Patent Publication Number: US-11654975-B2

Title: Vehicle frame rails and methods of assembling vehicle frame rails

Description:
The present invention relates generally to the field of vehicle components. In particular, the present invention relates to vehicle frame rails and methods of assembling vehicle frame rails. 
     BACKGROUND OF THE INVENTION 
     A typical vehicle chassis includes a pair of frame rails that extend along the length of the vehicle on opposite sides. The frame rails are connected by one or more cross members. Various vehicle components, such as, for example, suspension components, may be connected, either directly or indirectly, to the frame rails. 
     U.S. Pat. No. 2,327,585 discloses use of a bolt spacer or reinforcing member in connection with a vehicle chassis. This patent discloses a structural member having three elements. The first element includes a channel member forming a first panel. The second element includes a second panel. The third element includes one or more sockets and is positioned between the first and second elements. The sockets receive reinforcing elements in the form of tubular spacers. The reinforcing elements include a longitudinal bore sized to receive a bolt. The bolt, in combination with a nut, holds the three elements together. 
     U.S. Pat. No. 4,863,214 discloses a spacer tube matrix. The spacer tube matrix is intended for use within a vehicle frame having a box beam construction. The spacer tube matrix aligns a plurality of spacer tubes with openings in the side walls of the box beam construction. Bolts may be inserted through the openings in the box beam construction and the spacer tubes. 
     U.S. Pat. No. 8,484,930 discloses a box frame member having two sections with one or more openings in each section. Locators are formed around each of the holes. The locators extend into opposite ends of spacers placed between the two sections. 
     SUMMARY OF THE INVENTION 
     In one embodiment of the present invention, a vehicle frame rail includes a front rail section, a center rail section, a rear rail section, a first spacer locating member, a second spacer locating member a third spacer locating member and a plurality of spacers. The front rail section has a first end, a second end, a first section and a second section. The first section of the front rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section of the front rail section has a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the front rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the front rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The center rail section has a first end connected to the second end of the front rail section, a second end, a first section and a second section. The first section of the center rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section of the center rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the center rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the center rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The rear rail section has a first end connected to the second end of the center rail section, a second end, a first section and a second section. The first section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the rear rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the rear rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The first spacer locating member has a body section, a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the front rail section, and a support member. The support member has a first section extending from the body section and a second section extending from the first section. The second section of the support member is connected to the central section of the second section of the front rail section so as to position the body section of the first spacer locating member between and spaced apart from the central section of the first section of the front rail section and the central section of the second section of the front rail section. The second spacer locating member has a body section, a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the center rail section, and a support member. The support member has a first section extending from the body section and a second section extending from the first section. The second section of the support member is connected to the central section of the second section of the center rail section so as to position the body section of the second spacer locating member between and spaced apart from the central section of the first section of the center rail section and the central section of the second section of the center rail section. The third spacer locating member has a body section, a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the rear rail section, and a support member. The support member has a first section extending from the body section and a second section extending from the first section. The second section of the support member is connected to the central section of the second section of the rear rail section so as to position the body section of the third spacer locating member between and spaced apart from the central section of the first section of the rear rail section and the central section of the second section of the rear rail section. Each spacer has a first end, a second end and a bore extending from the first end to the second end. A first one of the plurality of spacers is located in one of the holes of the first spacer locating member such that the bore is aligned with one of the holes in the first section of the front rail section and with one of the holes in the second section of the front rail section. A second one of the plurality of spacers is located in one of the holes of the second spacer locating member such that the bore is aligned with one of the holes in the first section of the center rail section and with one of the holes in the second section of the center rail section. A third one of the plurality of spacers is located in one of the holes of the third spacer locating member such that the bore is aligned with one of the holes in the first section of the rear rail section and with one of the holes in the second section of the rear rail section. 
     In one embodiment, the first and second flanges of the second section of the front rail section are located between the first and second flanges of the first section of the front rail section. In another embodiment, the first and second flanges of the second section of the center rail section are located between the first and second flanges of the first section of the center rail section. In other embodiments, the first and second flanges of the second section of the rear rail section are located between the first and second flanges of the first section of the rear. 
     In other embodiments, the first end of the center rail section is located between the first and second sections of the front rail section. In one embodiment, the hole patterns in the first and second sections of the front rail section are aligned at least in part with the hole patterns in the first and second sections of the center rail section. In certain embodiments, the second end of the center rail section is located between the first and second sections of the rear rail section. 
     In another embodiment, the second end of the center rail section is located between the first and second sections of the rear rail section. 
     In other embodiments, the first spacer is connected to the first spacer locating member. 
     In certain embodiments, the vehicle frame rail further includes a first reinforcing member located between the first section of the center rail section and the second section of the center rail section. In other embodiments, the first reinforcing member includes a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the center rail section. In some embodiments, the first reinforcing member is located between the second spacer locating member and the first section of the center rail section. According to other embodiments of the invention, the hole pattern of the first reinforcing member corresponds at least in part to the hole pattern in the second spacer locating member. 
     In certain embodiments of the invention, the vehicle frame rail further includes a second reinforcing member located between the first section of the rear rail section and the second section of the rear rail section. In some embodiments, the second reinforcing member includes a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the rear rail section. In other embodiments, the second reinforcing member is located between the fourth spacer locating member and the first section of the rear rail section. In certain embodiments, the hole pattern of the second reinforcing member corresponds at least in part to the hole pattern in the fourth spacer locating member. 
