Frame structure for a vehicle

Abstract

Present invention relates to a frame structure (100) for a vehicle. The frame structure (100) comprises one or more long members (102) extending rearwardly in the vehicle front-rear direction. The frame structure (100) further comprises one or more cross members (104) extending in a vehicle width direction (W1), each of the one or more cross members (104) comprising one or more recessed portions (120a, 120b), each of the recessed portions (120a, 120b) adapted to receive and support the one or more long members (102). The frame structure (100) comprises a reinforced framework with integration one or more cross members (104) and one or more long members (102) to distribute the load evenly and minimize deformation thereby enhancing the torsional performance resulting in reduced local stressed zones, vehicle weight, assembly time and labour cost.

Description

[0001] TITLE OF INVENTION

[0002] FRAME STRUCTURE FOR A VEHICLE

[0003] FIELD OF THE INVENTION

[0004]

[0001] Present invention generally relates to a vehicle. More particularly, the present invention relates to a frame structure for the vehicle.

[0005] BACKGROUND OF THE INVENTION

[0006]

[0002] Cargo vehicles such as trucks or lorries are designed for transporting freight and carrying specialized payloads. These vehicles are crucial for commercial and utilitarian purposes where efficient cargo transportation is required. Available in various configurations, each vehicle is tailored to specific needs based on size, power, and payload capacity. For example, vehicles range from small delivery vans to large trucks capable of carrying several tons of cargo. Existing L7 category cargo vehicles face regulatory challenges due to limitations in kerb weight not exceeding 550 kg. This regulation aims to ensure safety and efficiency while maintaining compliance with government standards. However, current cargo vehicles in this category often exceed this weight limit, particularly when designed to maximize cargo space and load carrying capacity, which range from 1 to 1.5 tons.

[0007]

[0003] Further, users demand for fuel efficiency and advanced features in the vehicle that pose further constraints on vehicle weight. Adding features typically increases weight of the vehicle, making it difficult for Original Equipment Manufacturers (OEMs) to comply with weight regulations while meeting consumer expectations. Moreover, ensuring better crash ratings while reducing vehicle weight is another challenge. Cargo vehicles must be robust enough to carry heavy loads (500+ kg) without compromising on safety standards. One approach involves using lightweight, high-strength materials in the vehicles. However, these materials are often costly and require the development of new manufacturing processes, making them impractical and economically unfeasible for widespread adoption by OEMs. Another approach is to reduce the number of parts in the vehicle. This method requires significant investment and often results in vehicles with limited features, failing to meet consumer demands for comprehensive utility. Additionally, designing vehicles with reduced cargo space and volume carrying capacity is not viable, as consumers prefer maximum load capabilities.

[0008]

[0004] Furthermore, the conventional attachment of the long member and the cross member in the chassis includes multiple joints and connections through bolts, nuts, brackets etc which increases weight of the vehicle as well as increases assembly time, and labour costs, which in turn raise the overall cost associated with the vehicle. This type of joining also leads to high stress in the joinery areas, which may case failure of the parts in joinery areas. To mitigate high-stress zones in the joinery areas, additional material is often used, further increasing the vehicle's weight. Moreover, in existing vehicles, the connection between long members and cross members typically includes a separate bracket and reinforcement member for the long members, and a reinforcement member with additional damper parts for the cross members. This not only adds weight to the vehicle but also increases the number of sub-assembly parts that need to be maintained in inventory.

[0009]

[0005] In view of the above, there is a need for a frame structure for a vehicle, which addresses at least the aforementioned problems.

[0010] SUMMARY OF THE INVENTION

[0011]

[0006] In one aspect, the present invention is directed towards a frame structure for a vehicle. The frame structure has one or more long members extending rearwardly in the vehicle front-rear direction. The frame structure further has one or more cross members extending in a vehicle width direction. Each of the one or more cross members has one or more recessed portions. Each of the recessed portions adapted to receive and support the one or more long members.

