Roll over protection system

A support frame assembly configured to strengthen an upper frame portion of a frame of a vehicle, comprising a first frame member having a first end and a second end, and a second frame member having a first end and a second end, wherein both the first ends of the first and second frame members are configured to couple to a front half of the frame and the second ends of the first and second frame members are configured to couple to the front half of the frame to strengthen the upper frame portion, at least one of the first and second ends of each of the first and second frame members including at least one mechanically coupled joint configured for coupling each of the first and second frame members to the front half of the frame.

FIELD OF THE INVENTION

The present invention relates to off-road vehicles including side-by-side vehicles or utility vehicles (“UTVs”), specifically to upper frame portions of these off-road vehicles.

BACKGROUND OF THE INVENTION

Generally, UTVs or off-road side-by-side vehicles are used to carry one or more passengers and a small amount of cargo over a variety of terrains. Due to the terrain often traveled when using UTVs, the frame of the vehicle is susceptible to damage. Thus, a need exists for a frame design that is capable of further protecting the frame as well as other components of the vehicle.

SUMMARY OF THE INVENTION

In one embodiment of the disclosure, a vehicle comprises a plurality of ground-engaging members, and a frame assembly extending longitudinally between a front portion and a rear portion, the frame assembly having an upper frame portion, a lower frame portion, and a support frame assembly, the support frame assembly being separable from the upper frame portion and the lower frame portion and configured to reinforce the upper frame portion, wherein the support frame assembly includes at least one mechanically coupled joint between the support frame and a remainder of the frame.

In another embodiment of the disclosure, a support frame assembly configured to strengthen an upper frame portion of a frame of a vehicle comprises a first frame member having a first end and a second end, and a second frame member having a first end and a second end, wherein both the first ends of the first and second frame members are configured to couple to a front half of the frame and the second ends of the first and second frame members are configured to couple to the front half of the frame to strengthen the upper frame portion, at least one of the first and second ends of each of the first and second frame members including at least one mechanically coupled joint configured for coupling each of the first and second frame members to the front half of the frame.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference first toFIGS. 1-4, the vehicle of the present invention will be described. As shown, the vehicle is generally depicted as reference number2which includes front ground engaging members4and rear ground engaging members6. Front ground engaging members4are comprised of rims8and tires10, and rear ground engaging members6are comprised of rims14and tires16. Ground engaging members4and6support a vehicle frame, which is shown generally at20, through front and rear suspension assemblies40and42, respectively. Vehicle frame20supports a seating area22comprised of a driver's seat24and a front passenger seat26. In various embodiments, seating area22may also include one or more rear passenger seats28positioned rearward of driver's seat24and front passenger seat26. As best shown inFIG. 2, vehicle2further includes a steering assembly for steering front ground engaging members4whereby the steering assembly includes a steering wheel34.

Referring now toFIGS. 5 and 6, frame20of vehicle2is comprised of an upper frame portion or cab frame30that generally extends over the seating area22and a lower frame portion32positioned below and supporting cab frame30. Frame20is configured to support various body panels35(FIGS. 1-4).

Cab frame30of frame20will now be described in further detail. Cab frame30generally includes a pair of longitudinal frame members36extending from a front38of frame20to a rear41of frame20, a plurality of laterally-extending frame members43coupled between longitudinal frame members36, a pair of downwardly-extending frame members44extending from each of longitudinal frame member36and coupling cab frame30to lower frame portion32, and a rear frame member46(illustratively having an L-shape) coupled to one of each of the longitudinal frame members36and of the rearward downwardly-extending frame members44for coupling cab frame30to lower frame portion32. Downwardly-extending frame member44includes a first or forward member45and a second or rearward member47, where first member45is positioned forward of second member47.