     In one embodiment of the present invention, a vehicle frame rail includes a first half, a second half, a spacer locating member and a spacer. The first half has a hole. The second half has a hole and is connected to the first half such that the hole in the first half is aligned with the hole in the second half and so as to form an enclosed space between the first half and the second half. The spacer locating member has a body section spaced apart from the first half and the second half and a hole. The spacer has a first end, a second end and a bore extending from the first end to the second end. The spacer is located in the hole of the spacer locating member such that the bore is aligned with the hole in the first half and the hole in the second half. 
     In one embodiment, the spacer locating member is located within the enclosed space. In another embodiment, the body section of the spacer locating member is located between the first half and the second half. 
     In other embodiments the spacer locating member includes a support member connected to the second half. In certain embodiments, the support member has a first section extending from the body section of the spacer locating member and a second section extending from the first section. In one embodiment, the first section of the support member is perpendicular to the body section of the spacer locating member. In another embodiment, the second section of the support member is perpendicular to the first section of the support member. In certain embodiments of the invention, the first section of the support member extends from an edge of the body section of the spacer locating member. 
     In one embodiment, the first half has a first flange and a second flange, the second half has a first flange and a second flange, and the first and second flanges of the second half are located between the first and second flanges of the first half. 
     In another embodiment, the vehicle frame rail has a front rail section, a center rail section and a rear rail section, the first half of the vehicle frame rail includes a first section of the front rail section, a first section of the center rail section and a first section of the rear rail section, and the second half of the vehicle frame rail includes a second section of the front rail section, a second section of the center rail section and a second section of the rear rail section. In one embodiment, the center rail section has a first end located between the first and second sections of the front rail section. In certain embodiments, the center rail section has a first end and a second end and the second end of the center rail section is located between the first and second sections of the rear rail section. In another embodiment, the center rail section has a first end located between the first and second sections of the front rail section and a second end located between the first and second sections of the rear rail section. 
     In other embodiments, the first half has a plurality of holes, the second half has a plurality of holes and at least two holes in the first half are aligned with at least two holes in the second half. In one embodiment, the spacer locating member includes a plurality of holes and at least two holes in the spacer locating member are aligned with at least two holes in the first half and with at least two holes in the second half. 
     In certain embodiments of the present invention, the vehicle frame rail further includes a reinforcing member having a hole and the reinforcing member is located in the enclosed space such that the hole in the reinforcing member is aligned with the hole in the first half and the hole in the second half. In other embodiments, the reinforcing member is located between the spacer locating member and the first half. In some embodiments, the reinforcing member is aligned with the hole in the spacer locating member. In other embodiments, the spacer is located in the hole in the reinforcing member. 
     In one embodiment of the present invention, a vehicle frame rail includes a first half, a second half, a spacer locating member and a plurality of spacers. The first half has a plurality of holes. The second half has a plurality of holes and is connected to the first half such that at least two of the holes in the first half are aligned with at least two of the holes in the second half and so as to form an enclosed space between the first half and the second half. The spacer locating member has a body section having a plurality of holes with at least two of the holes in the spacer locating member aligned with at least two of the holes in the first half and with at least two of the holes in the second half. Each of the spacers has a first end, a second end and a bore extending from the first end to the second end. A first one of the plurality of spacers is located in a first one of the holes of the spacer locating member so as to align the bore of the first spacer with at least one of the holes in the first half and with at least one of the holes in the second half. A second one of the plurality of spacers is located in a second one of the holes of the spacer locating member so as to align the bore of the second spacer with at least one of the holes in the first half and with at least one of the holes in the second half. 
     In one embodiment, the spacer locating member is located within the enclosed space. In another embodiment, the body section of the spacer locating member is spaced apart from the first half and the second half. 
     In other embodiments, the spacer locating member includes a support member connected to the second half. In another embodiment, the support member has a first section extending from the body section of the spacer locating member and a second section extending from the first section. In certain embodiments, the first section of the support member is perpendicular to the body section of the spacer locating member. In one embodiment, the second section of the support member is perpendicular to the first section of the support member. In other embodiments, the support member extends from an edge of the body section of the spacer locating member. 
     In certain embodiments, the first half has a first flange and a second flange, the second half has a first flange and a second flange, and the first flange of the first half is located between the first and second flanges of the second half and the second flange of the second half is located between the first and second flanges of the first half. 
     In one embodiment, the vehicle frame rail has a front rail section, a center rail section and a rear rail section, the first half of the vehicle frame rail includes a first section of the front rail section, a first section of the center rail section and a first section of the rear rail section, and the second half of the vehicle frame rail includes a second section of the front rail section, a second section of the center rail section and a second section of the rear rail section. In another embodiment, the center rail section has a first end located between the first and second sections of the front rail section. In other embodiments, the center rail section has a first end and a second end and the second end of the center rail section is located between the first and second sections of the rear rail section. In certain embodiments, the center rail section has a first end located between the first and second sections of the front rail section and a second end located between the first and second sections of the rear rail section. 
