Modular light truck chassis frame structure that maximizes the package volume of a rechargeable energy storage system for a non-load-bearing electric vehicle architecture.

Abstract

This invention relates to a vehicle frame structure including a pair of elongated center bracket guides, wherein a crossbeam extends between the rear ends of the pair of center bracket guides. A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated center bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated center bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of center bracket guides to the pair of elongated rear bracket guides.

Description

Technical Field

[0001] This disclosure relates to a modular light truck chassis frame structure that maximizes the package volume of a rechargeable energy storage system for a non-load-bearing electric vehicle architecture. Background Technology

[0002] The information provided in this section is intended to provide a general overview of the background of this disclosure. For the purposes of this section, references to the inventors' work and descriptions that may otherwise be inconsistent with the prior art at the time of filing are not expressly or implicitly considered to be prior art to this disclosure.

[0003] Because the transition zone between the middle bracket guide rail and the rear bracket guide rail limits the length of the rechargeable energy storage system package, existing light truck chassis frame structures have a limited rechargeable energy storage system package volume. Summary of the Invention

[0004] A vehicle frame structure includes a pair of elongated center bracket guides, wherein a crossbeam extends between the rear ends of the pair of center bracket guides. A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated center bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated center bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of center bracket guides to the pair of elongated rear bracket guides.

[0005] According to another aspect of this disclosure, the first pair of reinforcing members and the second pair of reinforcing members are welded to the pair of elongated middle bracket guide rails and the pair of elongated rear bracket guide rails.

[0006] According to another aspect of this disclosure, the first pair of reinforcing members and the second pair of reinforcing members extend outward from the pair of elongated rear bracket guides to the pair of elongated middle bracket guides.

[0007] According to another aspect of this disclosure, the first pair of reinforcing members and the second pair of reinforcing members are connected to the side surface of the elongated rear bracket guide rail and the top surface of the elongated middle bracket guide rail.

[0008] According to another aspect of this disclosure, the first pair of reinforcing members includes a mounting portion disposed on the top surface of the elongated center bracket guide rail and an overlapping top portion of at least one side surface of the elongated center bracket guide rail.

[0009] According to another aspect of this disclosure, the ends of the pair of elongated central bracket guide rails are closed by a second pair of reinforcing members.

[0010] According to another aspect of this disclosure, a second pair of reinforcing members are welded to the pair of elongated rear bracket guides.

[0011] According to another aspect of this disclosure, a rechargeable energy storage chamber is located between the pair of elongated central bracket rails, which extend along the vehicle travel direction behind the first pair of reinforcing members, and includes a plurality of battery cells within the rechargeable energy storage chamber.

[0012] According to another aspect of this disclosure, a rechargeable energy storage chamber is directly disposed between the pair of elongated rear bracket rails.

[0013] According to another aspect of this disclosure, a central crossbeam extends between the pair of central bracket guide rails, and a third pair of reinforcing members are connected between the central crossbeam and the front ends of the pair of rear bracket guide rails.

[0014] A vehicle frame structure includes a pair of elongated center bracket guides, wherein a crossbeam extends between the rear ends of the pair of center bracket guides. A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated center bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated center bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of center bracket guides to the pair of elongated rear bracket guides. The first pair of reinforcing members and the second pair of reinforcing members are welded to the pair of elongated center bracket guides and the pair of elongated rear bracket guides.

[0015] A vehicle frame structure includes a pair of elongated center bracket rails, with a rear crossbeam extending between the rear ends of the pair of center bracket rails. A middle crossbeam extends between the pair of center bracket rails. A pair of elongated rear bracket rails defines an overlapping joint with the pair of elongated center bracket rails, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket rails to the pair of elongated center bracket rails, and a second pair of reinforcing members connects the rear ends of the pair of center bracket rails to the pair of elongated rear bracket rails. A third pair of reinforcing members connects between the middle crossbeam and the front ends of the pair of rear bracket rails. A rechargeable energy storage compartment is located between the pair of elongated center bracket rails, extending along the vehicle's direction of travel behind the first pair of reinforcing members, and a plurality of battery cells are disposed within the rechargeable energy storage compartment.

