Adjustable truck body sub-frame and body panel assemblies

Abstract: A body sub-frame assembly supports the left and right body panels (31 and 32) via the body supports brackets (39 and 40), respectively. The body support brackets (39) are fixed to the left sub-frame rail (37) on the opposite side from the sub-frame brace tubes (41), and the body support brackets (40) are fixed to the right sub-frame rail (38) on the opposite side from sub-frame brace tubes (42). The mounting brackets (33 and 34) of the left and right body panels align with the respective body support brackets (33 and 34). The mounting brackets (33 and 34), and the body support brackets (39 and 40), each have a series of holes at a predetermined spacing along their length. The sub-frame assembly is thereby adjustable to fit a variety of different chassis widths.

Description: The present invention relates to an apparatus according to the preamble of claim 1. Truck chassis with custom body assemblies are well known in certain industries (i.e. the wrecker and car carrier industries). A body assembly typically comprises a left body panel and a right body panel, and typically includes storage compartments for tools and supplies. The body assembly makes up the structural truck body that covers the chassis and drive train. An example of a truck chassis with an attached body assembly that is typical of the prior art is US patent No. 5267773 to Kalis, Jr. et al. (Kalis). Kalis shows a body assembly that is formed from metal panels that are welded together and then bolted to the truck chassis. Apparatuses comprising adjustable body panels for mounting on a truck chassis are also known in the art from US 4117942, US 4570967, US 4412699, FR 2498149, US 4441851 and US 3888368. Truck chassis are available in various different standard sizes (width and length) depending on the country of origin. For example, the United States truck manufacturers generally produce two standard truck chassis widths suitable for a wrecker, 34" and 37.5", and the Japanese and European manufacturers produce different standard chassis sizes. The body assembly width that a given chassis can accommodate is governed by the chassis width, in combination with the cab width and width between the outermost rear wheels (i.e. depending on the size of the rear wheels, and whether the chassis includes two or four rear wheels). Each different chassis width, therefore, accommodates a different range of body assembly widths. Further, to mount a desired body on a given chassis, the body must include a frame with a width that matches the width of the chassis. Chassis lengths also vary, which in turn governs the length of a body assembly that can be accommodated by a given chassis. Therefore, each body assembly must be produced with specific dimensions depending on the particular chassis for which the body assembly is designated. Accordingly, manufacturers must produce different body assemblies for the various different chassis sizes. Factories must then either expand manufacturing capabilities to facilitate simultaneous production of the different body assemblies, or re-tool their manufacturing lines to switch between body assembly sizes. Factories must also increase their parts inventories to accommodate the different body assembly sizes, and distributors, to the extent that they stock body assemblies, must increase their inventories. The prior art, therefore, presents several drawbacks, including increased manufacturing tooling costs, increased factory and distributor inventory requirements, and increased manufacturing lead times. The present invention overcomes the drawbacks of the prior art by providing an adjustable body sub-frame assembly for mounting on a truck chassis, and an adjustable body panel assembly for mounting on the body sub-frame assembly. One universal, adjustable body sub-frame assembly and one universal, adjustable body panel assembly of the present invention fit virtually any truck chassis. The present invention thereby reduces the manufacturing capability and inventory requirements associated with multiple body sub-frame and body panel assembly sizes. It is known from US-A-4117942 to provide an apparatus comprising an adjustable body panel for mounting on a truck chassis, the adjustable body panel comprising at least one mounting bracket fixed to the body panel in a direction extending laterally inward from an inner side of the body panel, the at least one mounting bracket aligning with at least one corresponding body support bracket fixed to the truck chassis in a direction extending laterally outward from the truck chassis, the body panel being mountable on the at least one body support bracket in a plurality of lateral positions, wherein the at least one mounting bracket has a series of holes at a predetermined spacing along its length, wherein the at least one corresponding body support bracket has a series of holes at a predetermined spacing along its length, and wherein at each of the plurality of lateral mounting positions, a subset of the series of holes in the mounting bracket aligns with a subset of the series of holes in the body support bracket. An apparatus according to the present invention is additionally characterised by an adjustable body sub-frame assembly for mounting on the truck chassis and for accommodating the adjustable body panel to be mounted thereon, the adjustable body sub-frame assembly comprising left and right sub-frame rails that mount on left and right chassis rails of the truck chassis, respectively, each sub-frame rail having at least one sub-frame brace tube fixed thereto in a lateral direction extending inward from the respective chassis rail, and each sub-frame rail having at least one body support bracket fixed thereto in a lateral direction extending outward from the respective chassis rail, the sub-frame assembly further comprising at least one sub-frame brace sleeve having two open ends, the sub-frame brace sleeve receiving the sub-frame brace tube of the left sub-frame rail in one open end and receiving the sub-frame brace tube of the right sub-frame rail in the other open end and the sub-frame brace tubes being inserted into the sub-frame brace sleeve to a position such that each sub-frame rail aligns with the respective