[0012]

[0007] In an embodiment of the present invention, the frame structure has a load deck mounted on the one or more long members and the one or more cross members.

[0008] In an embodiment of the present invention, the load deck has a floor member disposed on the one or more long members and the one or more cross members.

[0013]

[0009] In an embodiment of the present invention, the floor member being welded to at least one of the one or more long members and the one or more cross members.

[0014]

[0010] In an embodiment of the present invention, the one or more cross members being coupled to the one or more long members.

[0015] [Oi l] In an embodiment of the present invention, the one or more cross members being welded to the one or more long members.

[0016]

[0012] In an embodiment of the present invention, at least one of the cross members has a first portion, a central portion and a second portion. Herein, the first portion and the second portion being disposed adjacent to ends of the central portion.

[0017]

[0013] In an embodiment of the present invention, each of the first portion, the central portion, the second portion has a bottom wall, a pair of sidewalls extending from both opposite side edges of the bottom wall, one or more flanges extended from ends of the bottom wall and ends of the pair of sidewalls. Herein, the one or more flanges being adapted to be in contact with the one or more long members.

[0018]

[0014] In an embodiment of the present invention, the first portion and the second portion are provided with a tapered profile.

[0019]

[0015] In an embodiment of the present invention, a top surface of each of the one or more cross members being arranged in a same plane of a top surface of the one or more long members.

[0020]

[0016] In an embodiment of the present invention, the one or more long members has a first long member and a second long member. The first long member being spaced apart from the second long member. A central portion of each of the one or more cross members being attached to the first long member and the second long member in the vehicle width direction. A first portion of the cross member being attached to the first long member and a second portion of the cross member being attached to the second long member. BRIEF DESCRIPTION OF THE DRAWINGS

[0021]

[0017] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

[0022] Figure 1 illustrates a bottom perspective view of a frame structure of a vehicle, depicting one or more long members and one or more cross members, in accordance with an embodiment of the present invention.

[0023] Figure 2 illustrates an exploded view of the frame structure of the vehicle, depicting a load deck, in accordance with an embodiment of the present invention.

[0024] Figure 3 illustrates a perspective view of a cross member, depicting a first portion, a central portion and a second portion of the cross member, in accordance with an embodiment of the present invention.

[0025] Figure 4A illustrates an exploded view of the frame structure of the vehicle, in accordance with an embodiment of the present invention.

[0026] Figures 4B illustrates a perspective view of the frame structure of the vehicle, depicting mounting of the one or more cross members onto the one or more long members, in accordance with an embodiment of the present invention.

[0027] Figure 5A illustrates a top perspective view of the frame structure of the vehicle, in accordance with an embodiment of the present invention.

[0028] Figure 5B illustrates a side view of the frame structure of the vehicle, in accordance with an embodiment of the present invention.

[0029] DETAILED DESCRIPTION OF THE INVENTION

[0030]

[0018] The present invention generally relates to a vehicle. More particularly, the present invention relates to a frame structure for the vehicle. The frame structure comprises a reinforced framework with integrated one or more cross members and one or more long members to distribute the load evenly and minimize deformation thereby enhancing the torsional performance resulting in reduced local stressed zones, vehicle weight, assembly time and labour cost.

[0031]

[0019] In the present disclosure, arrow indications provided in Figures pertain to directional indications of the vehicle. As such, the terms “front side”, “rear side”, “right side”, “left side”, “upside” and “downside” respectively correspond to front, rear, right, left, up and down sides of the vehicle, until and unless specified otherwise.

[0032]

[0020] Figure 1 illustrates a bottom perspective view of a frame structure 100 of a vehicle, in accordance with an embodiment of the present invention. In an embodiment, the vehicle is a four-wheeled vehicle, for example a four-wheeled cargo vehicle. It may be contemplated that the frame structure 100 as explained in the present invention may also find its application in vehicles other than four-wheeled cargo vehicle like a threewheeled cargo vehicle or a multi-axle and multi-wheeled vehicle as well. Therefore, the exemplary embodiment of four-wheeled vehicle should not be meant to limiting the scope of the present invention.

