SPACE - FRAME CHASSIS STRUCTURE FOR VEHICLE

FIELD OF THE INVENTION

The present invention generally relates to, chassis structure for vehicles, more particularly, the present invention relates to, the space frame chassis structure for four-wheeled vehicles.

BACKGROUND OF THE INVENTION:

In the modem scenario, transportation has become unavoidable for people. The transportation may be in the context of local and global travel and via the media of road, rail and sea. In such a scenario, automotives are used predominantly for the purpose of travel, wherein the context of travel is via roads.

In the case of road travel, the durability of the automotive depends primarily on the sturdiness of the frame of the automotive on which the remainder of the components is mounted. Several techniques are known through which the vehicle components can be bolted on to the rest of the vehicle frame.

The oldest techniques of vehicle construction primarily involved building an internal frame on to which the body of the vehicle is bolted. This was typically known as the chassis technique of construction as it first involved building the chassis consisting of the frame plus the 'running gear' like engine, transmission, drive shaft, differential and suspension. Thereafter, a body, which is usually not necessary for integrating the structure, was built on the chassis to complete the vehicle. Therefore, if there was any flex or vibration, the frame was the structure that took the bulk of the stress, and the body was not intended to provide any structural reinforcement. Early cars comprised of very simple chassis type of construction, often consisting of just two rails running the length of the car with occasional lateral bracing. A significant advantage of the body-on-frame or a chassis construction was that it allowed frequent changes to the car's bodywork and interiors while leaving the frame unchanged, thus lowering costs of alterations and reducing design time. This feature also enabled ease of repair after accidents.

An alternative construction technique is a monocoque construction (i.e. one-piece) in which the structural members around the windows and doorframes are built by folding the skin material several times. In such situations, the main concerns are spreading the toad evenly, leaving no holes for the corrosion to start, and reducing the overall work load. Also, when a vehicle with a monocoque design is involved in an accident, difficulty arises in effecting repair, as it has to be done only by cutting out and welding rather than by bolting on new parts ( as would be the case in a chassis construction). However, the monocoque construction technique is more sophisticated, highly efficient and also provides greater ride comfort as compared to the conventional chassis technique.

Generally, commercial vehicles and particularly vehicles designed for extreme off-road conditions are of a chassis construction. The present invention however adopts a hybrid construction technique and is an optimal combination of monocoque and conventional chassis constructions thereby, retaining the advantages of both modes of construction, namely the monocoque mode and the chassis mode, while overcoming the disadvantages of both the aforementioned modes.

A proposal in the art is revealed in Japanese Publication No. JP2006076371 entitled "Body shell for a vehicle and a method for its manufacture" and describes a monocoque structure of a vehicle.

Yet another proposal in the art is revealed in US Patent No. 5863070 discloses an improved vehicle chassis for motor homes and buses with a front chassis sub -component, a rear chassis sub-component and a central rail flooring system. This invention essentially aims at integrating the chassis with the superstructure thereby, reducing the height of the vehicle and consequently the centre of gravity without lowering the ground clearance.

Yet another proposal in the art is revealed in a heavy vehicle chassis configuration, which is disclosed in US Patent Publication No. 2002117345 titled

Truck Chassis Configuration but, it relates more particularly to a mid-engine chassis power train configuration, suitable for use in a fire truck.

Another proposal in the art is revealed in WO2004020268, which describes a chassis frame, which is of lesser weight than conventional chassis frames but made suitable primarily for special heavy trucks with a fixed base structure.

Yet another proposal in the art is revealed in Japanese Patent Publication No. JP2005212688, which discloses a structure capable of easily and inexpensively manufacturing a chassis frame having a required length and strength, according to an application or the like of a truck. The chassis frame comprises a plurality of units formed of small side members and cross members or parts. The chassis frame having a predetermined length is formed by connecting between units. Assembling for each unit can be performed, a required apparatus can be mounted, and repair every unit is allowed when the chassis frame breaks. However, this invention does not incorporate the advantages of high mobility and the performance characteristics of a monocoque structure.