truck chassis rail and the sub-frame brace tubes being welded in the sub-frame brace sleeve. In a preferred embodiment, at least one deck plate mounts on a top surface at an inner rear edge of the body panel to cover a portion of the truck chassis. Preferably, a plurality of deck plates mount together in an overlapping fashion, and mount on a top surface at an inner rear edge of the body panel to cover a portion of the truck chassis, the plurality of deck plates overlap a predetermined amount in accordance with a width of the truck chassis. Alternatively, there is a deck plate on a top surface at an inner rear edge of the body panel covering a portion of the truck chassis, the deck plate being cut to a size in accordance with a width of the truck chassis. A length spacer panel is conveniently provided that is cut to size in accordance with a length of the truck chassis, and is mounted in a space between a front end of the body panel and a truck cab located at a front end of the truck chassis. The present invention provides advantages over the prior art by providing an adjustable body panel assembly for mounting on a body sub-frame assembly and an adjustable body sub-frame assembly for mounting on a truck chassis. The body panel assembly is adjustable in both the width and the length dimensions, and the body sub-frame assembly is adjustable in the width dimension, to fit chassis of varying sizes. The width adjustment of the body panel assembly accommodates the body sub-frame width, cab width, and width between the outermost rear wheels of the truck chassis, and the width adjustment of the body sub-frame assembly accommodates the truck chassis width. The length spacer panel accommodates variations in chassis length. The present invention thereby provides for one universal body panel assembly and one universal body sub-frame assembly that are adjustable to fit virtually any truck chassis. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 illustrates a top view of the body panel assembly and body sub-frame assembly of an exemplary embodiment of the present invention, mounted on a wide truck chassis, with component deck plates. FIG. 2 illustrates a left side view of a wrecker with a body panel assembly and body sub-frame assembly in accordance with an exemplary embodiment of the present invention. FIG. 3 illustrates a top view of the body panel assembly and body sub-frame assembly of an exemplary embodiment of the present invention, mounted on a narrow truck chassis, with component deck plates. FIG. 4 illustrates a top view of the body panel assembly and body sub-frame assembly of an exemplary embodiment of the present invention, with integral deck plates. DESCRIPTION OF THE PREFERRED EMBODIMENTS Figure 1 shows a top view of the body assembly and sub-frame assembly of an exemplary embodiment of the present invention. The body assembly comprises left and right body panels 31 and 32, each with a pair of mounting brackets 33 and 34, respectively. The left and right body panels mount on a body sub-frame assembly, which comprises left and right sub-frame members 35 and 36. Each sub-frame member comprises a sub-frame rail 37,38, a pair of body support brackets 39,40, and three sub-frame brace tubes 41,42. The left and right sub-frame members are held together as the body sub-frame assembly via three sub-frame brace sleeves 45. Except where expressly stated otherwise, the left and right body panels 31 and 32, and the left and right sub-frame members 35 and 36, are mirror images of each other. Figure 2 shows a left side view of a wrecker 10 equipped with adjustable sub-frame and body panel assemblies in accordance with the exemplary embodiment of the present invention. The wrecker also includes a lift assembly for towing a disabled vehicle. A wide variety of different lift assembly embodiments can be employed with the adjustable sub-frame and body panel assemblies of the present invention, and following description illustrates one such embodiment. The wrecker comprises a chassis 12, with a cab 11 and lift assembly 50 mounted thereon. The lift assembly includes a main boom 55 pivotally mounted to the truck chassis with a hydraulic system (not shown) for raising, lowering, extending, and/or retracting the main boom 55. The lift assembly 55 further includes an extension boom 62 pivotally connected to the end of the main boom 55 with a hydraulic system (not shown) for rotating the extension boom 62 up and down. A wheel grid assembly 64 is attached at the end of the extension boom 62 for engaging the front or rear wheels of a vehicle to be towed. The body panel 15 includes the pair of mounting brackets 33, each engaging a body support bracket 39 of the left sub-frame member. The body panel is secured to the sub-frame member by bolting the mounting brackets 33 to the respective body support brackets 39 with bolts 22. A length spacer panel 20 is cut to cover a portion of the chassis between the cab 11 and the body panel 15. As illustrated in Figure 1, the body sub-frame assembly is assembled with two opposing sub-frame members 35 and 36 connected together with their respective sub-frame brace tubes 41 and 42 inserted into respective sub-frame brace sleeves 45. Each of the three sub-frame brace tubes 41 of the left sub-frame member 35 is inserted into one end of a sub-frame brace sleeve 45. Each of the three sub-frame brace tubes 42 of the right sub-frame member 36 is inserted into the other end of the sub-frame brace sleeve 45 opposite to a corresponding sub-frame brace tube 41. The sub-frame brace tubes 41,42 are inserted a predetermined distance into the sub-frame brace sleeves 45. The sub-frame brace tubes 42 are fixed to the sub-frame rail 38 of the right sub-frame member 36, and the sub-frame brace tubes 41 are fixed to the sub-frame rail 37 of the left sub-frame member 35. The predetermined distance that the sub-frame brace tubes 41,42 are inserted into the sub-frame brace sleeves 45 is set such that the sub-frame rails 37 and 38 line up with the chassis rails 13 and 14, respectively. The sub-frame brace tubes are welded into the sub-frame brace sleeves in that position. The body sub-frame assembly is then ready for mounting on the desired chassis. For example, comparing Figure 1 to Figure 3, the body sub-frame