Patent ID: 12187353

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. For example, while the following description refers primarily to UVs, certain features described herein may be applied to other applications such as ATVs, snowmobiles, motorcycles, mopeds, etc.

With reference first toFIGS.1-2, the vehicle of the present disclosure will be described. The vehicle is shown generally at10and is commonly referred to as an all terrain vehicle (ATV), a side-by-side vehicle (SxS) or a utility vehicle. As shown, vehicle10generally comprises a frame12supported by ground engaging members14and16. As shown in this disclosure, ground engaging members14and16are comprised of wheels18and tires20; and wheels22and tires24. Vehicle10further comprises a drive train30(FIG.2) operatively connected to frame12and drivingly connected to one or more of the ground engaging members14,16. In the present disclosure, the drivetrain30is comprised of a fuel-burning engine32and transmission34combination, coupled to both of the front and rear ground engaging members14,16, as described in greater detail herein. However, any drivetrain could be contemplated such as hybrid, fuel cell or electric. The drivetrain30is more thoroughly described in our U.S. Pat. Nos. 8,973,693 and 8,997,908, as well as in pending patent application Publication Number 20120223500, the subject matter of which is incorporated herein by reference.

As shown inFIGS.1-2, vehicle10further includes a body portion or chassis shown generally at40to include a hood42, front fender44, dash46, sideboard48, front floorboard50, rear sideboard52and rear cargo area56. As also shown, vehicle10is comprised of seating area60, having a driver seat62and a passenger seat64. Driver seat includes a seat back62aand a seat bottom62b, while passenger seat64includes a seat back64aand a seat bottom64b. Furthermore, vehicle10includes operator controls shown generally at68, which includes controls for steering, acceleration and braking, as described further herein. Vehicle10also includes a front suspension70and a rear suspension72. A cab frame74is positioned over the operator area and seats to project the driver and passengers.

With respect now toFIGS.3-4, frame12is generally comprised of a main frame section80extending longitudinally along the center line of the vehicle. Frame12also includes front frame section82, mid frame section84, rear frame section86and cab frame support section88and90. Frame12provides mounting accessories for mounting various vehicle components. Front section82includes a front suspension mount100, steering mount104(FIG.4), brake cylinder mount108(FIG.4), and front differential mount110(FIG.3). Mid frame section84includes seating mount112. Rear section86includes engine mount120(FIG.4), rear final drive mount122, rear suspension mount124, rear cargo box support126and fuel tank support128.

With reference still toFIGS.3-4, frame12will be described in greater detail. As shown, main frame section80includes two longitudinally extending frame rails130having front sections130A, with frame sections130B which angle outwardly and rear sections130C. Transverse sections132and134are coupled to the frame rails130and further couple to outer frame rails136. Frame rails136include front portions136A which couple to portions130A of frame rails130. Frame rails136further include longitudinally extending portion136B which couples to the transverse portions132and134. Another set of frame rails140are coupled to frame rails136by way of transverse channels142. Vertical posts144extend upwardly from a front end of frame rails140and are coupled to transverse rails146,148. Cab frame support section88is coupled to a top of the vertical post144. Front posts150have lower portions150A coupled to rails130A and rearwardly extending portions150B which couple to transverse rail146. A transverse rail153extends between rearwardly extending portions150B while vertical posts154extend downwardly from rail153to frame rails136. Frame tubes160are supported by posts154and posts150and include upper couplers162for the front suspension mount100. Couplers164are also provided at a front end of the frame rail130which also provide couplers for front suspension mount100.

With reference now toFIG.4, seating mount112is shown including vertical posts170,171,173longitudinally extending rails172, front transverse rail174, and rear transverse rail176(FIG.3). As shown inFIG.4, bracket178is coupled to diagonal rail180for mounting of a passenger seat as described herein. Another horizontal rail182spans the frame12above seat frame12.

Rear frame section86includes vertical posts190coupled to the rear end of frame rails136and support the rear cab frame support section90. Rear cargo box mount support126includes rearwardly extending frame rails192which couple to vertical posts196and to rear plate198. Rear suspension mount124is defined by channels200,202(FIG.3) which provide upper and lower coupling points for suspension arms.

With reference now toFIGS.5-7, brake cylinder mount108and brake master cylinder220will be described in greater detail. As shown best inFIG.6, mount108is coupled to vertical post154and includes sidewall220, front plate222having an aperture at224, and an upper wall at226. As shown inFIG.7, brake master cylinder220includes a reservoir230positioned above the brake cylinder body232. A flange234is coupled to an end of the body232and has threaded members236positioned on either side. A push rod238protrudes from body232and has a clevis240at its end. As shown, clevis240and push rod238are positioned through aperture224and threaded members236protrude through apertures246of plate222where fasteners250(FIG.6) couple master cylinder220to the brake mount108. A seal254(FIG.7) is positioned on a front side of plate222(FIG.6). Clevis240would be coupled to brake actuator to actuate the master cylinder and thereby the brakes at wheels14,16.