Yet another proposal in the art is revealed in another US Patent Publication No. 20070000715A1 which discloses an all-terrain four-wheeled vehicle frame for carrying at least two passengers in side-by-side riding configuration comprising of a rigid tubular frame body with a forward passenger compartment and a rearward engine compartment.

The vehicle frame includes a vertical, load-bearing truss member extending along a longitudinal, central axis of the vehicle within the passenger compartment, the truss member forming a load-bearing structural member between the pair of seats.

There is therefore, a need for a simple method of assembly of a fused space frame.

It is an object of the present invention to provide a fused space frame chassis structure for four wheelers, particularly off-road vehicle

SUMMARY OF THE INVENTION

Accordingly, the first aspect of the present invention is to provide a simple method of assembly of a fused space frame.

Yet another embodiment of the present invention is to provide a chassis frame, which is capable of providing the stability and strength of a conventional chassis design for withstanding tough off-the-road conditions, while at the same time retaining the mobility and performance characteristics of a monocoque design in terms of ride comfort Yet another embodiment of the present invention is to provide a space frame chassis that provides the dual advantage of excellent stability along with high mobility and riding comfort.

Yet another embodiment of the present invention is to provide an optimal configuration of vehicle geometries to achieve stability of the vehicle under adverse conditions.

Yet another embodiment of the present invention is to provide a provision for mounting the engine onto the fused space frame chassis near the center of gravity of the vehicle, to enhance the stability of the vehicle under adverse conditions.

Yet another embodiment of the present invention is to provide a provision for maximizing natural airflow through the radiator core thereby keeping the temperature of transmission, transfer case and drive line parts under control in adverse driving conditions.

Yet another embodiment of the present invention is to provide a technique for ensuring continued stability during motion, by designing the construction of parts such that the original vehicle geometries are retained over a reasonably long service period.

Yet another embodiment of the present invention is to provide a vehicle with a high payload carrying capacity by constructing a strong chassis frame without adding weight/material to the vehicle.

Also, vehicles existing in the relevant field usually have a lot of empty space in such areas of the body that makes the space unusable. There is therefore, a need for use of the additional space available for storage of specific material either by creating hollow spaces in the chassis frame or by making provisions for the assembly of additional fitments in the vehicle. Yet another embodiment of the present invention is to provide additional space available for storage of specific material either by creating hollow spaces in the chassis frame or by making provisions for the assembly of additional fitments in the vehicle.

Another embodiment of this invention is fo ensure continued stability during motion, by designing the construction of parts such that the original vehicle geometries are retained over a reasonably long service period.

Still another embodiment of the present invention is to provide cavities/hollow spaces in the outriggers and provisions for additional fitments allowing ample storage/fitting space for a water tank, tool kits, repair kits, a battery customized fitment etc.

Yet another embodiment of the present invention is to provide the vehicle a high ground clearance of upto 350 mm by mounting the lower most points of the vehicle i.e. the differential assembly on top of the chassis cross members.

A further embodiment of the present invention is to provide ample peripheral clearance around the tyres thereby permitting sufficient degree of freedom for the movement of tyres without fouling even in extreme conditions.

Another embodiment of the present invention is to provide space frame for mounting the body panels through easy and inexpensive manufacturing by avoiding costly manufacturing processes and dies.

A space frame chassis comprising plurality of longitudinal beams of rectangular box-type cross-sections and plurality of transverse cross members. The radiator, front differentials, transfer case support, rear differential etc. are mounted on these cross members. The engine bracket is mounted on to the vertical face of the longitudinal beams in the front portion of the frame and the battery bracket is housed underneath an openable floor cavity. A central support cross member of a hollow fabricated structure is provided to prevent flexing of the chassis and torsional imbalance to which the vehicle is subject during extreme off-road conditions.

Outriggers are attached to the plurality of longitudinal beams to provide structural stability and additional storage space in the vehicle. The rear end of the chassis accommodates the fuel tank mounting frame with rear extension beams for mounting the fuel tank, and a hollow circular rib-like structure providing the structural strength for towing of any other vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and together with the general description provided above, and the detailed description of the embodiment provided below, serve to explain the principles of the invention.