assembly of Figure 1 is mounted on a wide truck chassis, compared to the body sub-frame assembly of Figure 3 mounted on a narrower truck chassis. The sub-frame brace tubes 41,42 of the sub-frame members in Figure 1 are partially inserted into the sub-frame brace sleeves 45, resulting in a wider positioning of the sub-frame rails 37 and 38 to line up with the wider configuration of chassis rails 13 and 14, respectively. Comparatively, the sub-frame brace tubes 41,42 of the sub-frame members in Figure 3 are fully inserted into the sub-frame brace sleeves 45, resulting in a narrower positioning of the sub-frame rails 37 and 38 to line up with the narrower configuration of chassis rails 13 and 14, respectively. The sub-frame assembly is thereby adjustable to fit a variety of different chassis widths. The body sub-frame assembly supports the left and right body panels 31 and 32 via the body support brackets 39 and 40, respectively. The body support brackets 39 are fixed to the left sub-frame rail 37 on the opposite side from the sub-frame brace tubes 41, and the body support brackets 40 are fixed to the right sub-frame rail 38 on the opposite side from sub-frame brace tubes 42. The mounting brackets 33 and 34 of the left and right body panels align with the respective body support brackets 33 and 34. The mounting brackets 33 and 34, and the body support brackets 39 and 40, each have a series of holes at a predetermined spacing along their length. The predetermined spacing is set such that the holes of a given mounting bracket line up with the holes of the corresponding body support bracket in a manner allowing for various lateral mounting positions for the body panel on the body sub-frame assembly. The various lateral positions are designed to accommodate a number of standard truck chassis and cab widths. Each body panel is positioned on the corresponding body support brackets at a desired lateral position with respect to the cab width and width between outer rear wheels, and bolted in that position. For example, again comparing Figure 1 to Figure 3, the left and right body panels 31 and 32 of Figure 1 are mounted on a wide truck chassis, compared to the left and right body panels 31 and 32 of Figure 3 mounted on a narrower truck chassis. The mounting brackets 33 and 34 of the body panels in Figure 1 are partially inserted over the respective body support brackets 39 and 40 of the respective sub-frame members 35 and 36, resulting in a wider positioning of the body panels with respect to the truck cab and chassis. Comparatively, the mounting brackets 33 and 34 of the body panels in Figure 3 are almost fully inserted over the respective body support brackets 39 and 40 of the respective sub-frame members 35 and 36, resulting in a narrower positioning of the body panels with respect to the truck cab and chassis. A single universal body panel is thereby adjustable to fit truck chassis of a variety of widths, and is also readily removable for replacement or easy access to the chassis and drive train for repairs. Once the left and right body panels are mounted on the body sub-frame assembly, left deck plates 51 and 52 are connected to each other in an overlapping fashion, as are right deck plates 53 and 54. The connected deck plate assemblies 51/52 and 53/54 are mounted to the top surfaces at the inner rear ends of the left and right body panels 31 and 32, respectively, as illustrated in Fig. 1. The amount of overlap between deck panels of a connected pair depends on the width of the particular truck chassis, further increasing the flexibility of fitting universal adjustable body panels on truck chassis of a variety of widths. Alternatively, single left and right deck plates can be cut to size in accordance with the chassis width, and mounted to the top surface at the inner rear ends of the left and right body panels 31 and 32, respectively. The deck plates form a deck between the respective body panels 31 and 32 and the automobile lift assembly 50. The deck plates or deck plate assemblies can be bolted, welded, riveted, or otherwise fixed together and in place. Alternatively, as shown in Figure 4, single deck plates 61 and 62 can be integrally provided as part of the respective body panels 31 and 32. The deck plates 61 and 62 are cut to size in accordance with the desired chassis width. Further, left and right length spacer panels 20 and 21, respectively, are cut to size and mounted to the left and right body panels, covering spaces between the left and right body panels 31 and 32, and the truck cab 11. Body support brackets 57 and 58 are fixed to the outer sides of the left and right chassis rails 13 and 14, respectively. The body support brackets 57 and 58 align with mounting brackets 59 and 60 of the left and right length spacer panels 20 and 21, respectively. As with the mounting brackets and body support brackets of the body panels 31 and 32, the mounting brackets 59 and 60, and the body support brackets 57 and 58, each have a series of holes at a predetermined spacing along their length. The predetermined spacing is set such that the holes of a given mounting bracket line up with the holes of the corresponding body support bracket in a manner allowing for various lateral mounting positions for the body panel on the body sub-frame assembly. The various lateral positions are designed to accommodate a number of standard truck chassis and cab widths, and provide for alignment of the length spacer panels 20 and 21 with the respective left and right body panels 31 and 32. Each length spacer panel is positioned on the corresponding body support bracket at a desired lateral position with respect to the respective body panel, and bolted in that position. Further, each length spacer panel is bolted to the respective body panel, as illustrated in Figures 1, 3, and 4. The length spacer panels thereby accommodate for a variety of truck chassis lengths upon which the universal adjustable body panels of the present invention can be mounted. Of course, it should be understood that a wide range of modifications can be made to the exemplary embodiments described above. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it be understood that it is the following claims which are intended to define the scope of this invention.