     In certain embodiments of the present invention, the vehicle frame rail further includes a reinforcing member having a plurality of holes and the reinforcing member is located in the enclosed space such that at least two of the holes in the reinforcing member are aligned with at least two of the holes in the first half and with at least two of the holes in the second half. In some embodiments, the reinforcing member is located between the spacer locating member and the first half. In other embodiments, at least two of the holes in the reinforcing member are aligned with at least two of the holes in the spacer locating member. In certain embodiments, the first one of the plurality of spacers is located in a first one of the holes in the reinforcing member and the second one of the plurality of spacers is located in a second one of the holes in the reinforcing member. 
     In one embodiment of the present invention, a vehicle frame rail includes a front rail section, a center rail section, a rear rail section, a spacer locating member, a first reinforcing member, a second reinforcing member and a plurality of spacers. The front rail section has a first end, a second end, a first section and a second section. The first section of the front rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section of the front rail section has a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the front rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the front rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The center rail section has a first end connected to the second end of the front rail section, a second end, a first section and a second section. The first section of the center rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section of the center rail section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the center rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the center rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The rear rail section has a first end connected to the second end of the center rail section, a second end, a first section and a second section. The first section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern. The second section has a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section. The first flange of the first section of the rear rail section extends toward and is connected to the first flange of the second section and the second flange of the first section of the rear rail section extends toward and is connected to the second flange of the second section such that the hole pattern of the first section and the hole pattern of the second section are at least partially aligned and so as to form an enclosed space between the first and second sections. The spacer locating member has a body section, a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the center rail section, and a support member. The support member has a first section extending from the body section and a second section extending from the first section. The second section of the support member is connected to the central section of the second section of the center rail section so as to position the body section of the first spacer locating member between and spaced apart from the central section of the first section of the center rail section and the central section of the second section of the center rail section. The first reinforcing member is located between the first and second sections of the front rail section and has a body section and a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the front rail section. The second reinforcing member is located between the first and second sections of the rear rail section and has a body section and a hole pattern corresponding at least in part to the hole pattern in the first and second sections of the rear rail section. Each spacer has a first end, a second end and a bore extending from the first end to the second end. A first one of the plurality of spacers is located in one of the holes of the spacer locating member such that the bore is aligned with one of the holes in the first section of the center rail section and with one of the holes in the second section of the center rail section. A second one of the plurality of spacers located in one of the holes of the first reinforcing member such that the bore is aligned with one of the holes in the first section of the front rail section and with one of the holes in the second section of the front rail section. A third one of the plurality of spacers located in one of the holes of the second reinforcing member such that the bore is aligned with one of the holes in the first section of the rear rail section and with one of the holes in the second section of the rear rail section. 
     In one embodiment of the present invention, a method of assembling a vehicle frame rail, includes the steps of (a) providing a front rail section of the frame rail, the front rail section having a first end, a second end, a first section and a second section, the first section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern, the second section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section; (b) providing a center rail section of the frame rail, the center rail section having a first end, a second end, a first section and a second section, the first section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern, the second section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section; (c) providing a rear rail section, the rear rail section having a first end, a second end, a first section and a second section, the first section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern, the second section having a central section, a first flange extending from the central section, a second flange extending from the central section, and a hole pattern corresponding at least in part to the hole pattern in the first section; (d) providing a spacer locating member having a hole; (e) providing a spacer; (f) connecting the first end of the first section of the center rail section to the second end of the first section of the front rail section and connecting the second end of the first section of the center rail section to the first end of the first section of the rear rail section to form a first half of the frame rail; (g) connecting the first end of the second section of the center rail section to the second end of the second section of the front rail section and connecting the second end of the second section of the center rail section to the first end of the second section of the rear rail section to form a second half of the frame rail; (h) connecting the spacer locating member to the second half of the frame rail; (i) inserting the spacer in the hole of the spacer locating member; and; (j) connecting the first half of the frame rail to the second half of the frame rail such that the first flange of the first section of the front rail section is located between the first and second flanges of the second section of the front rail section, the second flange of the second section of the front rail section is located between the first and second flanges of the first section of the front rail section, the first flange of the first section of the center rail section is located between the first and second flanges of the second section of the center rail section, the second flange of the second section of the center rail section is located between the first and second flanges of the first section of the center rail section, the first flange of the first section of the rear rail section is located between the first and second flanges of the second section of the rear rail section, and the second flange of the second section of the rear rail section is located between the first and second flanges of the first section of the rear rail section. 
     Other features of the present invention will be apparent from the following description of embodiments of the invention and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of a vehicle frame rail according to one embodiment of the present invention. 
         FIG.  2    is an exploded perspective view of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  3 A  is a perspective view of a first spacer locating member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  3 B  is a side view of the spacer locating member shown in  FIG.  3 A . 
         FIG.  3 C  is a top view of the spacer locating member shown in  FIG.  3 A . 
         FIG.  4 A  is a perspective view of a second spacer locating member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  4 B  is a side view of the spacer locating member shown in  FIG.  4 A . 
         FIG.  4 C  is a top view of the spacer locating member shown in  FIG.  4 A . 
         FIG.  5 A  is a perspective view of a third spacer locating member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  5 B  is a side view of the spacer locating member shown in  FIG.  5 A . 