It will be apparent to a person skilled in the art, that, the drawings and the accompanying supporting description are for the purpose of illustration only, and therefore, any combination or variation in the aforesaid inventive concept is well within the scope and ambit of the present disclosure.

Figure 1 is the top view depicting the tubular arrangement of the space frame chassis.

Figure 2 illustrates the structure of the space frame chassis with the engine and radiator mounted thereon. In particular, it depicts the flow of air and the consequent cooling of rear differential and transfer case.
Figure 3 is an exploded view of the space - frame chassis, depicting clearly the various parts that comprise the structure.

DETAILED DESCRIPTION OF THE DRAWINGS

The following detailed description sets forth numerous specific details, to provide a thorough understanding of the invention. However, those skilled in the art will appreciate, that the invention may be practiced with a combination or variation, of these specific details.

It would also be apparent to a person skilled in the art, that the abovementioned combinations and variations thereof, are also considered to be well within the scope and ambit of the present disclosure.

In this regard, the present invention comprises a space frame chassis, that has a tubular structure (1). The chassis comprises four longitudinal members of rectangular box-type cross-sections (2A & 2B) and plurality of transverse cross members (3).

The longitudinal members provide for attachment of suspension arms through bushes. The distance between the longitudinal members is variable in accordance with the manufacturing requirements and the vehicle architecture.

The cross members (3) are provided on either side of the longitudinal members (2A and 2B) and provide the necessary structural stability to the vehicle in all kinds of extreme conditions.

The cross members (3) are mounted between the longitudinal members (2A& 2B) at pre-determined points in a manner, that they are perpendicular to the outer longitudinal members (2A) and meet the inner longitudinal members (28) at two pre-determined points, one perpendicular and the other angular.

The entire space frame is constructed so as to enable all body parts to be fastened onto it, thereby making them easily removable. This frame provides the base structure for accommodating the various components of the vehicle. The components such as the radiator, front differential, transfer case support, rear differential etc. are mounted on the transverse cross members (3).

The abovementioned and additional features have been dealt with in detail, in conjunction with the detailed description of each accompanying drawing. . In this context, Figure. 1 is the top view depicting the tubular arrangement of the space frame chassis.

As illustrated in Figure 1., the present invention pertains to a space-frame chassis which has a tubular structure (1), comprising of four longitudinal members of rectangular box-type cross sections (2A & 2B) and plurality of transverse cross members (3). The longitudinal members denote both inner longitudinal member (2A) and outer longitudinal member (2B) of the chassis. The longitudinal members provide for attachment of suspension arms through bushes. A man skilled in the art can very well decide the distance between the longitudinal members is governed by the manufacturing requirements of the vehicle architecture.

The cross members (3) which are provided on either side of the longitudinal members (2A and 2B) are outriggers which substantially provide the requisite structural stability to the vehicle in all kinds of extreme conditions. The outriggers (3) are affixed between the longitudinal members (2A& 2B) at pre-determined points in such a manner that, they are perpendicular to the outer longitudinal members (2A) and meet the inner longitudinal members (2B) at two predetermined points, one perpendicular and the other angular.

The abovementioned and additional features pertaining to structure of the space frame chassis with the engine and radiator mounted thereon, and also flow of air and the consequent cooling of rear differential and transfer case have been dealt with in detail in conjunction with Figure. 2.

Thereafter, Figure. 2. illustrates the structure of the space frame chassis with the engine and radiator mounted thereon. In particular, it depicts the flow of air and the consequent cooling of rear differential and transfer case.

Figure 2 illustrates the entire constructional arrangement of the chassis with the engine (4) and radiator (5) mounted thereon. The engine (4) is mounted onto the fused space frame chassis near the centre of gravity of the vehicle (13), which enhances the stability of the vehicle under adverse conditions.