[0016] Other applicable areas of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0017] The present invention also includes the following technical solutions.

[0018] Technical Solution 1. A vehicle frame structure, comprising:

[0019] A pair of slender central support rails;

[0020] The rear crossbeam extends between the rear ends of the pair of center bracket guide rails;

[0021] A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated middle bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated middle bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of middle bracket guides to the pair of elongated rear bracket guides.

[0022] Technical Solution 2. The vehicle frame structure according to Technical Solution 1, wherein the first pair of reinforcing members and the second pair of reinforcing members are welded to the pair of elongated middle bracket guide rails and the pair of elongated rear bracket guide rails.

[0023] Technical Solution 3. The vehicle frame structure according to Technical Solution 1, wherein the first pair of reinforcing members and the second pair of reinforcing members extend outward from the pair of elongated rear bracket guide rails to the pair of elongated middle bracket guide rails.

[0024] Technical Solution 4. The vehicle frame structure according to Technical Solution 1, wherein the first pair of reinforcing members and the second pair of reinforcing members are connected to the side surface of the elongated rear bracket guide rail and the top surface of the elongated middle bracket guide rail.

[0025] Technical Solution 5. The vehicle frame structure according to Technical Solution 1, wherein the first pair of reinforcing members includes an mounting portion disposed on the top surface of the elongated center bracket guide rail and an overlapping top portion of at least one side surface of the elongated center bracket guide rail.

[0026] Technical Solution 6. The vehicle frame structure according to Technical Solution 1, wherein the ends of the pair of elongated center bracket guide rails are closed by the second pair of reinforcing members.

[0027] Technical Solution 7. The vehicle frame structure according to Technical Solution 6, wherein the second pair of reinforcing members are welded to the pair of elongated rear bracket guides.

[0028] Technical Solution 8. The vehicle frame structure according to Technical Solution 1 further includes a rechargeable energy storage chamber located between the pair of elongated central bracket guide rails, extending along the vehicle travel direction to the rear of the first pair of reinforcing members, and including a plurality of battery cells within the rechargeable energy storage chamber.

[0029] Technical Solution 9. The vehicle frame structure according to Technical Solution 8, wherein the rechargeable energy storage chamber is directly disposed between the pair of elongated rear bracket guide rails.

[0030] Technical Solution 10. The vehicle frame structure according to Technical Solution 9 further includes an intermediate crossbeam extending between the pair of middle bracket guide rails and a third pair of reinforcing members, the third pair of reinforcing members being connected between the intermediate crossbeam and the front ends of the pair of rear bracket guide rails.

[0031] Technical Solution 11. A vehicle frame structure, comprising:

[0032] A pair of slender central support rails;

[0033] The rear crossbeam extends between the rear ends of the pair of center bracket guide rails;

[0034] A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated middle bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated middle bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of middle bracket guides to the pair of elongated rear bracket guides.

[0035] The first pair of reinforcing members and the second pair of reinforcing members are welded to the pair of slender middle bracket guide rails and the pair of slender rear bracket guide rails.

[0036] Technical Solution 12. The vehicle frame structure according to Technical Solution 11, wherein the first pair of reinforcing members and the second pair of reinforcing members extend outward from the pair of elongated rear bracket guides to the pair of elongated middle bracket guides.

[0037] Technical Solution 13. The vehicle frame structure according to Technical Solution 11, wherein the first pair of reinforcing members and the second pair of reinforcing members are connected to the side surface of the elongated rear bracket guide rail and the top surface of the elongated middle bracket guide rail.