With reference now toFIGS.8-10, a fuel tank258is shown coupled to fuel tank mount128. As shown best inFIG.10, fuel tank mount128includes a plate portion260coupled to a bottom of frame rail130. Mount128includes a rear wall262having an extension at264forming a groove at266. Wall262includes an extension at270defining a slot at272. As shown inFIG.9, fuel tank258is coupled to frame12by way of a strap280having a hook282coupled to groove266(FIG.9) at a first end and to a bracket286at a front end (FIG.8). Bracket286has a vertical leg288coupled to transverse rail132and a horizontal arm290having a tab at292. A fastener294couples strap280around the fuel tank and to the frame. As shown inFIGS.8and9, strap300is also coupled around fuel tank260. As shown inFIG.8, strap300includes a strap portion302having a tab304coupled to rail136by way of a fastener306positioned in aperture308(FIG.10). As shown inFIG.9, strap300includes a portion310having a T-shaped coupler312positioned in slot272(FIG.10).

As shown best inFIG.8, fuel tank258includes a front tank portion258A and a rear tank portion258B. As shown, portion258A extends to a position proximate frame rail136whereas portion258B is rearward of diagonal brace180and extends outward to a position adjacent to longitudinal rail140. As also shown inFIG.8, fuel tank258includes a filler cap314such that filler cap314is accessible through side panel52(FIG.1) while fuel tank portion258A is substantially under seat62.

With reference now toFIGS.11-16, the seating area60will be described in greater detail. With reference first toFIG.11, the driver's seat62and passenger seat64is shown coupled to the seat mount112. Driver seat62is separate from passenger seat64and may be removed independently of passenger seat64. As shown inFIG.12, seat bottom62B includes latch fingers320at a front edge thereof which correspond with openings322of latches324. Seat62may be removed by unlatching a rear latch (not shown) and rotating the seat forward to remove the latch fingers320from the associated openings322.

With reference now toFIG.13, bench portion64is coupled to rear rail176by way of a first linkage330and a second linkage332. Linkage330includes a first fixed bracket338coupled to rail176by way of fasteners340. Linkage330further includes a link arm344coupled to seat frame346and pivotally coupled about axis350by way of fasteners352and354. With reference toFIGS.13and14, linkage332also includes a link arm360coupled to seat frame portion362where link arm360is the counterpart to link arm344. Link arm360is coupled to bracket178by way of a fastener366such that link arm360pivots about axis370. As shown inFIG.13, axes350and370are coaxial. As shown inFIG.13, bracket178is coupled to rail180by way of fasteners376. A gas shock378is coupled to a channel380which in turn is coupled to rail180where gas shock378may be extended by lifting the seat from the front thereof. As shown inFIG.13, gas shock is in the collapsed position. Gas shock378includes a lower portion382coupled to bracket380by way of fasteners at384. Gas shock includes an upper end at386which is coupled to a bracket388which in turn couples to seat frame362.

With reference now toFIG.15, bench seat portion64is shown in solid line where the bench is in the down position, and when bench seat rotates in the direction of arrow390, bracket360rotates upward to the position shown in phantom line about axis370and gas shock378moves from the position shown in solid line to an extended position shown in phantom. Due to the offset between axis370and axis396bthat is, distance X2, a moment is created on the seat bottom64and the gas shock holds the bench portion64of passenger seat in the up position (phantom position ofFIG.15). When the seat bottom64bis in the down position, axis396ais rearward of axis370by a distance X1.

With reference now toFIG.16, a pedestal portion400is shown which overlies the seat mount128including the vertical posts170,171and173, as well as horizontal rails174and176. Seats62and64are shown removed yet the latches324for driver seat62are shown exposed through cutouts402of the pedestal portion400. Pedestal portion400includes a front wall406, left sidewall408and a right sidewall410. Right sidewall410extends rearwardly to a back wall412and an inner side panel414covers diagonal brace180and extends to the back wall412. As the passenger seat64cantilevers the seat mount112(FIG.11), bench seat64B extends beyond sidewall410defining a space416under passenger seat64. This provides enough space for a 5 gallon bucket418to be placed in the space416and tie downs420are provided in the space to allow bungee cords and the like to be used to retain objects under the seat.

In a like manner, on the left-hand side and as shown inFIG.17, a rear diagonal panel422is provided which extends to sidewall408and also covers diagonal brace108on the left hand side (FIG.11). This defines a space424between sidewall408and outer side panel52of the vehicle. Space424provides more floorboard space adjacent to pedestal, that is floorboard space50A, as shown inFIG.16which allows more room for an operator's feet for ingress and egress. Space424also provides access space when a door is provided.

