of the frame
assembly of FIG. 2 with wires of an exemplary wire harness assembly
connected to the frame assembly.
[0014] FIG. 8 is a perspective view from the left side of the frame
assembly of FIG. 2 of a front portion of the frame assembly of FIG.
2 with wires of an exemplary wire harness assembly connected to the
frame.
[0015] FIG. 9 is a perspective view from the right side of the
frame assembly of FIG. 2 of a front portion of the frame assembly
of FIG. 2.
[0016] FIG. 10 is an enlarged and slightly tilted view of a portion
of FIG. 9.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0017] A few inventive aspects of the disclosed embodiments are
explained in detail below with reference to the various figures.
Exemplary embodiments are described to illustrate the disclosed
subject matter, not to limit its scope, which is defined by the
claims. Those of ordinary skill in the art will recognize a number
of equivalent variations of the various features provided in the
description that follows.
I. Overall Vehicle
[0018] Various vehicular design factors may make it challenging to
sufficiently impede or prevent deformation of the vehicle frame
defining the passenger area upon application of significant force
inputs into the frame assembly. The stiff portions of the vehicle
frame that are spaced from the passenger area, such as but not
limited to frame structures around the front suspension components,
rear suspension components and/or powertrain components, can
transmit most of or the entire load or kinetic energy input to the
portion of the vehicle frame defining the passenger area. Typical
vehicle frame design constraints and requirements may also limit
the use of structures for managing the input load or kinetic
energy. As a result, the portion of the vehicle frame defining the
passenger area can be subject to deformation due to the input load
or kinetic energy.
[0019] It may therefore be beneficial to provide a vehicle and a
frame for the vehicle with an apparatus that addresses at least one
of the above and/or other challenges of related art vehicles. In
particular, it may be beneficial to enhance input load and energy
management performance upon application of an external load, such
as by controlling deformation of the vehicle frame and/or
mitigating energy transmission to the passenger area caused by the
input load or kinetic energy. For example, portions of the vehicle
frame assembly can be configured to absorb and transfer, in a
predetermined controlled manner, the load or kinetic energy that
originated from the input load or kinetic energy.
[0020] In some of these and/or other embodiments, the vehicle frame
can be configured to deform at portions spaced from the passenger
area. In addition, the frame can be configured with structures that
can resist deformation during routine off-road usage of the
vehicle, but that can deform in a predetermined controlled manner
in response to an input load or kinetic energy. In some of the
disclosed and/or other embodiments, the vehicle frame can be
configured to deform in the vicinity of the passenger area in a
predetermined controlled manner so that the dimensions of the
passenger area after loading can be substantially the same as the
dimensions of the passenger area prior to the input load or kinetic
energy.
[0021] It may therefore be beneficial to provide a vehicle with a
frame assembly that addresses at least one of the above and/or
other disadvantages or concerns of the related art. In particular,
it may be beneficial to utilize a frame assembly that is
sufficiently rigid to cope with load and/or energy inputs from the
suspension as the vehicle travels over uneven terrain of an
unimproved path, and that is sufficiently deformable in a
predetermined controlled manner in response to load and/or energy
inputs different from those input by the suspension. For example,
it may be beneficial to utilize a frame assembly that includes a
front frame assembly that is configured to distribute loads and/or
energy input by each suspension component throughout the entire
frame assembly such that the suspension load and/or energy inputs
can be transferred to a main frame assembly to which the front
frame assembly can be connected.
[0022] FIG. 1 is a perspective view of an exemplary vehicle 10
including frame assembly 18 in accordance with the disclosed
subject matter. The vehicle 10 shown in FIG. 1 is specialized for
use on an unimproved path or on an unmarked path, and can be
referred to as a multipurpose utility vehicle (MUV) or as a
side-by-side all-terrain vehicle (SxS, or SxS ATV).
[0023] However, the disclosed vehicle frame assembly can be used
with any vehicle that is configured for travel along any one or
combination of improved, unimproved, and unmarked paths. For
example, embodiments are intended to include or otherwise cover any
type of automobile, including a passenger car, minivan, truck,
other types of all-terrain vehicle (ATV), semi-tractor, off-highway
vehicle, etc.
[0024] The vehicle 10 can include a body 12, a pair of front
wheels, 14L, 14R, a pair of rear wheels 16L, 16R, a frame assembly
18, a pair of door assemblies 20L, 20R, and a powertrain. Portions
of the frame assembly 18 are hidden from view in FIG. 1 by the body
12 (but are shown in FIG. 2), and the powertrain is omitted from
FIG. 1 for simplicity and clarity of the drawing.
[0025] The vehicle 10 can include a pair of front seats 22L, 22R
mounted in a passenger area of the vehicle 10. The frame assembly
18 can include a roll cage 28 configured to extend around and above
the seats 22L, 22R and the passenger area. The roll cage 28 can
cooperate with the body 12 and/or at least a portion of the frame
assembly 18 to define a pair of door openings through which a
passenger may pass in order to enter or exit the passenger
area.
[0026] The door assemblies 20L, 20R, which occupy the door
openings, each can include a door 24 and a window panel assembly
26, and can be configured to selectively open and close access
through the door openings by moving between a closed position and a
fully opened position. (The door 24 of the right-side door assembly
20R is obscured from view in FIG. 1). In the closed position, the
door assemblies 20L, 20R, can span the respective door openings to
obstruct access to the passenger area via the door openings. In the
closed position, the front portion of each door assembly 20L, 20R
can be latched to the roll cage 28. The fully opened position can
be any position where the door assemblies 20L, 20R are pivoted away
from the respective door openings to provide substantially
unobstructed access to the passenger area via the door openings.
FIG. 1 shows the door assemblies 20L, 20R in the closed
position.