[0038] Technical Solution 14. The vehicle frame structure according to Technical Solution 11, wherein the first pair of reinforcing members includes an mounting portion disposed on the top surface of the elongated center bracket guide rail and an overlapping top portion of at least one side surface of the elongated center bracket guide rail.

[0039] Technical Solution 15. The vehicle frame structure according to Technical Solution 11, wherein the ends of the pair of elongated center bracket guide rails are closed by the second pair of reinforcing members.

[0040] Technical Solution 16. The vehicle frame structure according to Technical Solution 11 further includes a rechargeable energy storage chamber located between the pair of elongated center bracket guide rails, extending along the vehicle travel direction to the rear of the first pair of reinforcing members, and including a plurality of battery cells within the rechargeable energy storage chamber.

[0041] Technical Solution 17. The vehicle frame structure according to Technical Solution 16, wherein the rechargeable energy storage chamber is directly disposed between the pair of elongated rear bracket guide rails.

[0042] Technical Solution 18. The vehicle frame structure according to Technical Solution 17 further includes an intermediate crossbeam extending between the pair of middle bracket guide rails and a third pair of reinforcing members, the third pair of reinforcing members being connected between the intermediate crossbeam and the front ends of the pair of rear bracket guide rails.

[0043] Technical Solution 19. A vehicle frame structure, comprising:

[0044] A pair of slender central support rails;

[0045] The rear crossbeam extends between the rear ends of the pair of center bracket guide rails;

[0046] A central crossbeam extends between the pair of central bracket guide rails;

[0047] A pair of elongated rear bracket guides defines an overlapping joint with the pair of elongated middle bracket guides, wherein a first pair of reinforcing members connects the front ends of the pair of rear bracket guides to the pair of elongated middle bracket guides, and a second pair of reinforcing members connects the rear ends of the pair of middle bracket guides to the pair of elongated rear bracket guides.

[0048] The third pair of reinforcing members are connected between the front ends of the intermediate crossbeam and the pair of rear bracket guide rails;

[0049] A rechargeable energy storage compartment located between the pair of elongated central support rails, extending along the vehicle's direction of travel behind the first pair of reinforcing members; and

[0050] Multiple battery cells are disposed in the rechargeable energy storage chamber.

[0051] Technical Solution 20. The vehicle frame structure according to Technical Solution 8, wherein the rechargeable energy storage chamber is directly disposed between the pair of elongated rear bracket guide rails. Attached Figure Description

[0052] This disclosure will be more fully understood from the detailed embodiments and accompanying drawings, in which:

[0053] Figure 1 This is a rear perspective view of a portion of a light truck chassis frame structure based on the principles of this disclosure;

[0054] Figure 2 This is a side plan view of a part of the chassis frame structure of a light truck;

[0055] Figure 3This is a top view of part of the chassis frame structure of a light truck;

[0056] Figure 4 This is a top view of a portion of a light truck chassis frame with a long wheelbase;

[0057] Figure 5 This is a front perspective view of part of the chassis frame structure of a light truck;

[0058] Figure 6 This is a perspective view of the mounting accessories on the side of the upper rear guide rail;

[0059] Figure 7 This is a detailed rear perspective view of part of the chassis frame structure of a light truck;

[0060] Figure 8 This is a partial cutaway perspective view of a part of the chassis frame structure of a light truck;

[0061] Figure 9 A detailed rear perspective view of part of the chassis frame structure of a light truck; and

[0062] Figure 10 This is a cross-sectional view of a part of the chassis frame structure of a light truck.

[0063] In the accompanying drawings, reference numerals may be used repeatedly to identify similar and / or identical elements. Detailed Implementation

[0064] refer to Figure 1-3 and Figure 5 This diagram shows a portion of a light truck chassis frame structure 10. The light truck frame structure 10 typically includes a front bay segment (not shown), a center bay segment 12, and a rear bay segment 14. The front suspension system is typically mounted to the front bay segment, and the rear suspension system is typically mounted to the rear bay segment 14 to support the rear axle along line X, such as... Figure 3 As shown.