         FIG.  5 C  is a top view of the spacer locating member shown in  FIG.  5 A . 
         FIG.  6 A  is a perspective view of a fourth spacer locating member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  6 B  is a side view of the spacer locating member shown in  FIG.  6 A . 
         FIG.  6 C  is a top view of the spacer locating member shown in  FIG.  6 A . 
         FIG.  7 A  is a perspective view of a fifth spacer locating member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  7 B  is a side view of the spacer locating member shown in  FIG.  7 A . 
         FIG.  7 C  is a top view of the spacer locating member shown in  FIG.  7 A . 
         FIG.  8    is a perspective view of a spacer that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  9    is a perspective view of a first reinforcing member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  10    is a perspective view of a second reinforcing member that is a component of the vehicle frame rail shown in  FIG.  1   . 
         FIG.  11    is a perspective view illustrating an assembly step according to one embodiment of the present invention for vehicle frame rail shown in  FIG.  1   . 
         FIG.  12 A  is a side elevational view of certain components of the vehicle frame rail shown in  FIG.  1    in a partially assembled configuration. 
         FIG.  12 B  is a perspective view of area  12 B in  FIG.  12 A . 
         FIG.  12 C  is a perspective view of area  12 C in  FIG.  12 A . 
         FIG.  12 D  is a perspective view of area  12 D in  FIG.  12 A . 
         FIG.  12 E  is a perspective view of area  12 E in  FIG.  12 A . 
         FIG.  12 F  is a perspective view of area  12 F in  FIG.  12 A . 
         FIG.  13    is a sectional view taken along line  13 - 13  in  FIG.  1   . 
         FIG.  14    is a perspective view illustrating an assembly step according to another embodiment of the present invention for vehicle frame rail shown in  FIG.  1   . 
         FIG.  15    is an exploded perspective view of a vehicle frame rail according to another embodiment of the present invention. 
         FIG.  16    is a cross sectional view of the vehicle frame rail shown in  FIG.  15    taken along line  16 - 16 . 
         FIG.  17    is an exploded perspective view of a vehicle frame rail according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
       FIG.  1    is a perspective view of a vehicle frame rail  10  according to one embodiment of the present invention. Frame rail  10  has a first or front end  11 , a second or rear end  12 , a first or outer side  13 , a second or inner side  14 , an upper surface  15 , and a lower surface  16 . Frame rail  10  includes a first or front rail section  20 , a second or center rail section  30  and a third or rear rail section  40 . 
       FIG.  2    is an exploded perspective view of vehicle frame rail  10  shown in  FIG.  1   . As shown in  FIG.  2   , front rail section  20  includes a first or inner section  21  and a second or outer section  22 . First section  21  of front rail section  20  has a first end  21 A and a second end  21 B. First section  21  in the embodiment shown is a generally C-shaped member having a central section  21 C that is substantially perpendicular to a first section or flange  21 D and a second section or flange  21 E. First flange  21 D and second flange  21 E extend toward second section  22  of front rail section  20 . First section  21  further includes one or more openings or holes  21 F arranged in one or more hole patterns. 
     As used in this specification a “hole pattern” is a grouping of two or more holes. A single component of frame rails according to embodiments of the invention may include multiple hole patterns. For example, all of the holes  21 F in first section  21  constitute a first hole pattern. The first two holes  21 F adjacent front end  21 A of first section  21  constitute a second hole pattern. Holes need not be adjacent one another to constitute a hole pattern. 
     Second section  22  of front rail section  20  has a first end  22 A and a second end  22 B. Second section  22  in the embodiment shown is a generally C-shaped member having a central section  22 C that is substantially perpendicular to a first section or flange  22 D and a second section or flange  22 E. First flange  22 D and second flange  22 E extend toward first section  21  of front rail section  20 . Second section  22  further includes one or more openings or holes  22 F arranged in one or more hole patterns that correspond at least in part to a portion of one or more of the hole patterns in first section  21  of front rail section  20 . 
     As also shown in  FIG.  2   , center rail section  30  includes a first or inner section  31  and a second or outer section  32 . First section  31  of center rail section  30  has a first end  31 A and a second end  31 B. First section  31  in the embodiment shown is a generally C-shaped member having a central section  31 C that is substantially perpendicular to a first section or flange  31 D and a second section or flange  31 E. First flange  31 D and second flange  31 E extend toward second section  32  of center rail section  30 . First section  31  further includes one or more openings or holes  31 F arranged in one or more hole patterns. 
     Second section  32  of center rail section  30  has a first end  32 A and a second end  32 B. Second section  32  in the embodiment shown is a generally C-shaped member having a central section  32 C that is substantially perpendicular to a first section or flange  32 D and a second section or flange  32 E. First flange  32 D and second flange  32 E extend toward first section  31  of center rail section  30 . Second section  32  further includes one or more openings or holes  32 F arranged in one or more hole patterns that correspond at least in part to a portion of one or more of the hole patterns in first section  31  of center rail section  30 . 
     As further shown in  FIG.  2   , rear rail section  40  includes a first or inner section  41  and a second or outer section  42 . First section  41  of rear rail section  40  has a first end  41 A and a second end  41 B. First section  41  in the embodiment shown is a generally C-shaped member having a central section  41 C that is substantially perpendicular to a first section or flange  41 D and a second section or flange  41 E. First flange  41 D and second flange  41 E extend toward second section  42  of rear rail section  40 . First section  41  further includes one or more openings or holes  41 F arranged in one or more hole patterns. 