With reference now toFIGS.17and18, an optional door450is shown, which may be hingedly attached to vehicle10in a manner similar to that shown in U.S. Pat. Nos. 8,973,693 and 8,997,908; the subject matter which is disclosed herein by reference. Door450would be hingedly attached along a rear edge440and latch at a front edge of door450.FIG.18shows latch456positioned along a front edge458of door450. Door450includes a storage container460integrally defined with an inner side panel462of door450such that upon closing of the door, storage container460is profiled to occupy the space424defined beneath the seat bottom62B and outwardly of the pedestal sidewall408.

With reference now toFIGS.19and20, a clip470is shown for use when a side net472is used rather than door450. The profile of the opening surrounding the floorboard50is similar to that described in our U.S. Pat. Nos. 8,973,693 and 8,997,908 and U.S. Publication 2012/0223500, the subject matter of which is incorporated herein by reference. Side panels48and52(FIG.1) define a recess474surrounding the opening defining panel surfaces476,478and480. Clip470includes planar wall portions490and492having apertures494and496. A body portion498is provided having an opening at500defining a locking slot at502. Clip470may be retained in the recess474by way of a fastener504extending through aperture496and into threaded aperture506and by way of fastener508extending through aperture494into threaded aperture510. Thus the body portion498resides within the recess surrounding the opening rather than occupying space in the opening. Net472includes a locking lug512which would correspond with locking slot502to retain the net in position.

With respect now toFIGS.21and22, the operator's compartment has also been improved from the standpoint of NVH (noise, vibration, and harshness). As shown inFIG.21, a wall530is shown which is under the dash46although inside the compartment under the hood42. As shown, multiple entry points into the operator's compartment have been sealed such as by grommets532and534. As shown, grommet532includes an aperture536to allow sealed access to shift cable538, and a second aperture540for sealed access to a wire harness542. As shown inFIG.22, grommet532overlies an aperture550where fastener tabs552couple the grommet to the panel530. Grommet534includes a peripheral groove560, as shown inFIG.22, which overlaps an opening562in panel530. Grommet560also includes a sealing boot564to allow access to steering shaft566such that dust and noise is prevented from entering the operator's compartment through panel530. It should be understood that multiple access points may be sealed in similar manners by grommets or other sealing members.

With reference now toFIGS.23-35, rear cargo area56will be described in greater detail. As shown inFIG.23, rear cargo area56includes a dump box570having a left sidewall572, a right sidewall574, a front wall576, and a tailgate578. The inside of front wall576includes notches580which would cooperate with notches582on the tailgate (FIG.1) for the placement of dividers such as 2″×8″ or 2″×10″ wooden pieces, and sidewalls572and574include complementary notches584for also subdividing the dump box570. Top edges of the sidewalls572,574and front wall576include apertures590for use with applicant's LOCK & RIDE® retention system, which is the subject of U.S. Pat. No. 9,366,280, the subject matter of which is incorporated herein by reference. Dump box570also includes tie downs592which extend through the floor594for use with such items as bungee cords. On the back side of tailgate578cup holders596(FIG.1) are defined for use when the tailgate is in the down position. Tailgate578also includes a tailgate latch598for unlatching the tailgate578relative to the remaining portions of the dump box570. Furthermore, dump box570includes a latch release handle600which allows the dump box570to be released from a latching system and rotated relative to the remainder of the vehicle as is known in the art. Handle600is positioned in a recess602of sidewall572. With reference now toFIGS.25-28, tailgate578will be described in greater detail.

As shown inFIG.25, tailgate578is generally comprised of front panel610, rear panel612, top panel614, upper rail616, lower rail618, and latch598. With reference toFIG.25, front panel610includes an upper wall620, a lower wall622, sidewall624, and opposite sidewall626. Top wall620includes locking latches628spaced apart along top wall620. Lower wall622includes a plurality of tabs630also spaced apart along lower wall622. Front wall610includes a plurality of ribs, namely horizontal ribs636and vertical ribs638to rigidify front panel610. Front panel610also includes a top channel at640and a lower channel at642. Front panel610also includes bosses at644.

Rail616includes an elongate body650having an end wall652at each end including an aperture654and a U-shaped opening at656. Latch598includes latch handle660and a latching rod662having latch ends at664. Rail618includes a body668having a plurality of apertures at670and circular tubes672at each end.

Rear panel612includes a top wall680having latches682depending therefrom and cooperating with latch members628on front panel610. Rear panel612includes an opening at684for receipt of handle660and a plurality of apertures at686. As shown inFIG.26, rear panel612further includes tabs690(FIG.26) having apertures at692, where tabs690align with tabs630on front panel610. Rear panel612further includes a latch holding mechanism at696for holding latch handle660and mechanisms698for holding latch rod662. Mechanisms698include parallel walls700having apertures at702for receiving rod662and trunnion walls704for guiding rod662.