[0027] The powertrain can include an internal combustion engine,
one or more electric motor(s) or a hybrid of an internal combustion
engine and one or more electric motor(s), a hydrogen engine, or
other known engine/motor. The powertrain can have the engine/motor
output axis oriented in the longitudinal direction L or in the
traverse direction T of the vehicle 10. The powertrain can be
configured to drive only the front wheels 14L, 14R, or configured
to drive only the rear wheels 16L, 16R, or configured to drive all
of the wheels 14L, 14R, 16L, 16R, or configured to drive the rear
wheels 16L, 16R and selectively drive the front wheels 14L, 14R, or
configured to drive the front wheels 14L, 14 and selectively drive
the rear wheels 16L, 16R. In the exemplary embodiment of FIG. 1,
the powertrain is configured as a longitudinally oriented,
rear-mounted internal combustion engine that drives the rear wheels
16L, 16R and selectively drives the front wheels 14L, 14R.
II. Frame Assembly
[0028] FIG. 2 is a perspective view of the frame assembly 18. The
frame assembly 18 can be configured to support the body 12, door
assemblies 20L, 20R, seats 22L, 22R, suspension components for the
wheels 14L, 14R, 16L, 16R, powertrain, steering system, control
pedal assemblies, passengers and cargo items. The frame assembly 18
can be configured to withstand various modes of operation,
including operation on unimproved paths. As will be discussed in
greater detail below, the frame assembly 18 can be configured to
surround the passenger area.
[0029] The frame assembly 18 can include a main frame assembly 30,
a front frame assembly 32, a front bumper assembly 34 and a rear
frame assembly 36. As will be discussed in greater detail below, a
load and energy management apparatus can distribute loads input by
the front suspension on one side of the front frame assembly 32 to
the other side of the front frame assembly 32. Further, the load
and energy management system can distribute and attenuate loads and
energy throughout the front frame assembly 32 that are applied to
the front bumper assembly 34 to thereby manage the energy so that
any deflection of the frame assembly 18 in the vicinity of the
passenger area can be controlled in an advantageous predetermined
manner.
[0030] The main frame assembly 30 can define the passenger area of
the vehicle 10. The main frame assembly 30 can be configured to
provide an overall bending stiffness and torsional stiffness of the
vehicle 10 that can be advantageous for rugged terrain of an
unimproved path.
[0031] The front frame assembly 32 can be connected to the front
end of the main frame assembly 30. The front frame assembly 32 can
be configured with mounting points for the front suspension
components and any appropriate components/systems, such as but not
limited to portions of the body 12, a front final drive assembly,
steering system components, engine cooling system, headlights,
etc.
[0032] The front bumper assembly 34 can be connected to the front
end of the front frame assembly 32, such that the front frame
assembly 32 can be located between the front bumper assembly 34 and
the main frame assembly 30. The front bumper assembly 34 can extend
beyond the exterior of the body 12, or alternatively, one or more
portions of the body 12 can conceal the front bumper assembly
34.
[0033] The main frame assembly 30, front frame assembly 32, front
bumper assembly 34 and rear frame assembly 36 can be made from any
appropriate structural element(s), such as but not limited to
tubes, beams, stampings, etc., that can provide sufficient strength
and rigidity for a vehicle passenger area. The frame assembly 18
can be formed from a single type of structural element, or
alternatively the frame member 18 can be formed from any
combination of these structural elements. The structural elements
can have any appropriate cross-sectional shape, such as but not
limited to circular, rectangular, regular polygonal, irregular
polygonal, hollow, solid, variable along the length of the
structural element, etc.
[0034] The structural elements can be formed by any appropriate
process, such as but not limited to rolling, hydroforming, bending,
welding, extruding, stamping, any combination of these processes,
etc. Each structural element of the frame assembly 18 can be formed
from any appropriate material, such as but not limited to steel,
aluminum, titanium, magnesium, plastic, fiber-reinforced plastic,
carbon fiber, ceramic, a composite formed from any combination of
these exemplary materials, etc. Each structural element of the
frame assembly 18 can be connected to each adjoining structural
element in any appropriate manner, such as but not limited to
mechanical fasteners, welding, adhesive, any combination thereof,
etc.
[0035] A. Main Frame Assembly
[0036] The main frame assembly 30 can define the passenger area and
can include the roll cage 28, a pair of longitudinal members 38L,
38R, a plurality of lower cross members 40, 42, 44, a pair of upper
cross members 46, 48 and a pair of support members 72L, 72R.
[0037] The longitudinal members 38L, 38R can extend in the
longitudinal direction L of the vehicle 10, from the front of the
passenger area to the rear of the passenger area. The longitudinal
members 38L, 38R can each be configured as a substantially
straight, hollow beam having a substantially rectangular
cross-sectional shape.
[0038] The first through third lower cross members 40, 42, 44 can
extend in the transverse direction T of the vehicle 10, from the
left longitudinal member 38L to the right longitudinal member 38R.
The first lower cross member 40 can be slightly bent along the
longitudinal direction L near each end toward the rear of the
vehicle 10. The first lower cross member 40 can be a hollow tube
having a substantially circular cross-sectional shape. The second
and third lower cross members 42, 44 can be configured as a
substantially straight, hollow beam having a substantially
rectangular cross-sectional shape.
[0039] The first lower cross member 40 can be connected to each of
the longitudinal members 38L, 38R adjacent a respective front end
of the longitudinal members 38L, 38R. The second lower cross member
42 can be connected to each of the longitudinal members 38L, 38R
adjacent a respective rear end of the longitudinal members 38L,
38R. The third lower cross member 44 can be connected to each of
the longitudinal members 38L, 38R at a portion of the longitudinal
members 38L, 38R intermediate the front and rear ends of the
respective longitudinal members 38L, 38R. In the exemplary
embodiment of FIG. 2, welds can connect the lower cross members 40,
42, 44 to the longitudinal members 38L, 38R.
[0040] The first and second upper cross members 46, 48 can extend
in the transverse direction T of the vehicle 10 from the left cage
side assembly 50L to the right cage side assembly 50R. The first
upper cross member 46 can be spaced away from the second upper
cross member 48. The second upper cross member 48 can be connected
to the cage side assemblies 50L, 50R at a position that is higher
in the vertical direction V of the vehicle 10 than the position at
which the first upper cross member 46 is connected to the side
assemblies 50L, 50R.
