Patent ID: 12187369

While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the invention disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first joint,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first joint” is different than a “second joint.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.

In general, the present disclosure describes a modular chassis for an off-road vehicle that is configured to improve assembly, servicing, and repairing of a drivetrain of the off-road vehicle. The modular chassis is comprised of a chassis configured to support the components of the off-road vehicle. A front frame module is configured to be coupled with the front of the chassis, and a rear frame module is configured to be coupled with the rear of the chassis. The front frame module supports the lower suspension arms of the off-road vehicle by way of inboard bushing joints that allow the lower suspension arms to pivot vertically with respect to the front frame module. The front frame module is configured to support various components of the off-road vehicle, including at least a steering gear and a front differential. One or more service ports facilitate servicing or repairing of the various components without requiring removal from the front frame module.

The rear frame module is comprised of a tube-frame structure that is configured to support various components of the off-road vehicle. A lower portion of the rear frame module is comprised of directionally parallel bottom frame members that each extend rearward to a bent portion that joins with an angled frame member. The angled frame members each extend to a bent portion that joins with a vertical frame member that extends acutely toward a top frame member. The top frame member comprises a rear-most portion of the rear frame module that is configured to be coupled with upper side portions of the chassis. Several cross-members are disposed between the bottom frame members, the angled frame members, and the vertical frame members to impart structural integrity to the rear frame module. The rear frame module is configured to provide clearance for the vertical motion of rear trailing arms disposed adjacently to each of the bottom frame members.

FIG.1shows an off-road vehicle100that is particularly suitable for the implementation of a modular chassis system in accordance with the present disclosure. As disclosed hereinabove, the off-road vehicle100generally is of a Utility Task Vehicle (UTV) variety that seats two occupants, includes a roll-over protection system104, and may have a cab enclosure108. Rear wheels112of the off-road vehicle100may be operably coupled with a chassis116by way of a trailing arm suspension system. Front wheels120may be operably coupled with the chassis116by way of the front suspension system.

In addition to the off-road applications discussed herein, it is contemplated that, in some embodiments, the modular chassis may be incorporated into racing vehicles that are not necessarily intended for off-road racing. For example, the modular chassis may be incorporated into a vehicle that includes a tube-frame structure as well as racing vehicles that include any of formula racing, sports car racing, stock car racing, drag racing, touring car racing, production car racing, as well as amateur open-wheel racing applications, such as karting, and the like. In such applications, the modular chassis advantageously enables a drivetrain and suspension assembly to be quickly and easily assembled, serviced, and repaired, unlike in the case of conventional racing vehicles that may be sidelined during a race due to the failure of an individual part that requires a time-consuming procedure to access and replace. As such, vehicle100illustrated inFIG.1should be construed as including any vehicle that is suitable for the modular chassis disclosed herein, without limitation.

FIG.2illustrates a front view of a front suspension system124that is configured to couple the front wheel120with the passenger side of vehicle100. The front suspension system124is comprised of an upper suspension arm128and a lower suspension arm132that couple the front wheel120with the chassis116. Each of the upper and lower suspension arms128,132comprises two inboard mounting joints136to the chassis116and one outboard mounting joint to a spindle assembly140. As will be recognized, the upper and lower suspension arms128,132generally are of a double wishbone variety of suspension that facilitates controlling various parameters affecting the orientation of the wheel120with respect to the vehicle100, such as, by way of non-limiting example, camber angle, caster angle, toe pattern, roll center height, scrub radius, and scrub.

It should be understood that although the front suspension system124is disclosed specifically in connection with the passenger side of the vehicle100, a driver-side front suspension system is to be coupled with the driver-side of the vehicle. It should be further understood that the driver-side front suspension system is substantially identical to the front suspension system124, with the exception that the driver-side front suspension system is configured specifically to operate with the driver-side of the vehicle100. As will be appreciated, therefore, the driver-side front suspension system and the front suspension system124may be configured as reflections of one another across a longitudinal midline of the vehicle100.

As will be appreciated by those skilled in the art, there may be instances wherein disassembling one or more portions of the chassis116may be advantageous, such as during servicing or repairing the components comprising the front suspension system124. Further, assembling one or more portions of the chassis116simples manufacturing of vehicle100, as well as facilitating the repairing of damaged portions of the chassis116without cutting and welding the chassis as is commonplace with conventional vehicles. To this end, the illustrated embodiment of chassis116may be comprised of one or more portions, or chassis modules, that may be assembled and disassembled, as needed.

