Abstract:
An off road vehicle of modular construction, which a user may insert or remove modules to perform particular functions.

Description:
BACKGROUND 
       [0001]    Robust vehicles capable of operation on unimproved surfaces find application on farms, at construction sites, in industrial settings, and in the military. A wide variety of such vehicles, for single or multiple riders, are well known. While as a class off-road vehicles are diverse and fulfill many roles, individual vehicles are typically limited. A compact and maneuverable ATV useful for a hunter to travel well into the woods might seat only one or two people. A farm tractor can accommodate a variety of implements, but is ill-suited to transport workers to distant fields for picking. A multi-seat ATV could transport workers, but would not have the cargo capacity for harvested crops or related cargo. 
         [0002]    The capital costs of maintaining multiple vehicles, each with a limited purpose, are substantial. Furthermore, the capital costs of maintaining multiple assembly lines, each for a different vehicle, or else incurring the costs of frequent re-tooling, limit the ability of manufacturers to meet the demand of the market, especially for markets that are relatively small. 
       SUMMARY 
       [0003]    A vehicle comprising at least a front and a rear module, the modules being capable of attachment to one another to form a substantially unitary vehicle, but also capable of detachment without damage to accommodate one or more modules between them. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a perspective view of one embodiment of a modular off-road vehicle showing front and rear drive modules attached to one another. 
           [0005]      FIG. 2  is a perspective view of one embodiment of a modular off-road vehicle showing front and rear drive modules with an additional passenger module mounted between them. 
           [0006]      FIG. 3  is a perspective view of one embodiment of a modular off-road vehicle showing front and rear drive modules with a passenger module and a cargo module mounted between them. 
           [0007]      FIG. 4  is a perspective view of the forward portion of the front drive module depicted in  FIGS. 1-3 . 
           [0008]      FIG. 5  is a perspective view of the rearward portion of the front drive module depicted in  FIGS. 1-3  showing the connections to be made with the rear drive module or an intermediate module. 
           [0009]      FIG. 6  is a perspective view of the forward portion of the rear drive module depicted in  FIGS. 1-3  showing the connections to be made with the front drive module or an intermediate module. 
           [0010]      FIG. 7  is a perspective view of the rearward portion of the rear drive module depicted in  FIGS. 1-3  showing aspects of the cargo bed in more detail. 
           [0011]      FIG. 8  is a detailed view of the accessory coupler found on the rear drive module. 
           [0012]      FIG. 9  is a perspective view of the forward portion of an intermediate passenger module depicted in  FIGS. 2-3  showing the connections to be made with the front drive module or another intermediate module. 
           [0013]      FIG. 10  is a perspective view of the rearward portion of an intermediate passenger module depicted in  FIGS. 2-3  showing the connections to be made with the rear drive module or another intermediate module 
           [0014]      FIG. 11  is a detail view of the forward facing connections found on the rear drive module and intermediate modules, showing how they connect with a driveline coupler from another module. 
           [0015]      FIG. 12  is a perspective view of the rear drive module showing how the side and rear panels of a cargo box may be removed to form a flat bed. 
           [0016]      FIG. 13  is a perspective view of the rear drive module showing the side and rear panels of the cargo box affixed to the rear drive module to form a flat bed. 
           [0017]      FIG. 14  is a side elevation of the embodiment of an off-road vehicle depicted in  FIG. 1 . 
           [0018]      FIG. 15  is a detail of the joint between two modules showing the collar that prevents deformation of the frame under pressure from bolts and nuts being tightened. 
           [0019]      FIG. 16  is a detail showing the right panel of the bed, including the end of the top rail intended to insert into a box on the rear panel of the bed. 
           [0020]      FIG. 17  is a detail showing the end of the top rail of the right panel actually inserted into the box on the rear panel of the bed, as it would appear in operation. 
           [0021]      FIG. 18  is a detail showing the hinges connecting the right panel of the bed to the right side of the bed. 
           [0022]      FIG. 19  is a detail showing how the hinges connecting the right panel of the bed to the right side of the bed may be separated from each other to allow removal of the right panel. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    A sturdy vehicle built modularly can be adapted to any use by the addition or subtraction of chassis sections designed for particular purposes. 