[0041] The support members 72L, 72R can extend generally in the
vertical direction V of the vehicle 10 from the first upper cross
member 46 to the second upper cross member 48. The support member
72L, 72R can be spaced apart from each other in the transverse
direction T of the vehicle 10. The support members 72L, 72R can
each be configured as a hollow tube having a substantially circular
cross-sectional shape. In the exemplary embodiment of FIG. 2, welds
can connect the support members 72L, 72R to the upper cross members
46, 48.
[0042] The upper cross members 46, 48 and the support members 72L,
72R can be configured to support and secure a panel assembly (such
as but not limited to an instrument panel assembly 248 shown
schematically and in phantom in FIG. 6), a steering assembly,
and/or a portion of the body 12 (such as but not limited to a hood
panel 13--see FIG. 1).
[0043] The instrument panel assembly 248 (also referred to as a
dashboard assembly) can include one or more displays that indicates
at least one operating condition of the vehicle 10 such as but not
limited to vehicle speed, engine speed, engine coolant temperature,
oil temperature, oil pressure, fuel level, battery charge level,
etc. The instrument panel assembly 248 can be connected to either
one or both of the cross members 46, 48. The instrument panel
assembly 248 can extend in the transverse direction T of the
vehicle 10.
[0044] The roll cage 28 can include a pair of cage side assemblies
50L, 50R, a plurality of cage cross members 52, 54, 56, 58, 60. The
roll cage 28 generally defines the passenger compartment.
[0045] The cage side assemblies 50L, 50R can extend in the
longitudinal direction L of the vehicle 10, from the front end of
the passenger area to the rear end of the passenger area. The cage
side assemblies 50L, 50R can define the limits of the passenger
area in the transverse direction T of the vehicle 10, the
longitudinal direction L of the vehicle 10 and in the vertical
direction V of the vehicle 10. The cage side assemblies 50L, 50R
can be configured to support the door assemblies 20L, 20R and any
appropriate portion(s) of the body 12, such as but not limited to
flexible side panel(s) (transparent, opaque, or a combination
thereof), rigid side panel(s), roof panel (rigid or flexible),
flexible or rigid rear panel (transparent, opaque, or a combination
thereof), etc. The cage side assemblies 50L, 50R can be configured
to resist, impede, or minimize deformation that could be caused by
a load or kinetic energy input into either or both of the cage side
assemblies.
[0046] Each of the cage side assemblies 50L, 50R can be formed from
any appropriate number of structural elements, from one to any
number greater than one. The side cage assemblies 50L, 50R can be
configured with any shape and contour that can be advantageous to
meet the structural performance and aesthetic appeal desired for
the vehicle 10. The following description will be directed toward
the left cage side assembly 50L with the understanding that the
right cage side assembly 50R can be a mirror image of the left cage
side assembly 50L.
[0047] The left cage side assembly 50L can include a plurality of
cage side members 62, 64, 66, 68, 70. Each of the first through
fifth cage side members 62, 64, 66, 68, 70 can be configured as a
hollow tube having a substantially circular cross-section shape.
The cage side members 62, 64, 66, 68, 70 can be configured with any
appropriate elongated shape that can provide the desired
dimensionality of the passenger area and advantageously conform to
the aesthetic appearance desired for the vehicle 10.
[0048] The first cage side member 62 can be referred to as an
A-pillar. The first cage side member 62 can be connected at one end
to the left longitudinal member 38L adjacent the front end of the
left longitudinal member 38L such that the first cage side member
extends upwardly from the left longitudinal member 38L generally
along the vertical direction V of the vehicle 10. The first cage
side member 62 can be connected to a side of the left longitudinal
member 38L that can be opposite to the side to which the first
cross member 40 is connected. The one end of the first cage side
member 62 can be aligned in the transverse direction T with the end
of the first cross member 40 that is connected to the left
longitudinal member 38L. The instrument panel 248 can extend in the
transverse direction T of the vehicle 10 between the first cage
side members 62.
[0049] Each of the upper cross members 46, 48 can be connected to a
middle portion of the first cage side member 62 of each of the cage
side assemblies 50L, 50R.
[0050] The third cage side member 66 can be referred to as a
B-pillar. The third cage side member 66 can be connected at one end
to the left longitudinal member 38L adjacent the rear end of the
left longitudinal member 38L. The third cage side member 66 can be
connected to a side of the left longitudinal member 38L that can be
opposite to the side to which the second lower cross member 42 is
connected. The one end of the third cage side member 66 can be
aligned in the transverse direction T with the end of the second
cross member 42 that is connected to the left longitudinal member
38L.
[0051] The first through fifth cage cross members 52, 54, 56, 58,
60 can extend in the transverse direction T of the vehicle 10 from
the left side assembly 50L to the right side assembly 50R. The cage
cross members 52, 54, 56, 58, 60 can be connected to each of the
side assemblies 50L, 50R at respective locations spaced apart along
the longitudinal direction L of the vehicle 10. The cage cross
members 52, 54, 56, 58, 60 can be configured to maintain a
predetermined spacing between the left cage side assembly 50L and
the right cage side assembly 50R in the transverse direction T. The
cage cross members 52, 54, 56, 58, 60 can define the limits of the
passenger area in the longitudinal direction L of the vehicle 10
and the vertical direction V of the vehicle 10. The cage cross
members 52, 54, 56, 58, 60 can be configured to manage load and/or
energy inputs so that deflection of the frame assembly 18 in the
vicinity of the passenger area can be controlled in an advantageous
predetermined manner. In the exemplary embodiment of FIG. 2, the
cage cross members 52, 54, 56, 58, 60 can be connected to the cage
side assemblies 50L, 50R by welding.