FIGS.3A-3Cillustrate an exemplary embodiment of a front frame module144that may be fixedly coupled with chassis116. The front frame module144generally supports the lower suspension arms132on the passenger and driver sides of the vehicle100by way of the inboard mounting joints136. The inboard mounting joints136preferably are of a bushing variety that allows the lower suspension arms132to pivot vertically with respect to the front frame module144. As best shown inFIGS.4A-4C, the front frame module144is generally an elongate member comprised of inboard mounting brackets148disposed on opposite sides of the front frame module in locations suitable to receive the lower suspension arms as shown inFIGS.3A-3B. As will be appreciated, the front frame module144is comprised of a rigid metal, such as any of various suitable metal alloys, having a gauge thickness suitable for supporting the vehicle100and withstanding the forces due to the lower suspension arms132due to travel over terrain.

The front frame module144is comprised of a front mount152and a rear mount156disposed at opposite ends and configured to enable fastening the front frame module to chassis116. In the illustrated embodiment, the front mount152is comprised of a bracket configured to be coupled, such as by way of nuts and bolts, with a similar bracket disposed at the front-most portion of chassis116. The rear mount156is configured to be coupled with a tube-shaped member comprising the chassis116. In some embodiments, a bracket suitable for receiving the rear mount156may be fastened or welded onto the tube-shaped member of the chassis116. It should be understood, however, that the front and rear mounts152,156are not to be limited to the specific configurations shown and discussed herein, but rather the front and rear mounts152,156may be comprised of any structure suitable for fixedly coupling the front frame module144with the chassis116.

As best shown inFIG.3C, the front frame module144may be configured to support various components of the vehicle100. For example, in the illustrated embodiment, steering gear160and a front differential164may be fastened onto the front frame module144. As shown inFIGS.4A-4C, the front frame module144includes a steering mount168configured to receive the steering gear160, and comprises a plurality of brackets172suitable for receiving fasteners to mount the front differential164onto the front frame module. It is contemplated that suitably sized nuts and bolts may be utilized to fasten the steering gear160onto the steering mount168. Similarly, suitably sized bolts may be used to fasten the front differential164onto the plurality of brackets172. Further, in some embodiments, the brackets172may be configured to receive any of various cushioning mounts, such as rubber mounts, which may be coupled between the front differential164and the front frame module144.

In some embodiments, the front frame module144may include various ports, or openings, disposed on the front frame module to provide access to the various components fastened onto the front frame module. In the embodiment illustrated inFIGS.4A-4C, the front frame module144includes service ports176. As will be appreciated, the service ports generally facilitate servicing or repairing of the various components without requiring removal from the front frame module144. Those skilled in the art will recognize that the service ports176facilitate accessing an oil drain plug of the front differential164to drain and refill the front differential gear oil. It should be understood, however, that the front frame module144is not limited to the service ports176illustrated herein, and thus other openings and service ports may be incorporated into the front frame module144, as deemed necessary, without limitation. For example, any of various service ports176may be disposed on the front frame module144so as to allow fluids, such as trapped water due to travel in wet conditions, to drain from an interior of the front frame module, thereby inhibiting potential corrosion of the front frame module144.

As shown inFIGS.3A-3C, the front frame module144may be comprised of one or more panels that are configured to protect the various components coupled with the front frame module. For example, the illustrated embodiment of the front frame module144is comprised of debris shields180that serve to protect the steering gear160and the front differential164from damage due to flying road debris, such as rocks, that may occur during travel over rough terrain.

FIGS.5A-5Billustrate an exemplary embodiment of a rear frame module184that may be fixedly coupled with the chassis116. The rear frame module184generally is comprised of a tube-frame structure that is configured to couple with the chassis116and to support various engine components, as well as a transaxle and rear differential (not shown). The rear frame module184may be comprised of any suitably rigid metal, or non-ferrous materials, such as any of various metal alloys, having a gauge thickness suitable for supporting the vehicle100and withstanding forces typically encountered during travel over rough terrain.

As best shown inFIG.5A, a lower portion of the rear frame module184is comprised of parallelly disposed bottom frame members188that extend rearward with respect to chassis116, each toward a bent portion192. A bottom mount186is configured to couple the bottom frame members188with the chassis116. The bottom mount186may be comprised of brackets that are configured to receive suitably sized nuts and bolts that fasten the bottom frame members188to the chassis116. In some embodiments, a cross-member may be disposed between the bottom frame members188and received between the brackets so as to fixedly join the bottom frame members188with the chassis116. It is contemplated that the bottom mount186may be comprised of any suitable means for fixating the rear frame module184to the chassis116, without limitation.