To assemble tailgate578, rail616is positioned in channel640and rail618is positioned in channel642. Fasteners710may be positioned through the end wall624of front panel610and received in apertures654of rail616. Handle598is then assembled within rear panel612with rod662positioned through apertures702and rear panel612is brought into position with front panel610such that latches682latch with corresponding latches628on front panel and where tabs690align with tabs630. Top panel614may then be brought into position where tabs712align with bosses644and fasteners714are positioned through apertures686and into threaded engagement with bosses644. Fasteners716are then brought into position with apertures692(FIG.26) and brought into threaded engagement with apertures in tabs630. As shown inFIG.27, fasteners716extend through tabs630and690, and into apertures720of rail618. As assembled, rails616and618rigidify the tailgate578from both bending stresses and torsion. As shown inFIG.28, ribs694also overlap lower wall622of front panel610. Also tailgate578has a cleaner look as no fasteners are visible from the outside of the tailgate, even when the tailgate578is rotated to the open position.

Also, as shown inFIGS.25and27, tailgate578includes a defined surface730for directing dust away from the operator's compartment if dust is coming upward from the ground past the tailgate.

With reference now toFIGS.29-33, sidewall572of the dump box570will be described. As sidewall574is a mirror image of sidewall572, only sidewall572will be described. As shown inFIG.29, sidewall572includes an outer lower panel740, an outer upper panel742, and sidewall744of dump box570. Outer panel740and742couple together and couple to sidewall744to define sidewall572. As shown inFIG.33, latch600includes a handle750, an actuating arm752, and a spring loaded latch754(FIG.31). A catch756is provided on frame rail126. Arm752extends through a window746defined within opening602where opening746is at a front end of opening602. A sealing surround760(FIGS.30-32) is positioned adjacent to opening602and includes a sidewall762, an upper mounting flap764, and a frangible hinge766. As sealing surround760is positioned forward of wheel well770(FIG.23) it protects the latch structure from mud and debris collecting against the latch754or catch756. This can best be seen inFIG.31, as viewed from under the dump bed570looking forward at the sealing surround760. It should be appreciated that sidewall760is integrally molded with the remainder of the panel and the wall762is closed to the position shown inFIG.31, and fasteners772couple the top wall764to the underside of the dump bed570.

With reference now toFIGS.34-36, dump box570is also sealed along a front edge of dump box570. As shown inFIG.34, a rear panel780is positioned rearward of operator seats62,64and is fixed relative to the vehicle10and to frame12. Dump box570includes a front lip782(FIG.35) as part of the front wall576and wall780includes a tab784. Seal786is coupled to tab784and includes a sealing bead788having a sealing groove at790. Thus when dump box570opens, in the direction of arrow792inFIG.35, lip782lifts out of sealing groove790whereas when the box is lowered, lip782is moved back to the position shown inFIG.35. Therefore, dust is not able to travel upwardly between the panel and the dump bed, for example in the direction shown by arrow794and back into the operator's area.

With reference now toFIGS.37-40, the front suspension70will be described in greater detail. As shown, front suspension70is generally comprised of lower control arms800, upper control arms802, a shock absorber804, and a torsion bar806. The right suspension is a mirror image of the left suspension and includes a lower control arm810, upper control arm812, and a shock absorber814. Left wheel assembly is comprised of a wheel hub820, a disc brake822, and a steering knuckle824. Right wheel assembly is comprised of hub830, disc brake832, and steering knuckle834. As shown best inFIG.37, front wheel assemblies are steered by way of a steering system850which may comprise a power steering motor852, a steering shaft854, a steering gear856(shown as a rack-and-pinion steering system), and steering arms858(FIG.38). Each of the wheel hubs820,830are coupled to drive units840and842which would couple to front final drive by way of half shafts as is known in the art.

With respect now toFIG.40, the front right wheel assembly is shown in exploded view where knuckle834includes an upper coupling at860and a lower coupling at862. Upper coupling860is split at864and includes an aperture866extending therethrough for receipt of a fastener868. An upper aperture862extends downwardly through the coupling860. Lower coupling862includes an aperture at874. The control arms810and812are coupled to knuckle834by way of ball joints880and882. Lower ball joint880includes an upper ring at884, a reduced diameter section at886, a groove at888, an internal ball joint portion at890, a tapered shaft892, and a threaded shaft portion at894. In a like manner, upper ball joint882includes an upper ring900, a reduced diameter portion902, a groove at904, and a shaft at906. Shaft906is interrupted by a semi-circular groove at908as described herein. As also shown, lower control arm810includes a coupling joint at920and upper control arm812includes an upper coupling joint at922.

To assemble the knuckle834and hub830to the control arms810,812, ball joint880is positioned within coupling joint920such that diameter portion886resides within diameter930of coupling joint920whereupon a snap ring932is positioned within groove888of lower ball joint880. It should be appreciated that snap ring932retains ball joint880to the lower control arm810. Threaded shaft894is then inserted through aperture874which is profiled to receive tapered shaft portion892. This allows a portion of threaded shaft894to extend downwardly through coupler862whereupon a fastener936is threaded onto threaded diameter894to couple control arm810to the knuckle834.