Figure 3 depicts an exploded view of the chassis denoting the various parts of the chassis frame. The chassis frame is made of a plurality of longitudinal members wherein; the outer longitudinal members (2A) and the inner longitudinal members (2B) are connected by a plurality of transverse cross members/outriggers (3) on both sides. The outriggers (3) also house a plurality of cavities, which can be used for storing . Further, jack slots are provided at extreme ends of the comer of all outriggers (3) for fixing lift pads for lifting of the vehicle. The engine-mounting bracket (10) is located in the front portion of the chassis frame and is mounted onto {he vertical face of the longitudinal members. The mounting for steering cylinder assembly (9) is provided close to the engine-mounting bracket (10) at the front side of the chassis. The battery bracket is housed underneath an openable floor cavity that makes it totally enclosed from all sides and protected from adverse external environmental factors. The adverse external environmental factors may include, dust, moisture and the like. A central support cross member (6) of a hollow fabricated structure is provided right at the centre of the chassis frame for ensuring rigidity and robustness of the frame by preventing the chassis from flexing and avoiding the torsional imbalance to which the vehicle is subjected during extreme off-road conditions.

The floor plates are mounted on this central support cross member (6). The rear portion of the chassis frame comprises of the fuel tank mounting frame with (8) with rear extension beams (7) for the mounting of the fuel tank, a huge cargo box and a hollow circular rib structure which provides the structural strength for the towing of any other vehicle, by this vehicle. The underbelly of the vehicle is completely enclosed by a bolted hardened plate (14) on to the chassis, which protects all moving parts of the vehicle like engine, transmission etc. This helps ensure that the original vehicular geometries, which have been optimally configured, are retained even during motion.

Accordingly, a space - frame chassis structure for vehicles comprising: a tubular structure (1) having front assembly, middle assembly and rear assembly; wherein the said middle assembly comprising plurality of longitudinal members (2A & 2B) wherein the said longitudinal members are inner longitudinal member (2A) and outer longitudinal member (2B) of the chassis and plurality of transverse cross members (3) which connects the said inner and outer longitudinal members; floor plates are mounted on this central support cross member (6); the said rear assembly comprises of the fuel tank mounting frame with (8) with rear extension beams (7) for the mounting of the fuel tank, a huge cargo box and a hollow circular rib structure which provides the structural strength for the towing of any other vehicle, by this vehicle; the underbelly of the vehicle is completely enclosed and fastened with hardened plate (14) on to the chassis; the said front assembly comprising engine-mounting bracket (10) which is located in the front portion of the chassis frame and is mounted onto the vertical face of the longitudinal members; the steering cylinder assembly (9) is provided close to the said engine-mounting bracket (10) at the front side of the chassis; the battery bracket is housed underneath an openable floor cavity, that makes it totally enclosed from all sides and protected from adverse external environmental factors.

When vehicle is in a movement, the air enters into the vehicle as shown in figure 2, the starting point of the chassis frame indicating air flow (11) it passes through the vehicle, centre gravity point (13) and coming out from the vehicle through the Ending Points of the Chassis frame indicating air flow (12). Air flows (11) through the radiator (5) core and further flows down over the transmission drive line through air tunnel formed between longitudinal long members of the chassis. The air then passes on to the different parts in the chassis and comes out from the rear side of the vehicle. This natural draft of air aided by the space frame keeps the temperature of transmission, transfer case and drive line parts under control in adverse driving condition.
ADVANTAGES:

The present invention has the following features, resulting in distinct advantages. The present invention provides:

(a) a chassis frame, which is capable of providing the stability and strength of a conventional chassis design for withstanding tough of the-road conditions, while at the same time retaining the mobility and performance characteristics of a monocoque design in terms of ride comfort.

(b) an optimal configuration of vehicle geometries to achieve stability of the vehicle under adverse conditions.

(c) provision for mounting the engine onto the fused space frame chassis near the center of gravity of the vehicle, to enhance the stability of the vehicle under adverse conditions.

(d) a provision for maximizing natural airflow through the radiator core thereby keeping the temperature of transmission, transfer case and drive line parts under control in adverse driving conditions.