[0033]

[0021] The vehicle includes a prime mover which can be an Internal combustion engine (not shown) or an electric powertrain (not shown) or a combination of internal combustion engine and electric powertrain for driving the vehicle. The vehicle further includes one or more front wheels (not shown), two or more rear wheels (not shown), a seat assembly (not shown), and a frame structure 100. The frame structure 100 comprises one or more long members 102 that extend rearwardly in a vehicle frontrear direction between a front end and a rear end of the vehicle. The one or more long members 102 extending in the vehicle front-rear direction are substantially parallel to each other. The frame structure 100 further includes one or more cross members 104 that extend in a vehicle width direction Wl. The one or more cross members 104 are coupled to the one or more long members 102. In an embodiment, the frame structure 100 includes a pair of long members 102. The one or more cross members 104 extend transversely between the pair of long members 102.

[0034]

[0022] A front portion of the frame structure 100 is adapted to support a plurality of body panels to form a driver cabin (not shown). The driver cabin is adapted to accommodate the seat assembly and the handlebar. The vehicle further includes a cargo deck or the load deck 106 that is mounted and supported onto the one or more long members 102 and the one ore more cross members 104. The load deck 106 is disposed at a rear portion of the vehicle.

[0035]

[0023] Further, the two or more rear wheel (not shown) is arranged below the frame structure 100 and adapted to receive the motive force from the prime mover (not shown). A suitable transmission assembly (not shown) is provided for transferring the drive force from the prime mover onto the one or more front wheels and / or two or more rear wheel for driving or movement of the vehicle. In an embodiment, the load deck 106 may include provisions (not shown) for securing cargo to prevent shifting or damage during transit. In a non-limiting example, the provisions may include tie-down points, rails, or integrated anchor systems strategically placed along the load deck 106 for securing straps or ropes.

[0036]

[0024] Referring to Figure 2 in conjunction with Figure 1, the load deck 106 includes a floor member 108 disposed on the one or more long members 102 and the one or more cross members 104. In an embodiment, the floor member 108 is welded to the one or more long members 102 and the one or more cross members 104. The floor member 108 is a planar structure which is adapted to carry one or more weights like goods, cargo and the likes. In L7 category vehicles, the load deck 106 is adapted to facilitate transportation of good and materials. The floor member 108 of the load deck 106 provides a robust platform for carrying various types of cargo efficiently and safely. Unlike passenger vehicles, these trucks are designed to maximize cargo capacity while adhering to regulatory weight limitations and maintaining structural integrity. The load deck 106 is designed to withstand heavy loads and dynamic stresses encountered during transportation. In the present invention, such a load deck 106 is mounted on the frame structure 100 comprising a reinforced framework integrating the one or more cross members 106 and the one or more long members 102 to distribute the load evenly and minimize deformation. Thus, the frame structure 100 of the vehicle in the present invention provides better torsional performance resulting in reduced local stressed zones, vehicle weight, assembly time and labour cost.

[0037]

[0025] Figure 3 illustrates a perspective view of a cross member of the one or more cross members 104, in accordance with an embodiment of the present invention. For ease of understanding and explanation, a single cross member (hereinafter selectively referred to as ‘cross member 104’) is referred herein. Each of the cross member 104 comprises one or more distinct portions, such that each of the one or more cross members 104 comprises one or more recessed portions 120a, 120b. Each of the recessed portions 120a, 120b is adapted to receive and support the one or more long members 102. In the present invention, the one or more recessed portions 120a, 120b in the cross member 104 ensure a secure fit and proper alignment of the long members 102 within the cross member 104, thereby enhancing the overall structural integrity and stability of the vehicle chassis.