         [0024]    The most basic components required are the front drive module  10 , as shown in  FIGS. 4 and 5 , and the rear drive module  22 , as show in  FIGS. 6 and 7 . The front drive module  10  comprises ground-contacting surfaces  14  which may be used to steer the vehicle. In a preferred embodiment, the ground contacting surfaces  14  comprise wheels, and are also used to provide motive power. They may also take the form of tracks, as are familiar in earth-moving equipment and military vehicles, or, in snowy environments, skis. The front drive module  10  also includes a seat  16  for a driver and passengers, directional control device  18  (examples include a steering wheel or set of handlebars), and acceleration control  21  and braking control  23  (examples include pedals, rotating handles, and hand-operated levers). The front drive module  10  may also include such items as a keyhole for controlling starting and stopping of an engine, onboard electronics such as a radio or GPS, a control panel for adjustable suspension, and gauges to monitor the condition of the vehicle. In a preferred embodiment, the controls are very similar to the controls of an automobile. 
         [0025]    The front drive module  10  may also feature a motor  12  to propel the vehicle. The motor may be powered by any conventional means, including electrical, internal combustion, compressed gas, or any combination of known means for propelling a vehicle. Preferably, this motor  12  is located underneath the seat  16  in the front drive module  10 , and connected to the wheels  14  of the front drive module  10  through a conventional transmission and a differential  15  as shown in  FIG. 14 . To be located under the seat, the motor  12  is preferably of a boxer or opposed cylinder design, but may also be an inline engine provided it is capable of mounting horizontally for compactness. The motor  12  may be mounted transversally or longitudinally, according to design preference. A rear-facing driveline coupler  20  is located within the frame of the front drive module  10 , where it is intended to join another module. 
         [0026]    The rear drive module  22  comprises ground-contacting surfaces  24  and a differential  27 , along with a forward-facing driveline coupler  26  compatible with the rear-facing driveline coupler  20  found at the rear of the front drive module  10 . In a preferred embodiment, the rear drive module  22  has a pair of wheels  24 . However, more than two wheels  24  are possible, as are tracks. Preferably, the ground contacting surface  24  of the rear drive module  22  is designed to participate in the steering of the vehicle. For a wheeled vehicle, the wheels  24  in the rear drive module  22  are designed to pivot about an axis  28  substantially perpendicular to the ground surface, in response to mechanical control from a servo, hydraulic or pneumatic cylinder, or other actuation device (not shown). If tracks are used, they may be designed to run at different speeds to promote turning. The differential  27  permits the ground-contacting surfaces  24  to make turns smoothly as is conventional in automobiles and similar vehicles. In one embodiment, the driveline couplers  20 ,  26  on both modules  10 ,  22  are identical but designed to join matingly so as to transfer torque from the front drive module to the rear drive module. A non-limiting example is a flange with holes to accommodate bolts for joining. In another embodiment, the driveline coupler is a spline coupler. 
         [0027]    Both front and rear drive module are built around spine  11 , which in a preferred embodiment comprises rectangular metal tubes welded together to form an elongate plate-like structure. This spine is connected to the suspension of the vehicle and provides stiffness and support to the entire body. 
         [0028]    Both the rear drive module  22  and the front drive module  10  are preferably designed to function on difficult unimproved terrain. High ground clearance and substantial suspension travel are essential. In a preferred embodiment, the suspension is adjustable due to the use of air springs. This permits control over ride stiffness, compensation for sagging caused by cargo, and levelling of the vehicle when loaded. The frames  30 ,  32  of both modules must be able to withstand both static forces when loaded and parked on uneven ground, and dynamic forces such as bumps and jolts, which occur as the vehicle travels. The frames  30 ,  32  are preferably made of steel or aluminum tubing, welded together for rigidity. Other material choices may be made according to design preferences. 
         [0029]    Preferably, the front and rear drive modules have accessory coupler  100  affixed to the spine  11 , as best shown in  FIG. 8 . Accessory coupler  100  comprises two receivers  102 , each substantially identical to a standard Class III trailer hitch receiver, having a square opening of approximately two inches on a side, and a hole approximately ⅝ inches through the receiver  102  to receive a pin. These couplers  100  may be used for the mounting of accessories such as snowplows or for the towing of trailers. 
         [0030]    The rear drive module  22  and the front drive module  10  are capable of being detachably affixed to one another. The structural components may be joined by bolts, hooks, pins, or any other means intended to secure two components together firmly enough to permit operation of the connected modules as a single unitary vehicle, as best shown in  FIG. 1 . It is important that the vehicle, when in operation, constitute a rigid structure comparable in performance to a similar vehicle designed and built in a single piece. In one embodiment, bolts  34  and nuts  36  are used for maximum versatility and solidity in attachment. To prevent deformation of the tubing used to make the frame, collars  35  are welded into the frame to bear the stress caused by the tightening of bolts  34  and nuts  36 , as best shown in  FIG. 15 . The frame must be smooth where it mates with its counterpart. Welding the collars  35  in place therefore requires that the collars  35  or frame be chamfered so that the gab may be filled with weldment. If the collar is fitted and welded without the chamfer, then most of the weldment will be ground off to make the frame smooth, leaving inadequate strength once the grinding is accomplished. In alternative embodiments, bolts  34  attach to threaded portions of the frame, which design only permits modules to be joined in certain orientations. Pins may be provided with corresponding holes in the neighbouring module to guide bolt holes into alignment. Dovetails, mortise and tenon, and tongue-and-groove joints may all be employed. These attachment methods can be designed to have the advantage of not requiring tools, as bolts  34  and nuts  36  do, but are more expensive to manufacture and more difficult to secure in a way that results in a truly rigid structure. 