In a like manner, upper ball joint882is positioned through coupling joint922such that diameter portion902resides against surface940of coupling joint922and snap ring942can be positioned within groove904of upper ball joint882. This locks the ball joint and the upper control arm812together. Shaft906can thereafter be positioned within aperture862and fastener868can be positioned through aperture866. It should be appreciated that semi-circular groove908is profiled to align with aperture866such that a portion of threaded fastener868extends through the groove908and then outwardly to receive fastener870. As should be noted, both of the control arms810and812are mounted to knuckle834at a position above the couplers862and860which raises the control arms relative to the ground. Particularly in the case of the lower control arm810, the raising of the coupling point raises the ground clearance of the front suspension. The same construction could be employed for the rear suspension.

With reference now toFIGS.41-41B, the driveline of the vehicle will be described in greater detail. As shown inFIG.41, the driveline includes a transmission34in the form of transaxle950having an input shaft at952and an output at954. Output954is for the rear wheels where half-shafts would extend from the output954to the rear wheels16. Transaxle950also includes a front output at956(FIG.41A) which couples to a prop shaft (or drive shaft)958. Prop shaft958extends forwardly to a front final drive960(which may be a differential).

With reference still toFIG.41, drive shaft958includes a two-piece prop shaft including portions958A and958B. Prop shaft958includes two constant velocity joints966and972, and a centrally located universal joint968. Prop shaft portion958A rides within a bearing980as further described herein. With reference now toFIG.41B, universal joint portion968includes tubular portion990which is internally splined at diameter992and includes a grease fitting at994. Prop shaft portion958A further includes externally splined portion996which is movable longitudinally relative to tubular portion990. Prop shaft portion958A further includes a weld joint at1000and a second weld joint at1002which fuses together tubular portion1004to tubular portion1006. It should be appreciated that bearing980rides on surface1000A of weld joint1000and that tubular portion1004is forward of bearing980. Tubular portion1004has a smaller diameter and a lower torsional threshold than does tubular portion1006so as to define a torsional rupture point for shaft portion958A. The rupture point is created by a reduced cross-sectional area of metal at the location, in relation to other locations on the drive shaft.

That is, if the drive shaft exceeds a certain torque limit, the defined breaking point for the drive shaft958is within the reduced diameter tubular portion1004. This allows the remainder of the drive shaft958rearward of bearing980to still be held in place by bearing980and still allow the vehicle to have two-wheeled drive; that is, through the rear wheels. This prevents breaking the drive shaft958rearward of bearing980where drive shaft958would potentially spin about, damaging the engine or other vehicle components. While the prop shaft portion958A forward of the bearing may drop down from its present location, as it is not spinning, it will not damage any vehicle components.

With reference toFIGS.41and41A, the constant velocity joint is coupled to the shaft956by way of a coupler1008which includes brackets1008aand fasteners1008b. As shown inFIG.41A, the shanks of the fasteners1008breside in a groove1009of shaft956to retain the constant velocity joint972in a longitudinal sense relative to the shaft956. Any longitudinal movement of the shaft958is taken up in the constant velocity joints966,972.

Alternatively, and with reference toFIG.42, the constant velocity joints966,972could be replaced with universal joints966′,972′ where longitudinal movement of the shaft958′ is taken up by the universal joints966′,972′ sliding relative to the shafts,956′ for example.

With reference now toFIGS.43-48, optional gauges and electronic modules are shown for vehicle10. As shown inFIG.43, module1010is shown installed in the dashboard46while another module1012is installed in the center of the dash46. Module1010could include multiple different gauges such as a speedometer or tachometer whereas module1012is shown including a pair of cup holders for the vehicle. Optionally, module1010may comprise a different configuration of gauges such as module1014to be installed instead of module1010. Additionally, module1012may be replaced by removing module1012and replacing it with module1016. Module1016could be a monitor such as diagnostic indications. GPS, or infotainment. With reference now toFIGS.44and45, module1010is shown removable as an assembly. The rear of the module1010is shown inFIG.46as including connector interfaces such as1030and1032. These would connect with complementary connectors within the dash1026(FIG.45).

As shown inFIGS.47-48, module1010is shown as including the gauge assembly1040, a front facia1042, and a mounting member1044. Gauge assembly1040includes two tabs1048along a top edge thereof which mate with apertures1050in front facia1042. As shown inFIG.48, front facia1042includes two clips1054which clip on a back edge1056of gauge1040to couple the gauge1040to the front facia1042. The back of gauge1040includes threaded inserts1060which align with apertures1062in mounting member1044such that fasteners can be received through aperture1062into threaded engagement with threaded inserts1060to retain gauge1040and facia1042to the mounting member1044. The back of mounting member1044includes tabs1066which align with apertures1070in the dash (FIG.45) and fasteners1072may be received through apertures1074in mounting member1010and into threaded engagement with apertures1076, all of which is shown inFIG.45. It should be understood that module1014would include tabs similar to that as1066and apertures1074in a like position such that module assembly1014could be swapped with module1010to provide an alternate vehicle configuration. A similar replacement of module1016with module1012can upgrade the vehicle to include an electronics package such as GPS, etc. as discussed above.