[0052] B. Front Frame Assembly
[0053] Referring to FIG. 2, the front frame assembly 32 can be
connected to the first lower cross member 40 and each of the first
cage side members 62 of the main frame assembly 30. The front frame
assembly 32 can include the front bumper assembly 34, a pair of
front lower members 74L, 74R, a pair of first front members 76L,
76R, a pair of second front members 78L, 78R, a pair of
intermediate frame members 80L, 80R and a transverse frame assembly
82.
[0054] The front frame members 76L, 76R, 78L, 78R can be spaced
apart from each other in the transverse direction T of the vehicle
10 by a predetermined distance sufficient to accommodate any
component(s) and/or system(s) to be supported by the front frame
assembly 32. Referring to FIG. 3, the front frame assembly 32 can
be configured to support a front suspension and wheel assembly, a
radiator 84, a steering rack assembly and a front final drive
assembly 88. The front suspension and wheel assembly can include
suspension members 90L, 90R, 92L, 92R, damper and spring assemblies
94L, 94R, front hub assemblies 96L, 96R and the front wheels 14L,
14R.
[0055] Each of the second front frame members 78L, 78R can be
connected to each of a respective one of the first front frame
members 76L, 76R and a respective one of the front lower frame
members 74L, 74R. For example, a first end of each of the second
front frame members 78L, 78R can be connected to the respective one
of the lower frame members 74L, 74R, and a second end of each of
the second front frame members 78L,78R can be connected to the
respective one of the first front frame members 76L, 76R.
[0056] The intermediate members 80L, 80R can extend from and can be
connected to a respective one of the second front frame members
78L, 78R, and can extend from and can be connected to the first
upper cross member 46. Each of the intermediate frame members 80L,
80R can be connected to a respective one of the second front frame
members 78L, 78R at a location that is between the first end and
the second end of the respective one of the second front frame
members 78L, 78R. Each of the intermediate frame members 80L, 80R
can be welded or otherwise connected to the first upper cross
member 46 and to the respective one of the second front frame
members 78L, 78R.
[0057] In the exemplary embodiments of FIGS. 2-10, the intermediate
frame members 80L, 80R are connected to the respective second front
frame members 78L, 78R at a location that is closer to the second
end than the first end of the respective one of the second front
frame members 78L, 78R. However, exemplary embodiments are intended
to include or otherwise cover the intermediate frame members 80L,
80R connected to the second front frame members 78L, 78R at any
appropriate location at which the intermediate frame members 80L,
80R can deform in a predictable and controlled manner, which
deformation is described in detail below.
[0058] The transverse frame assembly 82 can extend in the
longitudinal direction L, the transverse direction T and the
vertical direction V. Referring to FIGS. 2, 4, 6, and 7, the
transverse frame assembly 82 can be connected to and extend from
each of the first and second frame members 76L, 76R, 78L, 78R. The
transverse frame assembly 82 can be configured to cooperate with
the front final drive assembly 88 to transfer load or kinetic
energy inputs from the front suspension and wheel assembly into
each of the front lower frame members 74L, 74R, which in turn, can
be configured to transfer the load or kinetic energy input into the
first lower cross member 40 of the main frame assembly 30. Further,
the transverse frame assembly 82 can be configured to collapse in
the longitudinal direction L of the vehicle 10 in response to a
load or kinetic energy input to the transverse frame assembly via
the front bumper assembly 34.
[0059] The front frame assembly 32 can include a plurality of
mounting brackets that can connect the front suspension and wheel
assembly, the radiator 84, and the front bumper assembly 34 to the
front frame assembly 32. The front suspension and wheel assembly
can be movably connected to each of the suspension brackets so that
the suspension members 90L, 90R, 92L, 92R can pivot relative to the
suspension brackets and the front wheels 14L, 14R can move
generally in the vertical direction V of the vehicle 10 as the
vehicle 10 travels along an improved or unimproved pathway. The
front bumper assembly 34 can be connected to each of the bumper
brackets 106L, 106R, 108L, 108R.
[0060] The front frame assembly 32 can include an upper bracket
110. The upper bracket 110 can be connected to and extend from each
of the first frame members 76L, 76R. The upper bracket 110 can
extend in the transverse direction T of the vehicle 10 to span from
the left first frame member 76L to the right first frame member
76L.
[0061] Referring to FIG. 3, an upper end of each of the spring and
damper assemblies 94L, 94R can be connected to a respective end of
the upper bracket 110 in an appropriate manner such as but not
limited to threaded fasteners.
[0062] In the exemplary embodiment of FIG. 7, each of the front
lower frame members 74L, 74R, the first front frame members 76L,
76R, the second front frame members 78L, 78R and the intermediate
frame members 80L, 80R are configured as hollow metal tubes having
a substantially circular cross-section. However, any combination of
the front lower frame members 74L, 74R, the first front frame
members 76L, 76R, the second front frame members 78L, 78R and the
intermediate frame members 80L, 80R can be have a cross-sectional
shape that is different from a substantially circular
cross-sectional shape. Further, any combination of the front lower
frame members 74L, 74R, the first front frame members 76L, 76R, the
second front frame members 78L, 78R and the intermediate frame
members 80L, 80R can be formed of a material other than metal, such
as but not limited to carbon fiber, plastic, carbon fiber
reinforced plastic, ceramic, pulp, or glass fiber reinforced
plastic.
[0063] Further, the front lower frame members 74L, 74R, the first
front frame members 76L, 76R, the second front frame members 78L,
78R and the intermediate frame members 80L, 80R can be welded to
each other to form the structure described above. However,
embodiments are intended to include or otherwise cover any
combination of the front lower frame members 74L, 74R, the first
front frame members 76L, 76R, the second front frame members 78L,
78R and the intermediate frame members 80L, 80R connected by
threaded fasteners, adhesives, a combination of brackets and
threaded fasteners, rivets, or other known connective structures,
materials, or methods.
[0064] The front frame assembly 32 can include a pair of upper
bumper brackets 106L, 106R and a pair of lower bumper brackets
108L. (The upper bumper brackets 106L, 106R are shown in phantom in
FIGS. 7-9, 12, 13 and 15).