         [0031]    Between the front drive module  10  and the rear drive module  22 , intermediate modules  38 ,  40  may be placed to alter the function of the vehicle. For instance, a passenger module  38 , depicted in  FIGS. 9 and 10 , (or more than one) containing seats  16  for riders may be placed between the front drive module  10  and the rear drive module  22  to expand the seating capacity, as shown in  FIG. 2 . A cargo module  40  could be added, featuring whatever form of cargo containment was needed. A special-purpose module containing equipment dedicated to a particular task could also be inserted. For instance, a module intended for the laying of pipe or cable might include a reel to hold the item to be laid and a motor for pushing it out and laying it into a prepared trench. An agricultural module might contain a tank and sprayers for applying fertilizer or pesticides. Even a toilet module is possible, and more useful than conventional portable toilets when it is expected that workers will need to move often. 
         [0032]    Some combination of intermediate modules these may be chosen for a particular purpose. For instance, when moving workers to a worksite, an operator might place a passenger module  38  to provide seating for the workers, and a cargo module  40  fitted with tool containers, to transport the tools required at the worksite, as shown in  FIG. 3 . On the other hand, an agricultural or construction employer might provide a cargo module  40  containing water tanks and a food-service module containing coolers or refrigerators, to bring lunch and hydration to workers who find themselves an inconvenient distance from buildings. A military field ambulance might contain a module with a litter or litters for carrying the wounded, and another filled with equipment and consumables such as bandages, disinfectant, and splints. 
         [0033]    Each intermediate module  38 ,  40  carries on its underside a driveline segment  42 , with driveline couplers  44 ,  46  at the front and back, as shown in  FIG. 11 . These couplers join matingly with the rear-facing driveline coupler  20  on the front drive module  10  and the forward-facing driveline coupler  26  found on the rear drive module  22 , to transmit torque to the rear wheels  24 . Control connections such as cables, hydraulics, and electrical plugs may be located in any convenient place, using couplers designed for easy and rapid attachment and detachment. In one embodiment, control connections are arranged on the inside of the vehicle. Well-known examples of useful couplers include: Connectors  48  used to connect trailers to automobiles, which transmit electrical power necessary to operate signal lights or quick-detach self-sealing hydraulic couplings  50 , which can be used to transmit braking power when brakes are operated hydraulically and steering impulses for the rear wheels, or pneumatic fittings for the same purpose. Any couplers which permit safe transmission of signals and power from one module to another may be used, and a wide variety are commercially available and well-known in the art. In a preferred embodiment, the placement of connections is standardized such that any module may replace any other while still allowing for safe operation of the vehicle. 
         [0034]    Intermediate modules  38 ,  40  may or may not have ground-contacting surfaces. In the simplest embodiment, intermediate modules merely join the front and rear drive modules  10 ,  22 , and are carried between them. However, in an alternative embodiment, an intermediate module might have free-running wheels intended to help support the weight of the cargo or passengers contained within it. This is particularly helpful in soft ground or snow, where the vehicle&#39;s tendency to sink in is mitigated by additional ground-contact surface area. The wheels might also be connected to the driveline segment  42  and steering mechanism to improve performance on slippery or soft ground. 
         [0035]    In addition to versatility as discussed above, emergency repairs and routine maintenance are simplified for applications in which a large number of vehicles are deployed. If the engine in a particular vehicle requires service or repair, a second front drive module  10  may be substituted to keep the remainder of the vehicle in service, while the first front drive module  10  is taken to the shop by itself. A similar substitution may be made for any module on the vehicle that needs attention. Of course, the same principle applies to replacement of modules that are irreparably damaged or destroyed. Thus modularity can greatly reduce downtime and lower the total number of vehicles required for a given business. 
         [0036]    Modularity also lowers the cost of customization. When a user has a highly specialized need which is not met by the marketplace, it is relatively inexpensive to purchase a generic empty intermediate module and then outfit it to suit that specialized need. Then the specialized module may be fitted to an otherwise generic vehicle. The capital cost of a customized module is much lower than the cost of a customized vehicle. 