With reference toFIGS.49-59, a busbar system1100is shown for the vehicle10. As shown inFIG.49, the system would comprise terminal blocks at various locations on the vehicle which are directly powered by the battery1103. For example and as shown inFIG.50, a front terminal block1102is located under the hood attached to panel530where terminal block1102is powered by a cable1104which runs through panel530and is sealed by seal1106. Cable1104is coupled directly to battery1103. Terminal block1102would include a plurality of outlets1110which would include electrical connectors for direct connection for accessories. As shown inFIG.50, terminal block1102presently has 6 positions and a plurality of dust covers1112which may be removed to make the electrical connection. Such accessories for connection to terminal block1102could be a winch on the front bumper, specialized accessory lights such as fog lights, and the like. As shown inFIG.49, other potential areas for a terminal block includes a roof terminal block1120coupled directly to the battery1103at1124. Also a terminal block1126could be coupled at a position adjacent the rear box56and coupled to the battery1103by wiring1128. The location for terminal blocks1102,1120and1126are shown representatively inFIG.49, and terminal blocks1102and1120are shown in detail inFIGS.50-55coupled to the cab frame74.

As shown inFIG.51, cab frame74includes front posts1130, upper posts1132, rear posts1134, front transverse channels1136, and rear transverse channels1138and1139. Rear posts1134include brackets1140which couple directly to the rear cab frame couplings90(FIG.3). Front posts1130have insert couplers1142which couple to front cab frame couplings88(FIG.3). Rear couplers couple posts1132,1134, and1138together and include outside couplers1150and inside couplers1152, where a pair of couplers1150,1152are on each side of the cab frame74as described herein. It should also be appreciated that the posts1130and1134are extruded such that the extrusion forms a hollow passage in the post, such that accessory wiring may be routed through the posts. While transverse channels1136and1138are fabricated metal, such as a sheet metal stamping, they too are hollow such that accessory wires may be routed through the transverse channels1136,1138and1139. It should also be appreciated that the couplers1142and1152are also provided with openings, such that accessory wiring may be routed upwardly through the insert couplers1142,1152and into their representative posts1130,1138as described herein.

With reference now toFIG.52, insert coupler1142is shown having a coupler end1160which extends up into the post1130such that it is not shown in FIG.51. Coupler1142also includes a connection face at1162which would couple to its complementary face1164(FIG.3). On the opposite side of face1162, an inner structure1166is defined having a surface1168which is opposite from face1162and includes two fastener receiving recesses1170for receiving such a fastener as a nut, not shown, which would couple the cab frame74to the frame12with a complementary fastener. Inner structure1166further includes an opening at1174which allows a wire to pass through the insert coupler1142and upwardly into the post1130.

In a like manner, insert coupler1152includes a coupler portion1180which would be inserted into the top end of post1134, and has an outer face at1182(FIG.54) providing a mounting face for outer coupler1150. Coupler1152further includes an inner structure1184having a surface1186opposite surface1182and includes fastener receiving recesses1188for receiving fasteners as described above. Coupler1152also includes an upper horizontal wall1190and a vertical wall1192which are profiled to receive an end of channel1138thereover as shown inFIG.54. Insert1152further includes an aperture1196which extends through insert end1180which would allow an accessory wire to pass upwardly from post1134and into channel1138through the insert coupler1152.FIG.54shows an exploded view of the cab frame74which is partially broken away showing the outer couplers1150, inner couplers1152being coupled by way of fasteners1200,1202. Finally, and with reference toFIG.50, it is anticipated to have a further terminal block1130positioned adjacent to a rear of the vehicle beneath the cargo area56.

With reference now toFIGS.55-58, the main wiring for the terminal block1120will be described. As shown, terminal block1120is shown positioned at an area adjacent to transverse channel1138. Main wiring1124is shown running up the rear rail1134. A connector assembly1220includes a header connector1222(FIG.58) and a socket connector1224. Socket connector1224is coupled to wiring harness1226which includes wire1228coupled to battery1103. With the terminal blocks1102and1120in position and wired to the battery1103, accessory wiring can be coupled to the terminal blocks for various accessories.

For example, it would be advantageous to have a wire1230coupled to terminal block1102by way of a connector1234. The cable could either run up the outside of the post1130or through the post as described above. This connection would terminate adjacent position1240in front transverse channel1136, for example for coupling when an accessory windshield and windshield wiper are provided. Thus, a wire could be routed upwardly through one of the posts1130and out of aperture1208as seen inFIG.54.