In the embodiment illustrated inFIG.5A, the bottom frame members188are centrally disposed adjacent to a midline of the chassis116and configured to provide clearance for vertical motion of driver side and passenger side rear trailing arms (not shown) disposed adjacently to each of the bottom frame members188. The bent portions192join each of the bottom frame members188with an angled frame member196that extends upwards along a lower rear portion of the vehicle100. A bent portion200joins each of the angle frame members196with a vertical frame member204that extends acutely toward a top frame member208. Several cross-members202are disposed between the parallel bottom frame members188, angled frame members196, and vertical frame members204. As will be appreciated, the cross-members202serve to fixate the parallel frame members,188,196,200, and thereby impart structural integrity to the rear frame module184.

As best shown inFIGS.6A-6B, the top frame member208comprises a rear-most portion of the rear frame module184that may be coupled with upper side portions212of the chassis116. The illustrated embodiment of the top frame member208is comprised of a series of straight tube portions and bent tube portions that are suitably assembled such that the top frame member208may be joined with the upper side portions212by way of a top mount216disposed at each end of the top frame member. The straight tube portions and the bent tube portions may be separate tube portions that are assembled to form the top frame member208, or the straight tube portions and the bent tube portions may comprise a single tube portion that is advantageously manipulated to form the top frame member208. Further, it is contemplated that the top mounts216may be comprised of any suitable means for fixating the top frame member208and the upper side portions212. In some embodiments, for example, the top mounts216may be comprised of suitably sized couplers211that are inserted between the top frame member208and the upper side portions212and then welded to fixate the rear frame module184and the chassis116. Other means for fixating the top frame member208and the upper side portions212will be apparent to those skilled in the art.

It is contemplated that a wide variety of brackets and other supportive members may be coupled with the rear frame module184and the chassis116so as to support various components of the vehicle100, such as engine components, as well as a transaxle and rear differential (not shown). For example, in the illustrated embodiment ofFIGS.5A-6B, a frame component mount220may be fastened to the chassis116so as to be advantageously located within the rear frame module184to support the abovementioned components. As best shown inFIG.6B, the frame component mount220may be fastened to chassis116by way of brackets224configured to receive suitably sized bolts and nuts. It is contemplated that the brackets224may be welded onto the chassis116, such that one or more holes in the brackets224may be aligned with mounting holes in the frame component mount220.

Moreover, it is further contemplated that any of the various brackets, holes, or openings may be coupled with, or disposed on, the frame component mount220for the purpose of fixedly receiving various components of the vehicle, as described herein. For example, as best shown inFIG.6A, two-component mounting brackets228are coupled with the frame component mount220. The component mounting brackets228may be welded, or otherwise fastened onto the frame component mount220, without limitation, in a parallel orientation to facilitate supporting a relatively heavy component of the vehicle100. Further, as shown inFIG.5A, holes232are disposed in various locations of frame component mount220. It is contemplated that holes232may be strategically located so as to receive various components that are intended to be fastened onto the frame component mount220.

It should be understood that neither the rear frame module184nor the front frame module144are to be limited to the specific shapes and structures shown in the illustrations and disclosed herein. In particular, the various brackets, holes, openings, and couplers disclosed herein are intended to be exemplary in nature, and thus any of the disclosed brackets, holes, openings, and couplers may be modified, varied, or exchanged for an equivalent, without limitation and without deviating beyond the spirit and scope of the present disclosure.

Moreover, it should be understood that the modular chassis disclosed herein is not limited solely to the chassis116, the front frame module144, and the rear frame module184, but rather it is contemplated that the chassis116may be further comprised of one or more modules, as desired. For example, in some embodiments, the chassis116may be comprised of the abovementioned roll-over protection system104implemented as a single component, or an assembly of components, that may be fastened onto the chassis116, and removed therefrom as needed. It is further contemplated that the one or more modules comprising the chassis116may include any of various brackets, mounts, holes, openings, couplers, and the like, that may be deemed necessary to assemble the modules comprising the chassis116and to couple vehicle components with the chassis, without limitation.

Furthermore, it should be borne in mind that the modular chassis disclosed herein may be incorporated into racing vehicles that are not necessarily intended for off-road racing. For example, the modular chassis may be incorporated into racing vehicles that may be used for any of formula racing, sports car racing, stock car racing, drag racing, touring car racing, production car racing, as well as amateur open-wheel racing applications, such as karting, and the like. It is contemplated that in such applications, the modular chassis advantageously enables a drivetrain and suspension assembly to be quickly and easily assembled, serviced, and repaired, unlike in the case of conventional racing vehicles that may be sidelined during a race due to the failure of an individual part that requires a time-consuming procedure to access and replace. As such, the vehicle100illustrated inFIG.1should be construed as including any vehicle that is suitable for implementation of the modular chassis as disclosed herein, without limitation, and without deviating beyond the spirit and scope of the present disclosure.

While the invention has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the invention is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in a certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process, when possible, as well as performed sequentially as described above. To the extent there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by the scope of the appended claims.