         [0037]    Because both the number and type of intermediate modules can be changed by a user, the vehicle that is the subject of this application is of variable, user-selectable length. 
         [0038]    Both the front and rear drive modules preferably have cargo beds  54 ,  55  for carrying whatever a user may wish to transport. The beds  54 ,  55  are preferably made by welding square or rectangular steel or aluminum tubing together to give a strong “corrugated” structure which is both structurally rigid and resistant to dents and other damage. A bed  54 ,  55  so constructed not only requires no additional frame or support structure to retain its shape, but also forms a part of the frames  30 ,  32  of the vehicle and contributes rigidity. It should be noted that due to warpage caused by heating, the bed is preferably welded with beads of less than 1″ long, evenly spaced along the length of the tubes being welded. Also preferably, both sides of the tubes are welded at once so that heat stresses are opposed to each other and as closely balanced as possible. Distortion may be relieved by heating to release the trapped stress as is well known in the art. 
         [0039]    In a preferred embodiment, the rear bed  54  may be converted from a cargo-box design, resembling the bed of a pickup truck (shown in  FIGS. 6 and 7 ), to a flat bed design, as depicted in  FIGS. 12 and 13 . The bed  54  has a front  56 , rear  58 , right  60  and left  62  sides, with corresponding front  66 , rear  68 , right  70  and left  72  panels. The front panel  66  is rigidly affixed along the front  56  of the bed  54 , while panels  68 ,  70 ,  72  are detachably affixed along their respective sides. The panels  66 ,  68 ,  70 ,  72  designed to interlock with one another and the bed to form a 5-sided rectangular box as show in  FIG. 7 . They may be joined in any convenient manner, such as pins, bolts, or dovetails. In a preferred embodiment, top rails  78 ,  80  on the right  70  and left  72  panels are slightly longer than the remainder of the panel. Top rails  78 ,  80  overhang the front  66  and rear  68  panels. A pin  82  may be inserted through the top rails  78 ,  80  into the front  66  and rear  68  panels, to secure the right  70  and left  72  panels. To maximize strength, box  84  is attached to rear panel  68 . Box  84 , comprised of steel plates welded together, completely surrounds end  86  of the top rails  78 ,  80  to capture them and prevent the right  70  and left  62  panels from bending outward under the strain of a full load of cargo, as shown in  FIGS. 15 and 16 . In this way the force is not borne entirely by relatively small pin  82 , and indeed pins  82  can even be omitted from the end  86  if preferred. 
         [0040]    Preferably, panels  68 ,  70  and  72  are joined to bed  54  by removable hinges  101 , as shown in  FIGS. 18 and 19 . Hinges  103  comprise a female half  103 , which is substantially a round tube welded to the bed  54 , and male half  104 , which is a pin sized so as to fit into the female half  103 , welded to the panel  68 ,  70 , or  72 . Preferably, the bed  54  has at least 3 female halves  103  per side. To attach a panel  68 ,  70 , or  72 , a user aligns the male haves 104 on the panel  68 ,  70 , or  72  with the corresponding female halves  103  on the rear  58 , right  60 . or left  62  side, and slides the male halves  104  into the female halves  103 . The panel can then be folded up or down as desired. 
         [0041]    Below the bed along the rear  58 , right  60 , and left  62  sides are triangular supports  74  mounted on hinges  76 , which fold flat against the body  78  when the bed  34  is used as a box. At least two hinges  76  must be found on each side, although more may be used for increased strength. When the bed  54  is to be used in a flat configuration, a user can fold the supports  74  out to carry the weight of the panels  68 ,  70 ,  72 . The panels  68 ,  70 ,  72  may then be detached from one another and attached to the supports  74 . The supports may be joined to the panels  68 ,  70 ,  72  in any well-known manner, including bolts, pins, and dovetails, or they may be simply permitted to lay flat with their position retained by a combination of weight on supports  74  and the hinges  101 . 
         [0042]    In a preferred embodiment, the bed  54  and panels  66 ,  68 ,  70 ,  72  are made of rectangular mild steel tubing with an approximate outside dimension of 30 mm×50 mm. The bed  54  is primarily composed of tubing with a wall thickness of approximately 1.5 mm, but uses a wall thickness of 2.5 mm for those tubes which are attached to the remainder of the frame. The panels  66 ,  68 ,  70 ,  72  are preferably composed of tubes having a wall thickness of approximately 1.0-1.2 mm, while the top rails  78 ,  80  are thicker, at 2.0-2.5 mm, to resist damage. 
         [0043]    The terms and expressions which have been employed in the forgoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalence of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.