     Second section  42  of rear rail section  40  has a first end  42 A and a second end  42 B. Second section  42  in the embodiment shown is a generally C-shaped member having a central section  42 C that is substantially perpendicular to a first section or flange  42 D and a second section or flange  42 E. First flange  42 D and second flange  42 E extend toward first section  41  of rear rail section  40 . Second section  42  further includes one or more openings or holes  42 F arranged in a hole pattern that correspond at least in part to a portion of one or more of the hole patterns in first section  41  of rear rail section  40 . 
     As further shown in  FIG.  2   , frame rail  10  also includes a first spacer locating member  50 , a second spacer locating member  60 , a third spacer locating member  70 , a fourth spacer locating member  80 , a fifth spacer locating member  90 , and a plurality of spacers  100 . 
     Referring to  FIGS.  3 A- 3 C , first spacer locating member  50  includes a main or body section  51 , a plurality of support members  52 , and one or more openings or holes  53  arranged in one or more hole patterns corresponding at least in part to a portion of the hole patterns in first section  21  and second section  22  of front rail section  20  of frame rail  10 . Body section  51  in the embodiment shown is a plate-like member having a first section  51 A and a second section  51 B disposed at an angle to first section  51 A. Each support member  52  in the embodiment shown includes a first section  54  extending from and edge of and generally perpendicular to body section  51  of first spacer locating member  50  and a second section  55  extending from and generally perpendicular to first section  54 . The number, configuration and positioning of support members  52  are selected so as to provide the necessary support around the periphery of body section  51  and so as to position first section  51 A and second section  51 B of body section  51  parallel to the inner surfaces of first section  21  and second section  22  of front rail section  20 . In the embodiment shown in  FIGS.  3 A- 3 C , first sections  54  of support members  52  extending from first section  51 A are longer than first sections  54  of support members  52  extending from second section  51 B. 
     Referring to  FIGS.  4 A- 4 C , second spacer locating member  60  includes a main or body section  61 , a plurality of support members  62  and one or more openings or holes  63  arranged in one or more hole patterns corresponding at least in part to a portion of the hole patterns in first section  21  and second section  22  of front rail section  20  and of first section  31  and second section  32  of center rail section  30  of frame rail  10 . Body section  61  of second spacer locating member  60  is a substantially flat plate-like member. Each support member  62  in the embodiment shown includes a first section  64  extending from and edge of and generally perpendicular to body section  61  of first spacer locating member  60  and a second section  65  extending from and generally perpendicular to first section  64 . The number, configuration and positioning of support members  62  are selected so as to provide the necessary support around the periphery of body section  61  and so as to position body section  61  parallel to the inner surfaces of first section  21  and second section  22  of front rail section  20  and of first section  31  and second section  32  of center rail section  30 . 
     Referring to  FIGS.  5 A- 5 C , third spacer locating member  70  includes a main or body section  71 , a plurality of support members  72  and one or more openings or holes  73  arranged in one or more hole patterns corresponding at least in part to a portion of the hole patterns in first section  31  and second section  32  of center rail section  30  of frame rail  10 . Body section  71  of third spacer locating member  70  is a substantially flat plate-like member. Each support member  72  in the embodiment shown includes a first section  74  extending from an edge of and generally perpendicular to body section  71  of first spacer locating member  70  and a second section  75  extending from and generally perpendicular to first section  74 . The number, configuration and positioning of support members  72  are selected so as to provide the necessary support around the periphery of body section  71  and so as to position body section  71  parallel to the inner surfaces of first section  31  and second section  32  of center rail section  30 . 
     Referring to  FIGS.  6 A- 6 C , fourth spacer locating member  80  includes a main or body section  81 , a plurality of support members  82  and one or more openings or holes  83  arranged in one or more hole patterns corresponding at least in part to a portion of the hole patterns in first section  41  and second section  42  of rear rail section  40  of frame rail  10 . Body section  81  of fourth spacer locating member  80  is a substantially flat plate-like member. Each support member  82  in the embodiment shown includes a first section  84  extending from an edge of and generally perpendicular to body section  81  of first spacer locating member  80  and a second section  85  extending from and generally perpendicular to first section  84 . The number, configuration and positioning of support members  82  are selected so as to provide the necessary support around the periphery of body section  81  and so as to position body section  81  parallel to the inner surfaces of first section  41  and second section  42  of rear rail section  40 . 
     Referring to  FIGS.  7 A- 7 C , fifth spacer locating member  90  includes a main or body section  91 , a plurality of support members  92  and one or more openings or holes  93  arranged in one or more hole patterns corresponding at least in part to a portion of the hole patterns in first section  41  and second section  42  of rear rail section  40  of frame rail  10 . Body section  91  of fifth spacer locating member  90  is a substantially flat plate-like member. One support member  92  in the embodiment shown includes a first section  94  extending from an edge of and generally perpendicular to body section  91  of fifth spacer locating member  90  and a second section  95  extending from and generally perpendicular to first section  94 . Another support member  92  in the embodiment shown includes a first section  94 A extending from and generally perpendicular to body section  91  of fifth spacer locating member  90  and a second section  95 A extending from and disposed at an obtuse angle OA to first member  94 A. The number, configuration and positioning of support members  92  are selected so as to provide the necessary support around the periphery of body section  91  and so as to position body section  91  parallel to the inner surfaces of first section  41  and second section  42  of rear rail section  40 . 