In a similar manner, an accessory wire1250(FIG.57) is shown coupled to terminal block1120by way of connector1252and be coupled to the transverse rail1138by clips1254, and terminate in connectors1260. The connectors1260could be used to access power for such items as overhead lights, etc. Wire organizers1262may also be provided for bundling the wires1124and1250and organizing them relative to the transverse channel1138. Terminal block1120could be coupled to an overhead roof of the vehicle (not shown) or to the transverse rail1138.

With reference now toFIGS.60and61, a cooling system of the vehicle is shown at1270including a mounting bracket1272, a first heat exchanger1274, a second heat exchanger1276, and a fan at1278. As shown inFIG.55, bracket1272couples heat exchangers1274,1276to the front frame portion82. While not seen inFIG.55, fan1278is positioned behind first and second heat exchangers1274,1276to draw air through the heat exchangers as is known in the art. The fin density of the first heat exchanger1274is narrower than the fin density of the second heat exchanger1276to allow particles to be caught in the first heat exchanger1274and not pass and be caught by the second heat exchanger1276.

With reference now toFIGS.62-64, a fuel evaporative system of the disclosed vehicle will be described in greater detail. The evaporative system is shown generally as1300and could be operative in the manner described in U.S. patent application Ser. No. 15/387,662, the subject matter of which is incorporated herein by reference.

With reference now toFIG.62, fuel tank258includes a fill tube1302, a roll over valve1304, and a fuel pump1306, and is generally positioned below seat bottom62b(FIG.62). Fill tube1302of fuel tank258is configured to receive liquid fuel from a fuel delivery apparatus, and generally includes cap314for containing both liquid fuel and fuel vapor within fuel tank258. Furthermore, fill tube1302is generally accessible from a side of vehicle10, as best herein inFIG.1.

Roll over valve1304of fuel tank258is configured to allow venting of fuel vapors collecting within fuel tank258, and prevent liquid fuel from escaping fuel tank258, specifically in the case of vehicle10overturning. Accordingly, roll over valve1304prevents liquid fuel from entering a fuel vapor line1310configured to receive fuel vapor from fuel tank258through roll over valve1304. Fuel pump1306of fuel tank258is configured to deliver liquid fuel from fuel tank258to engine32through fuel delivery line1314based on the operating conditions of vehicle10, for example based on information received from the throttle controls.

Still referring toFIGS.62-64, evaporative system1300includes an evaporation canister1320configured to receive and/or store fuel vapor received from fuel tank258, a fresh air intake1322coupled to evaporation canister1320and configured to provide fresh ambient air for mixing with the fuel vapor within evaporation canister1320, an air filter1328fluidly coupled to fresh air intake1322, a purge valve1324coupled to evaporation canister1320by way of fuel vapor line1330and configured to control the amount of fuel vapor delivered to engine32from evaporation canister1320through line1336. While not shown, a mixing volume could be provided and configured to mix fuel vapor provided from fuel tank258and/or evaporation canister1320with air. It should be appreciated that the fuel is delivered to throttle bodies of the engine32.

Evaporative system1300is configured such that fuel vapor from fuel tank258travels through roll over valve1304and fuel vapor line1310to evaporation canister1320. Evaporation canister1320adsorbs and stores the fuel vapors from tank258until purge valve1324is opened allowing fuel vapors and air to travel through fuel vapor line1336to the throttle bodies. Evaporation canister1320is also coupled to fresh air intake1322through air intake line1340such that ambient air is pulled into evaporation canister1320through air filter1328, positioned along air intake line1342, to mix with the fuel vapors within evaporation canister1320when purge valve1324is opened. Air intake line1342has a fitting1346at an intake end coupled to a frame tube of frame assembly12to prevent spiders or debris from entering air intake line1342.

Furthermore, as shown inFIGS.62-64, evaporation canister1320is generally positioned in close proximity to fuel tank258. A shorter connection path between the fuel tank258and evaporation canister1320is advantageous. This shorter path through line1310allows for quicker venting through the evaporation canister1320and less air restriction from the bends in the line1310. This is particularly true if the ORVR regulation gets implemented. This same reasoning also applies to the very short line1340which vents the system to atmosphere.

Furthermore, the shorter the line1310, the less fuel permeation there is through the line surface. This leads to less overall evaporative emissions for the vehicle. The load line always has fuel vapor in it unlike the purge lines. This can also allow for the use of low perm rubber line between the fuel tank and canister (which is not as low perm as nylon fuel line). The advantage of low perm rubber line is the tooling to form it is much quicker than nylon line. In this case, where the line is so short, a formed rubber line is not necessary to control routing. Therefore the canister position is advantageous for time to production.

The mounting location of the evaporative canister1320is generally advantageous for cost because of the short line lengths leading to less material to make the part as well as smaller tools. The location is generally advantageous because it is simple routing that is easy for the manufacturing line, reducing cost and time associated with manufacturing controls. Routing is better controlled with shorter lines and the canister1320and fuel tank258are exposed to the same dynamic inputs/vibration. This reduces the stress or strain on the line1310connecting the fuel tank258and canister1320and the line1340connecting the canister1320to the filter1328and the line1342connecting the filter1328to the chassis frame12through fitting1346.