[0065] C. Front Bumper Assembly
[0066] The front frame assembly 32 can include the front bumper
assembly 34. Referring to FIGS. 2 and 3, the front bumper assembly
34 can be connected to the front side of the first frame members
76L, 76R, such that the first and second frame members 76L, 76R,
78L, 78R are located between or intermediate the front bumper
assembly 34 and the main frame assembly 30.
[0067] The front bumper assembly 34 can include a pair of lower
connector members 112L, 112R, a pair of upper connector members
114L, 114R and a bumper member 116. The bumper member 116 can be a
separate structure connected to each of the connector members 112L,
112R, 114L, 114R, or can all be integrated together into a single
structure. The bumper member 116 can extend in the transverse
direction T of the vehicle 10 to span from the left upper connector
member 114L to the right upper connector member 114R.
[0068] A first end of each of the lower connector members 112L,
112R can be connected to a respective one of the lower bumper
brackets 108L, 108R. Lower connector members 112L, 112R can be
connected to the respective one of the bumper brackets such that
the lower bumper brackets 108L, 108R can pivot with respect to the
lower bumper brackets. The second end of the lower connector
members 112L, 112R can be connected to the bumper member 116.
[0069] A first end of the upper connector members 114L, 114R can be
connected to a respective one of the upper bumper brackets 106L,
106R. The second end of the upper connector members 114L, 114R can
be connected to the bumper member 116.
[0070] The upper connector members 114L, 114R can be configured to
deform in a predetermined and controlled manner in response to load
or kinetic energy input to the bumper member 116 that exceeds a
predetermined threshold. For example, the upper connector members
114L, 114R can be configured to collapse along the length of the
upper connector members 114L, 114R. That is, the upper connector
members 114L, 114R can be formed from any material and/or with any
structure that can promote the desired deformation. By way of
example only, FIGS. 2 and 3, show the upper connector members 114L,
114R as elongate members having a rectangular cross-sectional
shape. Further, by way of example only, the upper connector members
114L, 114R can include one or more holes, cutouts, corrugated
regions, bends, any combination thereof, etc., that can permit the
upper connector members 114L, 114R to deform in a predetermined and
controlled manner during an impact event.
[0071] The lower connector members 112L, 112R can pivot relative
the lower bumper brackets 1081, 108R as the upper connector members
114L, 114R collapse. However, exemplary embodiments are intended to
include any appropriate connection that can achieve the desired
performance of the bumper assembly 34 in response to a load and/or
energy that exceeds a predetermined threshold. The predetermined
threshold can be set at a value where only the front bumper
assembly 34 is subjected to deformation by the load or kinetic
energy input to the bumper member 116, without deformation to the
front frame assembly 32 or the main frame member 30.
[0072] The bumper member 116 can be configured with any appropriate
shape and dimensions that can achieve the desired performance of
the front bumper assembly 34 in response to the load or kinetic
energy input.
[0073] Referring to FIGS. 4 and 6, the upper bumper brackets 106L,
106R can include a flange to which a bottom of the radiator 84 can
be connected in any appropriate manner such as but not limited to
threaded fasteners, rivets, and welding. In an exemplary
embodiment, each of the upper bumper brackets 106L, 106R can
include a hole and the radiator 84 can include a pair of posts. A
rubber grommet can be secured in each bracket hole. The radiator
posts can be inserted into the grommets and the top end of the
radiator 84 can be bolted to an appropriate portion of the front
frame assembly 32.
[0074] D. Rear Frame Assembly
[0075] Referring to FIG. 2, the rear frame assembly 36 can include
a plurality of rear frame members 190, 192, 194, 196L, 196R, 198,
200, 202L, 202R, 204L, 204R, 206L, 206R, 208L, 208R. The rear frame
members 190, 192, 194, 196L, 196R, 198, 200, 202L, 202R, 204L,
204R, 206L, 206R, 208L, 208R can be configured to define a lower
cradle assembly, an upper bed support assembly, and a suspension
support assembly. The lower cradle assembly can be configured to
mount and supporting the power source and a portion of the rear
suspension and wheel assembly in any appropriate manner. The upper
bed support can be configured to support a storage area of the
vehicle 10. The suspension support assembly can be configured to
support another portion of the rear suspension and wheel
assembly.
III. Front and Rear Suspension and Wheel Assemblies
[0076] The vehicle 10 can include a front suspension and wheel
assembly and a rear suspension and wheel assembly. As discussed
above, the front suspension and wheel assembly can be connected to
the front frame assembly 32. At least a portion of the rear
suspension and wheel assembly can be mounted to the rear frame
assembly 36.
[0077] Referring to FIG. 3, the suspension members 90L, 90R, 92L,
92R of the front suspension and wheel assembly can be configured as
a double-wishbone suspension system (also referred to as upper and
lower A-arms). Each of the suspension members 90L, 90R, 92L, 92R
includes a pair of mounting points configured to be connected to a
respective pair of the suspension brackets 100L, 100R, 102L, 102R.
Each of the suspension members 90L, 90R, 92L, 92R can further
include a single mounting point configured to be connected to a
wheel hub or knuckle that can rotatably support a respective one of
the front wheels 14L, 14R. However, exemplary embodiments are
intend to include or otherwise cover suspension members that
provide a different geometry and/or include multiple links, a
strut, or other appropriate members in order to achieve the desired
suspension performance so long as at least one of the suspension
members on each side of the front frame assembly 32 is mounted to a
suspension mounting bracket in accordance with the first upper
mounting brackets 98L, 98R.
[0078] The rear suspension and wheel assembly can include the rear
wheels 16L, 16R and at least one suspension member for each of the
rear wheels 16L, 16R. The rear suspension and wheel assembly can
include any appropriate suspension members, such as those described
above for the front suspension and wheel assembly. Further, the
rear suspension and wheel assembly can have the same type of
suspension members as the front suspension and wheel assembly, or
can have a different type of suspension members as compared to the
front suspension and wheel assembly. For example, the rear
suspension and wheel assembly can include a first rear suspension
member, a second suspension member and a third suspension member
connected on each side of the rear frame assembly 36. The first and
second suspension members can be connected to each of the rear
frame assembly 36 and a respective one of the rear wheels 16L, 16R.