With reference still toFIGS. 5 and 6, lower frame portion32will be described in further detail. Lower frame portion32generally includes a pair of inner longitudinal frame members50, a pair of outer longitudinal frame members52, a pair of front upwardly-extending frame members54, a pair of middle upwardly-extending frame members56, a pair of rear upwardly-extending frame members58, a front U-shaped frame member60and a front laterally-extending frame member62coupled to front upwardly-extending frame members54. Rear ends64of outer longitudinal frame members52each include an upwardly-extending portion66, which are coupled together by a rear laterally-extending frame member68. In various embodiments, lower frame portion32further includes a rear frame member70coupled between rear laterally-extending frame member68and rear upwardly-extending frame members58. In one embodiment, rear frame member70may have an upside-down or reverse “S” shape in that rear frame member70includes a first bent or curved portion and a second bent or curved portion. In various embodiments, front, middle, and rear upwardly-extending frame members54,56, and58are angled relative to vertical. In one embodiment, front upwardly-extending frame members54are angled forwardly relative to vertical, while middle and rear upwardly-extending frame members56and58are angled rearwardly relative to vertical.

Lower frame portion32is coupled to cab frame30via U-shaped frame member60, where U-shaped frame member60is coupled to longitudinal frame member36at front ends72. Additionally, middle upwardly-extending frame members56of lower frame portion32are coupled to first member45of downwardly-extending frame members44of cab frame30. Lower frame portion32is also coupled to cab frame30with laterally-extending frame member68of lower frame portion32being coupled to second member47of downwardly-extending frame members44. Further, lower frame portion32is coupled to cab frame30when rear frame member70of lower frame portion32is coupled to rear frame member46of cab frame30.

Referring now toFIGS. 5-18, frame20further includes a support section or frame assembly80configured to couple cab frame30to lower frame portion32and, more particularly, is coupled between longitudinal frame members36of cab frame30and front upwardly-extending frame members54of lower frame portion32to provide additional support to cab frame30and strengthen cab frame30if a force is applied to cab frame30. In various embodiments, support section80is coupled to longitudinal frame members36at a first position76spaced apart from a forwardmost extent of longitudinal frame members36(e.g., spaced apart from front ends72) and is coupled to front upwardly-extending frame members54at a second position78spaced apart from an upwardmost extent of front upwardly-extending frame members54(e.g., spaced apart from upper end79thereof), wherein first and second positions76and78are positioned within a front half of vehicle2, or in some embodiments, a front ⅓ of vehicle2. In various embodiments, first position76is along longitudinal frame member36at a position that is higher than and longitudinally rearward of front end72, and second position78is along front upwardly-extending frame members54at a position that is lower than and longitudinally rearward of upper end79. As such, support section80is coupled to cab frame30and lower frame portion32at position rearward of at least one point in which cab frame30is coupled to lower frame portion32. Furthermore, in general, support section80is positioned forward of seats24,26and rearward of front ground engaging members4.

With reference toFIGS. 7-9, one embodiment80aof support section80is shown. Support section80agenerally includes a first or left-side panel82, a second or right-side panel84, and a laterally-extending frame member86coupled between first panel82and second panel84. Laterally-extending frame member86generally includes a bracket88at each end thereof for coupling to a protrusion90on an interior surface of each panel82,84via mechanical fasteners (e.g., bolts, nuts, screws, rivets), a welding, adhesive, and/or any other coupling mechanism (illustratively a plurality of couplers91). Protrusion90is opposite of an indentation92on an exterior surface of each of panels82,84. Laterally-extending frame member86is generally positioned longitudinally rearward of front laterally-extending frame member62and front U-shaped frame member60.

Each of first panel82and second panel84are coupled to longitudinal frame member36at a first or upper end94of panels82,84at position76and to front upwardly-extending frame members54at a second or lower end96of panels82,84at position78. In this way, upper and lower ends94,96of panels82,84also are positioned rearward of at least one point in which cab frame30is coupled to lower frame portion32. First end94is mechanically coupled to longitudinal frame member36via mechanical fasteners (e.g., bolts, nuts, screws, rivets), a welding, adhesive, and/or any other coupling mechanism. In various embodiments, first end94further includes at least one bushing95(illustratively, three bushings95) that extends between longitudinal frame member36and first end94and/or at least partially through longitudinal frame member36. Bushing(s)95provide spacing between longitudinal frame member36and first end94. In various embodiments, a washer may be positioned between bushing95and first end94and/or longitudinal frame member36. Second end96is coupled onto front upwardly-extending frame members54via recessed extensions98(FIG. 9) such that second end96is flush with front upwardly-extending frame member54. Once recessed extensions98are positioned on frame members54, welds, adhesives, or other coupling mechanisms may be used to further secure panels82,84to frame member54. In various embodiments, an opening100extends between longitudinal frame member36, front upwardly-extending frame member54and a forward surface102of panel82/84. In one embodiment, opening100is in the shape of a polygon.