     As shown in  FIG.  8   , each spacer  100  includes a first end  101 , a second end  102  and an opening or through bore  103  extending from first end  101  to second end  102 . 
     As also shown in  FIG.  2   , frame rail  10  in the embodiment shown includes a first reinforcing member  110  and a second reinforcing member  120 . First reinforcing member  110  ( FIG.  9   ) includes a main or body section  111 , a first flange  112  extending generally perpendicular to and along one side of body section  111 , a second flange  113  extending generally perpendicular to and along one side of body section  111 , and one or more openings or holes  114  arranged in one or more hole patterns. 
     Referring to  FIG.  10   , second reinforcing member  120  includes a main or body section  121 , a first flange  122  extending generally perpendicular to and along one side of body section  121 , a second flange  123  extending generally perpendicular to and along one side of body section  121 , and one or more openings or holes  124  arranged in one or more hole patterns. 
     As further shown in  FIG.  2   , frame rail  10  includes one or more brackets and/or reinforcing members. In the embodiment shown in  FIG.  2   , frame rail  10  includes a steering gear reinforcement  130 , a steering gear bracket  140 , a stabilizer bar attachment bracket  150 , a steering gear reinforcement  160 , a body mount bracket  170 , a frame rail end plate  180 , and a body mount reinforcement  190 . In the embodiment shown, steering gear bracket  140  includes one or more posts  141 , each of which includes a bore  142  sized to receive a fastener, such as a bolt. Body mount reinforcement  190  also includes one or more posts  191 , each of which includes a bore  192  sized to receive a fastener, such as a bolt. 
     In one embodiment of the present invention, frame rail  10  is assembled by overlapping second end  21 B of first section  21  of front rail section  20  with first end  31 A of first section  31  of center rail section  30  such that a portion of first section  31  is nested within first section  21  between first flange  21 D and second flange  21 E of first section  21 . Note that in the embodiment shown, several holes  21 F in first section  21  align with several holes  31 F in first section  31  in the area of overlap. First section  21  and first section  31  are then welded together or secured together by other means. Similarly, second end  31 B of first section  31  of center rail section  30  is overlapped with first end  41 A of first section  41  of rear rail section  40  such that a portion of first section  31  is nested within first section  41  between first flange  41 D and second flange  41 E. First section  31  and first section  41  are then welded together or secured together by other means. This forms a first half or outer frame rail side  10 A of frame rail  10  as shown in  FIG.  11   . 
     Second end  22 B of second section  22  of front rail section  20  is overlapped with first end  32 A of second section  32  of center rail section  30  such that a portion of second section  32  is nested within second section  22  between first flange  22 D and second flange  22 E of second section  22 . Note that in the embodiment shown, several holes  22 F in second section  22  align with several holes  32 F in second section  32  in the area of overlap. Second section  22  and second section  32  are then welded together or secured together by other means. Similarly, second end  32 B of second section  32  of center rail section  30  is overlapped with first end  42 A of second section  42  of rear rail section  40  such that a portion of second section  32  is nested within second section  42  between first flange  42 D and second flange  42 E. Second section  32  and second section  42  are then welded together or secured together by other means. This forms a second half or inner frame rail side  10 B of frame rail  10  as shown in  FIG.  11   . 
     First spacer locating member  50 , second spacer locating member  60 , third spacer locating member  70 , fourth spacer locating member  80 , fifth spacer locating member  90 , first reinforcing member  110 , second reinforcing member  120 , and steering gear bracket  140  are then secured (such as by welding or other means) to either first half  10 A or second half  10 B of frame rail  10 . 
       FIGS.  12 A- 12 F  show first spacer locating member  50 , second spacer locating member  60 , third spacer locating member  70 , fourth spacer locating member  80 , fifth spacer locating member  90 , steering gear bracket  140 , and frame rail end plate  180  positioned on and secured to second half  10 B. The spacer locating members may be secured to, for example, second half  10 B by any of various means, including, for example, by welding one or more of the support members of the spacer locating members to second half  10 B. 
     To do so, first spacer locating member  50  is positioned on second section  22  of front rail section  20  such that second section  55  of one or more support members  52  contacts central section  22 C of second section  22  and one or more holes  53  are aligned with one or more holes  22 F in second section  22  ( FIGS.  12 A and  12 B ). Steering gear bracket  140  is also positioned on second section  22  of front rail section  20  such that one or more bores  142  in posts  141  are aligned with one or more holes  22 F in second section  22 . 
     Referring to  FIGS.  12 A and  12 C , second spacer locating member  60  is positioned on second section  32  of center rail section  30  such that second section  65  of one or more support members  62  contacts central section  32 C of second section  32  and one or more holes  63  are aligned with one or more holes  32 F in second section  32 . As discussed above, and as shown in  FIG.  9   , several holes  22 F in second section  22  of front rail section  20  align with several holes  32 F in second section  32  of center rail section  30  when second section  22  and second section  32  are joined to form part of second half  10 B of frame rail  10 . In the embodiment shown in  FIGS.  10 A and  10 B , one or more holes  63  in second spacer locating member  60  align with one or more holes  22 F in second section  22  and with one or more holes  32 F in second section  32 . 