The third rear suspension member can be connected to a rear end
portion of the main frame assembly 30 and connected to the
respective one of the rear wheels 16L, 16R. In another exemplary
embodiment, the rear suspension and wheel assembly can include the
first, second and third suspension members described above, and can
additionally include a fourth suspension member connected on each
side of the rear frame assembly. However, exemplary embodiments are
intended to include or otherwise cover a rear suspension and wheel
assembly that includes at least one rear suspension member
connected to the rear frame assembly 36.
IV. Steering Assembly
[0079] The vehicle 10 can include a steering assembly configured to
transfer steering inputs from an operator in the passenger
compartment of the main frame assembly 30 to the front wheels 14L,
14R. Referring to FIG. 3, the steering assembly can include a
steering wheel, a steering column assembly 168 (shown in phantom),
a steering rack assembly, and a pair of tie rods 170L, 170R.
[0080] The steering rack assembly can be mounted to and supported
by the transverse frame assembly 82 of the front frame assembly 32.
The tie rods 170L, 170R can be coupled to the steering rack
assembly and to a respective one of the front wheels 14L, 14R. The
steering column assembly 168 can pass through an opening in a plate
of the transverse frame assembly 82 so that one end can be
connected to the steering rack assembly and a second end can be
located in the passenger compartment of the main frame assembly 30.
The steering wheel can be connected to the second end of the
steering column assembly 168. Either or both of the upper cross
members 46, 48 can support an upper end of the steering column
assembly 168 such that the steering wheel is located in the
passenger compartment of the vehicle 10.
[0081] Each of the ties rods 170L, 170R can be pivotally coupled to
a respective end of the steering rack and to the respective one of
the front wheels 14L, 14R such that linear displacement of the
steering rack results in pivoting of the front wheels 14L, 14R
about a kingpin axis associated with the front wheels 14L, 14R.
V. Load and Kinetic Energy Management Apparatus
[0082] The features of the front frame assembly 32 as described can
form a load and kinetic energy management apparatus. The load and
kinetic energy management apparatus can distribute a load or
kinetic energy throughout the front frame assembly 32. For example,
when a load or kinetic energy is input to the front frame assembly
32 via one or both of the front wheels 14L, 14R as the vehicle 10
travels along an improved or unimproved path, load concentrations
in any one particular component or portion of the front frame
assembly 32 can be reduced or prevented. Further, the load and
kinetic energy management apparatus can absorb and distribute a
load or kinetic energy input via the front bumper assembly 34 such
that deformation of the front frame assembly 32 can occur in a
predetermined and controlled manner.
[0083] The load and kinetic energy management apparatus can include
the first front frame members 76L, 76R, the second front frame
members 78L, 78R and the intermediate frame members 80L, 80R
configured by geometry and relative size and location, and
connected to each other and to the main frame assembly 30, such
that a load input by the front bumper assembly 34 to the first
front frame members 76L, 76R can be transferred at least in part to
each of the intermediate frame members 80L, 80R.
[0084] For example, as shown in FIGS. 4-6, each of the intermediate
frame members 80L, 80R can include a bend (generally indicated at
250) at an intermediate portion of each of the frame members 80L,
80R. (The right-side intermediate member is obstructed from view in
FIGS. 5 and 6). The bend 250 can be configured to facilitate
deformation of each of the intermediate members 80L, 80R in a
controlled and predictable manner and location if a predetermined
load or kinetic energy is applied to each of the intermediate
members 80L, 80R along the longitudinal direction L of the vehicle
10. The predetermined load or kinetic energy can be set at a
threshold value that is the same as or different from the
predetermined threshold set for the front bumper assembly 34. The
arc length and radius of curvature of the bend 250 can be based on
a desired amount of deformation, energy absorption and/or
load/energy transmitted to the main frame assembly 30. The arc
length and/or the radius of curvature of the bend 250 can be based
on the distance in the longitudinal direction L between the second
front frame members 78L, 78R and the first upper cross member
46.
[0085] Referring to FIG. 6, the bend 250 can be oriented to be
convex toward a respective one of the front lower frame members
74L, 74R such that the bend 250 can be oriented to be convex toward
a traveling surface on which the vehicle 10 travels. That is, the
bend 250 can form a convex portion. Further, the bend 250 can form
a concave portion that faces away from the respective one of the
front lower frame members 74L, 74R. The concave portion can
generally oppose the convex portion.
[0086] In the exemplary embodiment of FIGS. 2-10, the bend 250 is a
smooth curve. However, exemplary embodiments are intended to
include or otherwise cover the bend 250 that has an angular shape,
or a bend 250 that includes a plurality of curved portion abutting
each other, or a bend 250 that includes a plurality of straight
portions abutting each other at an angle where each of the angles
is the same or is unique, or a bend 250 that includes a combination
of at least one curved portion and at least one straight
portion.
[0087] The intermediate frame members 80L, 80R can be hollow tubes
that are bent to form the bend 250. The intermediate frame members
80L, 80R can further include a pair of straight portions 252, 254.
The first straight portion 252 can be connected to a respective one
of the second front frame members 78L, 78R. The second straight
portion 254 can be connected to the first upper cross member 46.
The bend 250 can be located between and can extend from each of the
straight portions 252, 254. However, exemplary embodiments are
intended to include or otherwise cover intermediate frame members
80L, 80R that have a bend 250 that extends from one end to the
other end of each of the intermediate frame members 80L, 80R,
continuously, or at intervals.