Claims: An apparatus comprising an adjustable body panel (31,32) for mounting on a truck chassis (12), the adjustable body panel comprising at least one mounting bracket fixed to the body panel (31,32) in a direction extending laterally inward from an inner side of the body panel (31,32), the at least one mounting bracket (33,34) aligning with at least one corresponding body support bracket (39,40) fixed to the truck chassis (12) in a direction extending laterally outward from the truck chassis, the body panel (31,32) being mountable on the at least one body support bracket (39,40) in a plurality of lateral positions, wherein the at least one mounting bracket (33,34) has a series of holes at a predetermined spacing along its length, wherein the at least one corresponding body support bracket (39,40) has a series of holes at a predetermined spacing along its length, and wherein at each of the plurality of lateral mounting positions, a subset of the series of holes in the mounting bracket (33,34) aligns with a subset of the series of holes in the body support bracket (39,40) characterised by an adjustable body sub-frame assembly (35,36) for mounting on the truck chassis (12) and for accommodating the adjustable body panel (31,32) to be mounted thereon, the adjustable body sub-frame assembly (35,36) comprising left and right sub-frame rails (37,38) that mount on left and right chassis rails (13,14) of the truck chassis (12), respectively, each sub-frame rail (37,38) having at least one sub-frame brace tube (41,42) fixed thereto in a lateral direction extending inward from the respective chassis rail (13,14), and each sub-frame rail (37,38) having at least one body support bracket (39,40) fixed thereto in a lateral direction extending outward from the respective chassis rail (13,14), the sub-frame assembly (35,36) further comprising at least one sub-frame brace sleeve (45) having two open ends, the sub-frame brace sleeve (45) receiving the sub-frame brace tube (41) of the left sub-frame rail (37) in one open end and receiving the sub-frame brace tube (42) of the right sub-frame rail (38) in the other open end, and the sub-frame brace tubes (41,42) being inserted into the sub-frame brace sleeve (45) to a position such that each sub-frame rail (37,38) aligns with the respective truck chassis rail (12) and the sub-frame brace tubes (41,42) being welded in the sub-frame brace sleeve (45). The apparatus of claim 1 further comprising at least one deck plate (51,52/53,54/61,62) that mounts on a top surface at an inner rear edge of the body panel (31,32) to cover a portion of the truck chassis (12). The apparatus of claim 1 further comprising a plurality of deck plates (51,52/53,54) that mount together in an overlapping fashion, and mount on a top surface at an inner rear edge of the body panel (31,32) to cover a portion of the truck chassis (12), the plurality of deck plates (51,52/53,54) overlap a predetermined amount in accordance with a width of the truck chassis. The apparatus of claim 1, further comprising a deck plate (61,62) on a top surface at an inner rear edge of the body panel (31,32) covering a portion of the truck chassis (12), the deck plate (61,62) being cut to a size in accordance with a width of the truck chassis (12). The apparatus of claim 1 further comprising a length spacer panel (20,21) that is cut to size in accordance with a length of the truck chassis (12) and is mounted in a space between a front end of the body panel (31,32) and a truck cab (11) located at a front end of the truck chassis (12). The apparatus of claim 1 comprising a plurality of the adjustable body panels (31,32).

Inventors: GOETZ CHRISTOPHER N, HUMPHRIES DAVID F, GOETZ, CHRISTOPHER N., HUMPHRIES, DAVID F.
Applicants: JERR DAN CORP, JERR-DAN CORPORATION
Application year: 1999
Main classification: B62D33
IPC codes: B60P3, B62D33, B62D21