     Third spacer locating member  70  is positioned on second section  32  of center rail section  30  such that second section  75  of one or more support members  72  contacts central section  32 C of second section  32  and one or more holes  73  are aligned with one or more holes  32 F in second section  32 . ( FIGS.  12 A and  12 D ) 
     Fourth spacer locating member  80  is positioned on second section  42  of rear rail section  40  such that second section  85  of one or more support members  82  contacts central section  42 C of second section  42  and one or more holes  83  are aligned with one or more holes  42 F in second section  42 . ( FIGS.  12 A and  12 E ) 
     Fifth spacer locating member  90  is positioned on second section  42  of rear rail section  40  such that section  95  of one or more support members  92  contacts central section  42 C of second section  42  and one or more holes  93  are aligned with one or more holes  42 F in second section  42 . ( FIGS.  12 A and  12 F ) 
     Spacers  100  are then positioned in one or more of the holes in one or more of the spacer locating members. For example, as shown in  FIGS.  12 A and  12 B , a spacer  100  is placed in each hole  53  in first spacer locating member  50 . In this manner, each bore  103  in a spacer  100  is aligned with a hole  22 F in second section  22  of front rail section  20 . In certain embodiments of the invention, spacers  100  are welded or otherwise secured to the spacer locating members, such as first spacer locating member  50 . One or more spacers  100  can also be placed in second spacer locating member  60 , third spacer locating member  70 , fourth spacer locating member  80  and/or fifth spacer locating member  90  in the same manner. 
     First reinforcing member  110  is positioned on first section  31  of center rail section  30  such that holes  114  are aligned with one or more holes  31 F in first section  31 . Second reinforcing member  120  is positioned on first section  41  of rear rail section  40  such that one or more holes  124  are aligned with one or more holes  41 F in first section  41 . Previously placed spacers  100  that are aligned with holes  114  and  124  will extend through those holes. Additional spacers  100  can also be placed in one or more holes  114  and/or  124 . Spacers  100  can be welded or otherwise secured to first reinforcing member  110  and second reinforcing member  120  if desired. 
     First half  10 A and second half  10 B are then positioned such that one or more holes  21 F,  31 F and/or  41 F in first section  21 , first section  31  and/or first section  41  align with one or more holes  22 F,  32 F and/or  42 F in second section  22 , second  32  and/or second section  42 . This also aligns one or more holes  21 F,  31 F and/or  41 F with holes  53 ,  63 ,  73 ,  83 , and/or  93  in first spacer locating member  50 , second spacer locating member  60 , third spacer locating member  70 , fourth spacer locating member  80  and/or fifth spacer locating member  90  that are aligned with the corresponding holes  22 F,  32 F and/or  40 F. In this manner, holes  114  in first reinforcing member  110  are also aligned with one or more holes  63  in second spacer locating member  60  and with one or more holes  32 F in second section  32 , and one or more holes  124  in second reinforcing member  120  are aligned with one or more holes  83  in fourth spacer locating member  80  and with one or more holes  42 F in second section  42 . 
     First half  10 A and second half  10 B are then secured together, such as by welding along the outer edges of first half  10 A and second half  10 B at weld lines or locations WL so as to form an enclosed space between first half  10 A and second half  10 B. Note that in the embodiment shown, second half  10 B is nested within first half  10 A. ( FIG.  13   ) 
     Steering gear reinforcement  130 , stabilizer bar attachment bracket  150 , steering gear reinforcement  160 , body mount bracket  170 , frame rail end plate  180 , and body mount reinforcement  190  can then be secured to first half  10 A and second half  10 B in the locations shown in  FIG.  1   . Note that posts  191  of body mount reinforcement  190  extend through holes  41 F on first section  41  of rear rail section  40 . Bolts or other fasteners may be used to connect frame rail  10  to a vehicle body and other components, including, for example, via steering gear reinforcement  130 , steering gear bracket  140 , stabilizer bar attachment bracket  150 , steering gear reinforcement  160 , body mount bracket  170 , frame rail end plate  180 , and body mount reinforcement  190 . For example,  FIG.  13    illustrates two bolts B extending through openings  41 F in first section  41  of rear rail section  40 , openings  124  in second reinforcing member  120 , bores  103  in spacers  100 , openings  83  in fourth spacer locating member  80 , and openings  42 F in second section  42  of rear rail section  40 . Nuts N or other securement means can be used to retain bolts B to frame rail  10 . Spacers  100  provide support to frame rail  10  at the fastening locations and resist the clamping forces of bolts B and nuts N. 
     In another embodiment of the invention, frame rail  10  is assembled by first forming front rail section  20 , center rail section  30  and rear rail section  40 , and then connecting center rail section  30  to front rail section  20  and rear rail section  40 . For example, front rail section  20  can be formed by securing the desired spacer locating members and other components within first section  21  and second section  22  of front rail section  20  and then securing first section  21  and second section  22  together such that second section  22  is nested within first section  21 . Center rail section  30  and rear rail section  40  can be assembled in the same manner. Opposite ends of center rail section  30  are then slid into one end of front rail section  20  and one end of rear rail section  40 , respectively, and the sections are welded together. ( FIG.  14   ). 