[0088] In the exemplary embodiment of FIGS. 2-10, each of the
intermediate members 80L, 80R is formed as a single, homogenous
structure such that the straight portions 252, 254 are continuous
with the bend 250. However, exemplary embodiments are intended to
include or otherwise cover an intermediate member that includes a
plurality of separate and distinct sections that are connected
together in any appropriate manner such that intermediate members
deform in a predictable and controlled manner. For example, an
intermediate portion of 80L, 80R can be made from a relatively more
elastic material as compared to opposite end portions of 80L, 80R.
Alternatively, the intermediate portion can be made of material
that is relatively more fragile, fracturable or frangible than
opposite end portions of 80L, 80R.
[0089] Referring to FIG. 5, the load and kinetic energy management
apparatus can include a tuning hole 256 in the intermediate frame
members 80L, 80R. The tuning hole 256 can be formed in the bend
250. For example, the tuning hole 256 can be formed in the concave
portion of the bend 250 at a location that is symmetrical with
respect to the length of the end 250 in the longitudinal direction
L of the vehicle 10. The tuning hole 256 can be configured to
facilitate deformation of each of the intermediate members 80L, 80R
in a controlled and predictable manner and location. The size and
location of the tuning hole 256 can be based on the desired amount
of deformation, energy absorption and/or load/energy transmitted to
the main frame assembly 30.
[0090] Referring to FIG. 10, each of the intermediate members 80L,
80R can include a drain hole 258. Since the intermediate members
80L, 80R can be hollow tubes, the drain hole 258 can permit any
fluid that enters into the hollow tube via the tuning hole 256 to
exit the hollow tube via the drain hole 258. The drain hole 258 can
be formed in the bottom portion of each of the intermediate members
80L, 80R that is closest to the front lower frame members 74L, 74R
in the vertical direction of the vehicle 10. The size and location
of the drain hole 258 can be selected to provide the most efficient
manner for evacuating any liquid that enters into the intermediate
members 80L, 80R.
[0091] Further, the load and kinetic energy management apparatus
can be configured such that a load or kinetic energy input into the
front frame assembly 32 by the front suspension and wheel assembly
on either side of the vehicle 10 can be distributed throughout both
sides of the front frame assembly 32 via the front final drive
assembly 88, and then distributed into the main frame assembly
30.
[0092] For example, a load or kinetic energy input by the left-side
upper suspension member 90L can be transferred to the left-side
first front frame member 76L. In turn, the left-side first front
frame member 76L can transfer a portion of the load or kinetic
energy input to the front lower frame member 74L. Further, the
front final drive assembly 88 can be connected to the first front
frame members 76L, 76R such that the front final drive assembly 88
can transfer a portion of the load or kinetic energy input by one
of the left-side first front frame member 76L to the right-side
first front frame member 76R. Subsequently, the right-side first
front frame member 76R can transmit a portion of the load or
kinetic energy input into the right-side front lower frame member
74R.
[0093] A similar example can occur with respect to the right-side
upper suspension member 90R, and each of the lower suspension
members 92L, 92R. Thus, the load and kinetic energy management
apparatus can distribute a load or kinetic energy input by the
front suspension and wheel assembly to both sides of the front
frame assembly 32 such that each of the front lower frame members
74L, 74R can distribute a respective portion of the load or kinetic
energy input by each of the suspension members 90L, 90R, 92L, 92R
throughout the front frame assembly 32 and then into the main frame
assembly 30.
[0094] In the exemplary embodiment described above, when following
the load and energy distribution paths described above, the load
and energy management apparatus can transmit a load or kinetic
energy input to one of the first front frame members 76L, 76R to
each of the front lower frame members 74L, 74R via the front final
drive assembly 88 and a different one of the first frame members
74L, 74R. Further, the load and energy management apparatus can
transmit a load or kinetic energy input by the front bumper
assembly 34 to front frame assembly 32 such that the front frame
assembly 32 can resist the load or kinetic energy input via the
front bumper assembly 34 until the front bumper assembly 34
initially collapses in the longitudinal direction L of the vehicle
10. Further, at least one portion of the front frame assembly 32
can collapse in the direction toward the main frame assembly 30 if
the load or kinetic energy continues to be inputted to the first
front frame members 76L, 76R via the front bumper assembly 34 after
the front bumper assembly 34 initially collapses. Accordingly, the
frame assembly 18 of the vehicle 10 can provide rigidity sufficient
to absorb and distribute a load or kinetic energy input by the
front suspension and wheel assembly without undesirable deformation
of the front frame assembly 32. Further, the frame assembly 18 of
the vehicle 10 can provide an ability to absorb and distribute a
load or kinetic energy input by the front bumper assembly 34 that
can permit deformation of the front frame assembly 32 in a
predetermined and controlled manner.
VI. Wire Harness Support
[0095] Referring to FIGS. 7-10, the intermediate frame members 80L,
80R also can be configured to support one or more wire harness
assemblies that can provide electricity to components and/or
systems mounted on or in the instrument panel assembly 248 such as
but not limited to the aforementioned displays (also referred to as
a combination meter, or as gauges), electrical switch(es), etc. The
wire harness assemblies can also supply electrical power to
components and/or systems mounted on the front frame assembly 32
such as the front final drive assembly 88 and a pair of headlight
assemblies. For example, the vehicle 10 can include a front wire
harness assembly 260 that passes into and through the instrument
panel assembly 248 (omitted from FIGS. 7-10 for simplicity and
clarity of the drawing views) mounted on the main frame assembly 30
and along the front frame assembly 32. The front wire harness
assembly 260 can include a sheath 262, a plurality of electrical
wires or cables 264, 266, 268, 270, 272, 274, 276 a plurality of
connectors 278, 280, 282, 284, 286, a branch sheath 288 and a
plurality of fasteners 290, 292, 294. The main sheath 262 can
bundle the wires 264, 266, 268, 270, 272, 274, 276 into a single
unit from which the wires can branch out in respective directions
to reach the respective component(s) and/or system(s). The front
wire harness assembly 260 can be divided into a plurality of
sections. Some of the connectors 278, 280, 282, 284, 286 can
electrically connect respective sections of the front wire harness
assembly 260. Others of the connectors 278, 280, 282, 284, 286 can
electrically connect the respective wire(s) to the respective
component(s)/system(s). The branch sheath 288 can bundle the fifth,
sixth and seventh wires 272, 274, 276 that branch from the main
sheath 262. As will be discussed in more detail below, the
fasteners 290, 292, 294 can secure respective portions of the front
harness assembly 260 to respective portions of the front frame
assembly 32.