The mounting location of the evaporative canister1320also protects the canister1320on multiple sides from road debris. The fuel tank258protectings two sides of the evaporative canister1320. That is, fuel tank portion258A has a surface1350and fuel tank portion258B has a surface1352which encompasses the evaporative canister1320, while the rear sideboard52, pedestal portion400, skid plate (not shown), and floor50protect the other portions of the evaporative canister1320.

With reference now toFIGS.65-67, an air intake system1360of the present vehicle will be described. As shown, the air intake system includes an air box1362positioned adjacent to engine32, having a duct1364to receive fresh air from a position adjacent a front of the vehicle, and a duct1366to feed air plenum1368. As shown, air box1362is positioned at least partially under the driver seat bottom62b. A line1370is shown which represents a centerline of the rear posts1374(FIGS.1,2and66) and airbox is at least partially forward of and at least partially rearward of, line1370. Airbox1362is also inside of a line1376, which is the innermost position of rear tire24, which prevents rocks and debris from striking the airbox1362. As shown inFIG.67, the airbox1362is vertically higher than the fuel tank258and lower than the driver's seat bottom62b. This provides for ease of access for servicing under the rear cargo area56(FIGS.1and2) as well as allowing duct1366to be relatively short due to the proximity of airbox1362to the engine32.

With reference now toFIGS.68-72, an alternate driver's seat assembly is shown at1400having a seat1402with a seat back1402aand a seat bottom1402b. Seat bottom1402bincludes an upper cushion portion1404and a seat bottom mount1406(FIG.70). Seat1402is coupled to a seat frame1408which in turn is coupled to the frame, namely to seating mount112(seeFIG.3). As shown best inFIG.70, seat frame1408includes an upper frame portion1410and a lower frame portion1412.

Lower frame portion1412includes a front frame portion1416, side frame portions1418,1420and rear frame portion1422. Frame portions1416-1422circumscribe an opening1424of lower frame portion1412. Front frame portion1416includes mounting tabs1426for mounting the seat frame1408to the seating mount112, and rear frame portion1422has a boss1428having apertures1430for mounting the seat frame1408to the seating mount112.

As shown best inFIG.69, upper frame portion1410includes a front frame portion1436, side frame portions1438,1440and rear frame portion1442. Frame portions1436-1442circumscribe an opening1444, which substantially overlies opening1424. Upper frame portion1410also includes corner brackets1450having a leg portion1452coupled to the side frame portions1438,1440; and further includes a portion (not seen) which extends upwardly into the seat back frame1456. Namely, the corner brackets have a portion extending upwardly through vertical tube portions1458of seat back frame1456, and are held together by way of fasteners1460,1462. By way of example, corner brackets1450could be a casting such as aluminum and coupled to the upper frame portion1410by way of fasteners, adhesives or welding.

Upper frame portion1410also includes channel shaped sections1470(FIG.70) which receives a slider mechanism (not shown) which allows the upper frame portion1410to slide forwardly and rearwardly relative to lower frame portion1412. More particularly, the slider mechanism includes an upper track coupled by way of fasteners1472(FIG.69) and a lower track coupled by way of fasteners1474(FIG.70), where the upper and lower tracks move by way of ball bearings. A latch mechanism1480(FIG.70) couples the slide mechanism into the fixed position as shown inFIG.68, but can be released by way of handle1482to allow the upper frame portion1410to slide relative to the lower frame portion1412, as is known in the art. It should be understood that the seat back1402aand seat bottom1402bslide together relative to the lower frame portion1412, and to the remainder of the vehicle.

With reference again toFIG.70, the coupling of the seat bottom1402bto the seat frame1408will be described in greater detail. As shown best inFIG.70, seat bottom mount1406includes two sheared sections1490, sheared away from section1492of seat bottom mount1406, which receives tabs1492of a clip1494. Clip1494has two hooks at1496which are received in slots1498(FIG.70) in upper frame portion1410. Clip1494is coupled to the seat bottom mount1406by way of fasteners1500.

As shown best inFIG.69, seat bottom1402bincludes a molded frame portion1510having a rear section1512having a molded living hinge1514. As shown inFIG.72, hinge is shown having a latch handle1516and a latch hook1520. As shown inFIG.69, upper frame portion1410includes a rear edge1524which receives the latch hook1520. Thus, seat bottom1402bcan be rotated open into the position ofFIG.69, by releasing the latch1514and rotating the seat bottom1402b. This allows access through openings1424,1444to items under the seat.

Finally, the seat bottom1402bhas a molded in sensor mount1530having wings1532for rotatably receiving a sensor1534, when rotated in a clockwise position shown inFIG.69.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.