(g) a technique for ensuring continued stability during motion, by designing the construction of parts such that the original vehicle geometries are retained over a reasonably long service period.

(h) a high payload carrying capacity by constructing a strong chassis frame without adding weight/material to the vehicle.

(i) additional space available for storage of specific material either by creating hollow spaces in the chassis frame or by making provisions for the assembly of additional fitments in the vehicle.

G) continued stability during motion, by designing the construction of parts such that the original vehicle geometries are retained over a reasonably long service period.

(k) cavities/hollow spaces in the outriggers and provisions for additional fitments allowing ample storage/fitting space for a water tank, tool kits, repair kits, a battery customized fitment etc.

(I) a high ground clearance of upto 350 mm by mounting the lower most points of the vehicle i.e. the differential assembly on top of the chassis cross members.

(m) ample peripheral clearance around the tyres thereby permitting sufficient degree of freedom for the movement of tyres without fouling even in extreme conditions.

(n) space frame for mounting the body panels through easy and inexpensive manufacturing by avoiding costly manufacturing processes and dies.

Though the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and are not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is therefore not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims.

Index of Parts

1. Tubular Structure

2. Longitudinal Members 2A- Outer Longitudinal Member 2B- Inner Longitudinal Member

3. Chassis Cross Members

4. Radiator

5. Engine

6. Central Support Cross Member

7. Rear Extension beams for fuel tank mounting

8. Fuel Tank Mounting frame

9. Mounting for steering cylinder assy

10. Engine Mounting bracket

11. Starting point of the chassis frame indicating air flow 12. Ending Points of the Chassis frame indicating air flow

We Claim:

1. A space - frame chassis structure for vehicles comprising: a tubular structure (1) having front assembly, middle assembly and rear assembly; wherein the said middle assembly comprising plurality of longitudinal members (2A & 2B) wherein the said longitudinal members are inner longitudinal member (2A) and outer longitudinal member (2B) of the chassis and plurality of transverse cross members (3) which connects the said inner and outer longitudinal members; floor plates are mounted on this central support cross member (6); the said rear assembly comprises of the fuel tank mounting frame with (8) with rear extension beams (7) for the mounting of the fuel tank, a huge cargo box and a hollow circular rib structure which provides the structural strength for the towing of any other vehicle, by this vehicle; the underbelly of the vehicle is completely enclosed and fastened with hardened plate (14) on to the chassis; the said front assembly comprising engine-mounting bracket (10) which is located in the front portion of the chassis frame and is mounted onto the vertical face of the longitudinal members; the steering cylinder assembly (9) is provided close to the said engine-mounting bracket (10) at the front side of the chassis; the battery bracket is housed underneath an openable floor cavity, that makes it totally enclosed from all sides and protected from adverse external environmental factors.

2. The space - frame chassis structure for vehicles as claimed in Claim 1, wherein, the space frame structure is tubular.

3. The space - frame chassis structure for vehicles as claimed in Claim 1, wherein, the longitudinal members are of rectangular box-type cross-section.

4. The space - frame chassis structure for vehicles, as claimed in Claim 1, wherein, the distance between the longitudinal members is variable in accordance with the manufacturing requirements and the vehicle architecture;

5. The space - frame chassis structure for vehicle as claimed in Claim 1, wherein, the outriggers (3) are affixed between the longitudinal members (2A& 2B) at pre-determined points in such a manner that, they are perpendicular to the outer longitudinal members (2A) and meet inner longitudinal members (2B) at two pre-determined points, one perpendicular and the other angular.

6. The space - frame chassis structure for vehicles as claimed in Claim 1, wherein, space frame is constructed, so as to enable all components to be fastened onto it, thereby making them easily removable.

7. The space - frame chassis structure for vehicles as claimed in Claim 1, wherein the vehicle is in a movement, the air enters into the vehicle through the radiator, the starting point of the chassis frame indicating air flow (11) and passes through the vehicle, center gravity point (13) and coming out from the vehicle through the ending points of the chassis frame indicating air flow (12).