[0038]

[0026] In an embodiment, the cross member 104 comprises a first portion 104a, a central portion 104b and a second portion 104c. In this context, the recessed portion 120a refers to a first gap between the first portion 104a and the central portion 104b. Similarly, the recessed portion 120b refers to a second gap between the central portion 104b and the second portion 104c.The first portion 104a and the second portion 104c are disposed adjacent to ends of the central portion 104b, for instance, the first portion 104a and the second portion 104c are disposed on opposite ends of the central portion 104b. Particularly, the first portion 104a is positioned at one end of the cross member 104. The first portion 104a includes a bottom wall 104g and a pair of sidewalls 104h, 104i extending from both opposite side edges of the bottom wall 104g. Further, the central portion 104b also includes a bottom wall 104d and a pair of sidewalls 104e, 104f extending from both opposite side edges of the bottom wall 104d. The second portion 104c is positioned at the opposite end of the cross member 104 from the first portion 104a. The second portion 104c includes a bottom wall 1041 and a pair of sidewalls 104j, 104k extending from both opposite side edges of the bottom wall 1041. In an embodiment, the first portion 104a and the second portion 104c are provided with a tapered profile.

[0039]

[0027] The first portion 104a, the central portion 104b and the second portion 104c ensures load distribution across the length of the cross member 104. Further, by accommodating long members 102 in recessed portions 120a, 120b, the cross member 104 simplifies assembly processes and enhances alignment accuracy during manufacturing.

[0040]

[0028] Ends of the bottom wall 104d, 104g, 1041 and the end of the pair of sidewalls 104h, 104i, 104e, 104f, 104j, 104k extend to form one or more flanges 112a, 112b. The one or more flanges 112a, 112b are adapted to be in contact with the one or more long members 102. In an embodiment, the one or more flanges 112a comprise a flat, broad surface extending outward at the ends of the bottom wall 104d and is adapted to couple with the long member 102. In another embodiment, the one or more flanges 112b comprise an angular surface extending outward at the ends of the pair of sidewalls 104e, 104f and is adapted to couple with the long member 102. In an embodiment, the recessed portions 120a, 120b can be a substantially U-shaped cutout. The one or more flanges 112a of the bottom wall 104g of the first portion 104a and the one or more flanges 112a of bottom wall 104d of the central portion 104b are coupled to corresponding wall of the corresponding long members 102. Similarly, the one or more flanges 112a of the bottom wall 104d of the central portion 104b and the one or more flanges 112a of the bottom wall 1041 of the second portion 104c are coupled to corresponding walls of the corresponding long members 102. The U-shaped cut-out provides the necessary opening for accommodating and supporting the one or more long members 102. In the present invention, the one or more flanges 112a, 112b ensure precise alignment of the cross member 104 with the long member 102 resulting in rigid and stable integration of the cross member 104 with the long member 102.

[0041]

[0029] Referring to Figure 4A in conjunction with Figure 3, the one or more long members 102 comprises a first long member 102a and a second long member 102b. The first long member 102a is spaced apart from the second long member 102b. The central portion 104b of each of the one or more cross members 104 is attached to the first long member 102a and the second long member 102b in the vehicle width direction Wl. The first portion 104a of the cross member 104 is attached to the corresponding side, for instance a left side, of the first long member 102a. The second portion 104c of the cross member 104 is attached to the corresponding side, for instance a right side, of the second long member 102b. In an embodiment, the one or more flanges 112a, 112b on both the opposite ends of the central portion 104b, the one or more flanges 112a, 112b of the first portion 104a and the one or more flanges 112a, 112b of the second portion 104c configured for joining with the long members 102a and 102bto enable coupling of the of the cross members 104 with the long members 102a and 102b.