Referring now toFIGS. 10-12, another embodiment80bof support section80is shown. Support section80bis substantially similar to first embodiment80awith like reference numbers referring to like features/components. However, in the embodiment ofFIGS. 10-12, panels82,84each include a lower or second end96′ which, rather than hooking onto front upwardly-extending frame members54, is instead coupled to front upwardly-extending frame members54at position78′ via a bracket104(FIGS. 11 and 12). Bracket104is mechanically coupled to panel82/84via mechanical fasteners, a welding, adhesive, and/or any other coupling mechanism and received onto front upwardly-extending frame members54similarly to second end96of panel82/84of first embodiment80avia recessed extensions98′. The use of bracket104results in a gap106between second end96′ of panel82/84and upwardly-extending frame member54.

With reference now toFIGS. 13-15B, yet another embodiment80cof support section80is shown. Support section80cgenerally includes a first vertical support frame member110, a second vertical support frame member112, and a laterally-extending support frame member114extending between and coupled to first and second vertical support frame member110and112. In various embodiments, laterally-extending support frame member114is welded to first and second support frame members110,112, while in other various embodiments, laterally-extending support frame member114may be coupled to first and second support frame member110,112via mechanical fasteners (e.g., brackets, bolts, nuts, screws, rivets), adhesive, and/or any other coupling mechanism.

First and second vertical support frame members110and112extend between and are coupled to longitudinal frame members36at a first or upper end116and to front upwardly-extending frame members54at a second or lower end118. In general, first and second vertical support frame members110and112are substantially linear and vertical frame members. In various embodiments, each end116and118of first and second vertical support frame members110and112include a bracket120having at least one flange122(illustratively, two flanges122) configured to be positioned on either side of longitudinal frame member36or front upwardly-extending frame member54. Bracket120, with flanges122on either side of frame member36or54, is coupled to frame member36or54through mechanical coupling mechanisms (for example, with a coupler passing through flanges122of bracket120and frame member36or54creating a mechanically coupled joint, a welding between bracket120and frame member36or54, or other various mechanical coupling mechanism).

Referring toFIGS. 14-15B, in various embodiments, bracket120further includes at least one bushing123extending at least partially (illustratively, fully at end116and partially at end118) through frame member36or54and coupled or welded to an interior surface of one or both of flanges122. When bushing123fully extends through frame member36or54(as seen at end116), bushing123passes through an opening125through frame member36and is substantially centered through frame member36. However, when bushing123partially extends through frame member36or54(as seen at end118), bushing123is received within an indentation127in frame member54and is substantially offset from center. Once bushing123is received within indentation127, bushing123may be buried into a large coped weld mechanically coupling bushing123to frame member54. When bracket120is coupled to frame member36or54, a space may exist between bushing123and frame member36or54for ease of installation. In various embodiments, a washer (not shown) may be positioned between bushing123and one or both of flanges122and/or between bushing123and frame member36or54.

In various embodiments, when first and second vertical support frame members110and112are coupled to frame member36and54, an opening124extends between either vertical support member110or112and the respective longitudinal frame member36and front upwardly-extending frame member54it is coupled to. In one embodiment, opening124is in the shape of a triangle. Similar to first and second embodiments80aand80b, laterally-extending frame member114is generally positioned longitudinally rearward of front laterally-extending frame member62and front U-shaped frame member60.

Referring now toFIGS. 16-18, a further embodiment80dof support section80is shown. Support section80dis substantially similar to third embodiment80cbut includes first and second vertically-extending frame members130,132which are bent or otherwise non-linear rather than substantially linear like first and second vertical support member110and112of support section80c. Support section80ddoes not include laterally-extending frame member114coupling frame members130and132. In addition, opening134of support section80d, while extending between either vertically-extending support member130or132and the respective longitudinal frame member36and front upwardly-extending frame member54it is coupled to, is not triangular in shape but rather in the shape of a polygon. In various embodiments, a first end136of vertically-extending support members130and132is coupled to longitudinal frame member36via bracket120, while a second end138of vertically-extending support member130and132is welded to front upwardly-extending frame member54. However, similar connections for vertical support members110and112are possible as well, as disclosed above.