[0096] Referring to FIGS. 5 and 7, each of the intermediate frame
members 80L, 80R can include a clip hole 296. The clip hole 296 can
be formed in an upper portion of each of the intermediate frame
members 80L, 80R that is spaced from the tuning hole 256 and the
bend 250. The clip hole 296 can be located between the tuning hole
250 and the end of each of the intermediate frame members 80L, 80R
that abuts the first upper cross member 46.
[0097] The first fastener 290 can include a clamp portion and a
base. The clamp portion can be wrapped around and tightened to the
branch sheath 288. The clamp portion can be integrally formed with
with or otherwise connected to the base. The base can include a
mating portion that can be secured in the clip hole 296 of the
right-side intermediate frame member 80R. Thus, the first, second
and third wires 264, 266, 268 can be secured to and supported by
the right-side intermediate frame member 80R.
[0098] Referring to FIG. 5, the left-side intermediate frame member
80L can include a connector bracket 298. The connector bracket 298
can be mounted on a side portion of the intermediate frame member
80L that faces toward the exterior of the vehicle 10. The fourth
connector 284 can be connected to an end of the fourth wire 270.
Referring to FIG. 8, the fourth connector 284 can be secured to the
connector bracket 298. Thus, the fourth wire 270 can be secured to
and supported by the left-side intermediate frame member 80L.
[0099] The front frame assembly 32 can further include a pair of
mounting brackets 300L, 300R. Each of the mounting brackets 300L,
300R can be connected to and can extend between a respective one of
the second front frame members 78L, 78R and a respective one of the
intermediate frame members 80L, 80R. Each of the mounting brackets
300L, 300R can include a clip hole 302.
[0100] The second fastener 292 can include a clamp portion and a
base. Referring to FIGS. 9 and 10, the clamp portion can be wrapped
around and tightened to the branch sheath 288 at a position that is
spaced away from the first fastener 290. The clamp portion can be
integrally formed with or otherwise connected to the base. The base
can include a mating portion that can be secured in the clip hole
302 of the right-side mounting bracket 300R. Thus, the first second
and third wires 264, 266, 268 can be supported by the right-side
intermediate frame member 80L.
[0101] The third fastener 294 can include a clamp portion and a
base. Referring to FIG. 9, the clamp portion can be wrapped around
and tightened to the fifth and sixth wires 272, 274. The clamp
portion can be integrally formed with or otherwise connected to the
base. The base can include a mating portion that can be secured in
the clip hole 302 of the left-side mounting bracket 300L. Thus, the
fifth and sixth wires 272, 274 can be supported by the left-side
intermediate frame member 80L.
VII. Alternative Embodiments
[0102] While certain embodiments of the invention are described
above, and disclose a best mode for practicing the various
inventive aspects, it should be understood that the invention can
be embodied and configured in many different ways without departing
from the spirit and scope of the invention.
[0103] For example, embodiments are disclosed above in the context
of a vehicle 10 shown in FIG. 1. However, embodiments are intended
to include or otherwise cover any type of vehicle disclosed above.
For example, exemplary embodiments are intended to include or
otherwise cover any type of vehicle that can travel on an improved
surface such as but not limited to a paved road.
[0104] Exemplary embodiments are intended to include or otherwise
cover any type of front frame assembly 32. In other words,
exemplary embodiments are intended to cover any application of
front frame assembly that can sustain load or kinetic energy inputs
from a front suspension and wheel assembly while also being capable
of responding in a predetermined and controlled manner to a load or
kinetic energy input in the longitudinal direction of the vehicle
10. For example, one or both of the first and second frame members
can be made from a plurality of parts or made as a unitary
homogenous component.
[0105] Exemplary embodiments are intended to include any
appropriate shape for each of the first and second frame members.
Further, exemplary embodiments are intended to include the first
frame members and the second frame members divided differently as
compared to the first and second frame members described above. For
example, exemplary embodiments are intended to include or otherwise
cover a first frame member that terminates at a junction with the
second frame member, and the second frame member includes a second
end that is connected to the main frame assembly.
[0106] Exemplary embodiments are intended to include or otherwise
cover the first frame member or the second frame connected to any
appropriate portion of the main frame assembly.
[0107] Exemplary embodiments are intended to include or otherwise
cover any type of front suspension and wheel assembly. For example,
embodiments are disclosed in the context of an upper suspension
member and a lower suspension member that are configured as A-arms
(also referred to as wishbones). Exemplary embodiments are intended
to include an upper suspension member that has a unique geometry
compared to the lower suspension member. Exemplary embodiments are
also intended to include an upper suspension member that has the
same geometry compared to the lower suspension member. Further,
exemplary embodiments are intended to include a front suspension
and wheel assembly that includes one or more suspension members
configured differently than the upper suspension member and the
lower suspension member, and used in place of the upper suspension
member and/or the lower suspension members.
[0108] Embodiments are disclosed above in the context of vehicle 10
shown in FIG. 1 having a front frame assembly that includes a front
bumper assembly. However, embodiments are intended to include or
otherwise cover any a vehicle that includes a rear frame assembly,
a rear bumper assembly and a rear suspension and wheel assembly
configured in a manner as described above with respect to the front
frame assembly, the front bumper assembly and the front suspension
and wheel assembly.
[0109] While the subject matter has been described in detail with
reference to exemplary embodiments thereof, it will be apparent to
one skilled in the art that various changes can be made, and
equivalents employed, without departing from the scope of the
invention. All related art references discussed in the above
Description of the Related Art section are hereby incorporated by
reference in their entirety.
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