[0065] The middle bracket segment 12 includes a pair of elongated middle bracket guide rails 16 connected by a rear crossbeam 18 and a middle crossbeam 20. The rear crossbeam 18 and the middle crossbeam 20 can each be received in a pair of corresponding orifices 18a and 20a in the pair of elongated middle bracket guide rails 16 and are welded to the pair of corresponding orifices 18a and 20a. An additional bridge support 22 can be connected to the upper surface of the middle bracket guide rails 16 via a bracket 24, which is connected to the elongated middle bracket guide rails 16 by welding or other fastening techniques.

[0066] The rear bracket segment 14 includes a pair of elongated rear bracket guide rails 26, which, together with the pair of elongated middle bracket guide rails 16, define an overlapping engagement area 30. (See Figures 9 and 9). Figure 10 As best shown, the overlapping joint area 30 includes a pair of first mounting brackets 32 welded to the front end of the elongated rear bracket guide rail 26 and the middle crossbeam 20.

[0067] The overlapping joint area 30 also includes a pair of second mounting brackets 34 welded to the elongated rear bracket guide 26 and the elongated middle bracket guide 16. The pair of second mounting brackets are welded to the side surface of the elongated rear bracket guide 26 and to the top and side surface of the middle bracket guide 16.

[0068] The overlapping joint area 30 also includes a pair of third mounting brackets 36 welded to the elongated rear bracket guide 26 and the elongated middle bracket guide 16. The pair of third mounting brackets 36 are weldable to the side and bottom surfaces of the elongated rear bracket guide 26 and to the rear end of the middle bracket guide 16, thus closing the rear end.

[0069] refer to Figure 7 and Figure 8 The third mounting bracket 36 may include an upper bracket portion 36A, which is welded to the side surface of the elongated rear bracket guide 26, extends outward and surrounds the outer surface of the elongated middle bracket guide 16, and is welded to the bottom surface of the elongated middle bracket guide 16. A lower bracket portion 36B of the third mounting bracket 36 is welded to the bottom surface of the rear end of the middle bracket guide 16, extends inward, and extends upward where it is welded to the bottom surface of the rear bracket guide 26. The upper bracket portion 36A and the lower bracket portion 36B of the third mounting bracket 36 enclose the rear end of the middle bracket guide 16.

[0070] Multiple additional crossbeams 38 can extend between the pair of elongated rear bracket guides 26. (Reference) Figure 6 Additional main mounting structures, such as assembly attachment 39, can be attached to the middle bracket guide rail 16 and the rear bracket guide rail 26.

[0071] The rechargeable energy storage compartment 40 is defined between the elongated center bracket rails 16 and extends directly in front of the rear crossbeam 18. Furthermore, the rechargeable energy storage compartment 40 can be positioned between the rear bracket rails 26 within the overlapping joint area 30. The modular light van chassis frame structure 10 maximizes the encapsulation volume of the rechargeable energy storage compartment 40 in a body-on-frame battery electric vehicle architecture by allowing the rechargeable energy storage compartment 40 to extend to the rear of the center bracket rails 16 and between the rear bracket rails 26 within the overlapping joint area 30. Multiple battery cells 42 (only a few shown) are disposed within the rechargeable energy storage compartment 40.

[0072] refer to Figure 4 This shows a portion of the slender wheelbase light truck chassis frame structure 110. Figure 4In an embodiment of the elongated wheelbase light truck chassis frame structure 110, the overlapping joint area 130 is extendable and includes an additional pair of fourth mounting brackets 136 welded to the elongated rear bracket guide 26 and the elongated center bracket guide 16. The pair of fourth mounting brackets 136 are welded to the side surface of the elongated rear bracket guide 26 and to the top and side surface of the center bracket guide 16. The rechargeable energy storage chamber 140 of the elongated wheelbase light truck chassis frame structure 110 can be lengthened along with the wheelbase.