       FIGS.  15  and  16    show a vehicle frame rail  200  according to another embodiment of the present invention. This embodiment of the invention does not utilize first spacer locator member  50 , second spacer locator member  60 , fourth spacer locator member  80 , fifth spacer locator member  90 , first reinforcing member  110 , or second reinforcing member  120 . Frame rail  200  does utilize third spacer locating member  70 , and includes a first reinforcing member  210  and a second reinforcing member  220  differing in configuration from first reinforcing member  110  and second reinforcing member  120 . Frame rail  200  may also include steering gear reinforcement  130 , steering gear bracket  140 , stabilizer bar attachment bracket  150 , steering gear reinforcement  160 , body mount bracket  170 , frame rail end plate  180 , and body mount reinforcement  190 . 
     As shown in  FIG.  15   , first reinforcing member  210  includes a main or body section  211  and one or more openings or holes  212  arranged in one or more hole patterns. Second reinforcing member  220  includes a main or body section  221  and one or more openings or holes  222  arranged in one or more hole patterns. 
     To assemble frame rail  200 , first half  10 A and second half  10 B are assembled as describe above, and third spacer locating member  70 , first reinforcing member  210 , second reinforcing member  220 , spacers  100  and other components are secured to and positioned within first half  10 A and second half  10 B in the manner described above. Spacers  100  may be secured to first reinforcing member  210  and/or second reinforcing member  220 , such as, by example, welds W ( FIG.  16   ). First half  10 A and second half  10 B are then positioned such that first flanges  21 D,  31 D and  41 D of first sections  21 ,  31 , and  41  of front rail section  20 , center rail section  30  and rear rail section  40  are located adjacent first flanges  22 D,  32 D and  42 D, respectively, and between first flanges  22 D,  32 D and  42 D and second flanges  22 E,  32 E and  42 E of second sections  22 ,  32  and  42  of front rail section  20 , center rail section  30  and rear rail section  40 . First half  10 A and second half  10 B are also positioned such that second flanges  22 E,  32 E and  42 E of second sections  22 ,  32 , and  42  of front rail section  20 , center rail section  30  and rear rail section  40  are located adjacent second flanges  21 E,  31 E and  41 E, respectively, and between first flanges  21 D,  31 D and  41 D and second flanges  21 E,  31 E and  41 E of first sections  21 ,  31  and  41  of front rail section  20 , center rail section  30  and rear rail section  40 . First half  10 A and second half  10 B are then secured together, such as by welding along the outer edges of first half  10 A and second half  10 B at weld lines or locations WL so as to form an enclosed space between first half  10 A and second half  10 B. In this manner, first half  10 A and second half  10 B overlap, as shown in  FIG.  16   , as opposed to one of the two halves being nested within the other half as shown in  FIG.  13   . 
       FIG.  17    is an exploded perspective view of a vehicle frame rail  300  according to another embodiment of the present invention. Like the embodiment of  FIGS.  15  and  16   , this embodiment does not utilize first spacer locator member  50 , second spacer locator member  60 , fourth spacer locator member  80 , fifth spacer locator member  90 , first reinforcing member  110 , or second reinforcing member  120 . Frame rail  300  does utilize third spacer locating member  70 , and includes a first reinforcing member  310  and a second reinforcing member  320  differing in configuration from first reinforcing members  110  and  210  and second reinforcing members  120  and  220 . 
     As shown in  FIG.  17   , first reinforcing member  310  includes a main or body section  311 , one or more openings or holes  312  arranged in one or more hole patterns, a first flange  313  extending perpendicular to and along one edge of body section  311 , and a second flange  314  extending perpendicular to and along the opposite edge of body section  311 . Second reinforcing member  320  includes a main or body section  321 , one or more openings or holes  322  arranged in one or more hole patterns, a first flange  323  extending perpendicular to and along one edge of body section  321 , and a second flange  324  extending perpendicular to and along the opposite edge of body section  321 . Frame rail  300  may be assembled in the manner described above in connection with frame rail  200 . 
     The various rail sections, spacer locating members and spacers of the present invention may be constructed from any material having sufficient strength and durability to withstand the forces experienced by the components in the applicable operating environment. 
     Although various embodiments of the invention have been shown and described in detail the same is to be taken by way of example only and is not a limitation on the scope of the invention. Numerous modifications can be made to the embodiments disclosed without departing from the scope of the invention. For example, one or both of first reinforcing member  110  and second reinforcing member  120  can be eliminated from the embodiments described above. One or more of the spacer locating members can also be eliminated. Additional reinforcing members and/or spacer locating members can be added to the embodiments. In other embodiments, hole patterns other than those illustrated can be utilized. The shape of the spacer locating members and reinforcing members, as well as the positioning of the spacer locating members and reinforcing members, can also be other than those specifically illustrated. Furthermore, either the nested or the overlapping configurations of first half  10 A and second half  10 B can be utilized with any of the embodiments disclosed. Other modifications to the embodiments described and illustrated are also within the scope of the invention.