[0073] The foregoing description is illustrative in nature and is not intended to limit this disclosure, its application, or use. The broad teachings of this disclosure can be implemented in various forms. Therefore, while this disclosure includes specific examples, its true scope should not be limited thereto, as other modifications will become apparent upon examination of the drawings, specification, and appended claims. It should be understood that one or more steps in a method can be performed in different orders (or simultaneously) without altering the principles of this disclosure. Furthermore, although each of the foregoing embodiments has certain features, any one or more of these features described with reference to any embodiment of this disclosure can be implemented with features of any other embodiment and / or combined with features of any other embodiment, even without explicitly described combinations. In other words, the described embodiments are not mutually exclusive, and substitution of one or more embodiments for each other remains within the scope of the invention.

[0074] Various terms are used to describe spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including “connection,” “joint,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “set.” Unless explicitly described as “direct,” when describing the relationship between the first and second elements in the foregoing disclosure, the relationship can be a direct relationship in the absence of any other intervening elements between the first and second elements, or an indirect relationship in the presence of one or more intervening elements (spatially or functionally) between the first and second elements. As used herein, at least one of the phrases A, B, and C should be understood as using the logic of a non-exclusive “OR” (A or B or C), and should not be understood as “at least one of A, at least one of B, and at least one of C.”

Claims

1. A vehicle frame structure, comprising: A pair of slender central support rails (16); Rear crossbeam (18) extends between the rear ends of the pair of center bracket guide rails; A pair of elongated rear bracket guide rails (26), the front ends of the pair of elongated rear bracket guide rails and the rear ends of the pair of elongated middle bracket guide rails define an overlapping engagement area (30), the overlapping engagement area (30) has a first end and a second end, and the spacing between the pair of elongated rear bracket guide rails (26) is smaller than the spacing between the pair of elongated middle bracket guide rails (16). Intermediate crossbeam (20) at the first end of the overlapping joint area (30); A pair of first mounting brackets (32) are fixed to the intermediate crossbeam (20) and connected to the front end of each of the pair of elongated rear bracket guides (26); A pair of second mounting brackets (34) extend outward from the rear bracket guide rail (26) and connect to the middle bracket guide rail (16) in the area between the second end of the intermediate crossbeam (20) and the overlapping joint area (30); and A pair of third mounting brackets (36) are connected to the rear end of the middle bracket guide rail (16) and extend inward to connect to the rear bracket guide rail (26).

2. The vehicle frame structure according to claim 1, wherein the second mounting bracket (34) and the third mounting bracket (36) are welded to the pair of elongated middle bracket guides and the pair of elongated rear bracket guides.

3. The vehicle frame structure according to claim 1, wherein the second mounting bracket (34) and the third mounting bracket (36) extend outward from the pair of elongated rear bracket guides to the pair of elongated middle bracket guides.

4. The vehicle frame structure according to claim 1, wherein the second mounting bracket (34) and the third mounting bracket (36) are connected to the side surface of the elongated rear bracket guide and the top surface of the elongated middle bracket guide.

5. The vehicle frame structure according to claim 1, wherein the second mounting bracket (34) comprises a mounting portion disposed on the top surface of the elongated center bracket guide and an overlapping top portion of at least one side surface of the elongated center bracket guide.

6. The vehicle frame structure according to claim 1, wherein the ends of the pair of elongated center bracket guides are closed by the third mounting bracket (36).

7. The vehicle frame structure according to claim 6, wherein the third mounting bracket (36) is welded to the pair of elongated rear bracket guides.

8. The vehicle frame structure according to claim 1 further includes a rechargeable energy storage chamber located between the pair of elongated center bracket rails extending along the vehicle travel direction behind the second mounting bracket (34) and including a plurality of battery cells within the rechargeable energy storage chamber.

9. The vehicle frame structure according to claim 8, wherein the rechargeable energy storage chamber is directly disposed between the pair of elongated rear bracket rails.

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