[0030] Referring to Figure 4B in conjunction with Figures 2 and 1, the one or more cross members 104 are coupled to the one or more long members 102. In a non-limiting example, the one or more cross members 104 is attached to the one or more long members 102 through conventional techniques known in the art such as a welding technique, a brazing technique and the like. Preferably, the one or more cross members 104 are welded to the one or more long members 102 to reduce the joining elements for reducing weight of the vehicle. In another embodiment, the one or more cross members 104 can be attached to the one or more long members 102 at a few locations through threaded fasteners. The alignment of the one or more cross members 104 and the one or more long members 102 is such that a top surface of each of the one or more cross members 104 is arranged in a same plane of a top surface of the one or more long members 102.

[0042]

[0031] Referring to Figures 5 A and 5B in conjunction with Figure 1, the load deck 106 includes the floor member 108 disposed on the one or more long members 102 and one or more cross members 104. In an embodiment, the floor member 108 is welded to the one or more long members 102 and the one or more cross members 104. The floor member 108 is welded to the long members 102 and the cross members 104 across the length of long members 102 and the cross members 104. In another embodiment, the one or more long members 102 can be integrated with the floor member 108 and then welded with the one or more cross members 104 through conventional techniques known in the art, preferably through welding technique. The present invention thus eliminates bolting connections and provides reduction in parts thereby reducing the assembling time as well as labour time and cost. The present invention also improves the structural connectivity between the cross members 104, the long members 102, and the load deck 106 resulting in distributed stress across the length of the joining components, such as cross members 104, the long members 102, and the load deck 106.

[0032] The claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies. The frame structure of the present invention comprises one or more cross members with one or more recessed adapted to receive and support the one or more long members thereby reducing the weight of the vehicle while providing maximum cargo space / volume and maximum load carrying capacity while maintaining the structural strength and integrity of the vehicle. The present invention provides welding connection between the load deck, long members and cross members thereby reducing the number of parts, joinery, local stressed zones, assembly time and labour cost.

[0043]

[0033] Further, the present invention reduces weight of the vehicle by eliminating multiple small parts from the vehicle such as connection brackets and its reinforcements, bolts, nuts, damper parts and directly connecting the load deck on the long members by connecting means such as welding. This in turn reduces the manufacturing cost and additional part count in the vehicle. The present invention effectively eliminates the requirement for precise alignment thereby simplifying the assembly process and reducing assembly time. As a result, the present invention is cost effective and enhances the aesthetic appeal of the vehicle.

[0044]

[0034] Further, in the present invention, due to direct connection between the cross members and the long members there is an increase in the torsional stiffness of the vehicle thereby reducing deformation of the chassis and increasing the durability of chassis and performance of the vehicle. Additionally, as the long members are received in the cross members in the present invention, height of the load deck is decreased this in turn reduces the loading height of the vehicle as well as turning stability of the vehicle. Furthermore, the cross members are tapered at the opposite end portions reducing the material required. Moreover, the long members and the cross members are attached via minimal use of joining components making assembly easier and less sophisticated.

[0045]

[0035] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

[0046] List of Reference Numerals

[0047] 100: Frame Structure for a Vehicle

[0048] 102: Long members

[0049] 102a: First long member

[0050] 102b: Second long member

[0051] 104: Cross members

[0052] 104a: First Portion of Cross member

[0053] 104b: Central Portion of Cross member

[0054] 104c: Second Portion of Cross member

[0055] 104d: Bottom wall of Central Portion

[0056] 104e,104f: a pair of sidewalls of Central Portion

[0057] 104g: Bottom wall of First Portion

[0058] 104i, 104h: a pair of sidewalls of First Portion

[0059] 1041: Bottom wall of Second Portion

[0060] 104k, 104j: a pair of sidewalls of Second Portion

[0061] 106: Load Deck

[0062] 108: Floor Member : First Mounting Member a: Flanges on the Bottom wallb: Flanges on the pair of side wallsa, 120b: Recessed portions

Claims

WE CLAIM:

1. A frame structure (100) for a vehicle, the frame structure (100) comprising: one or more long members (102) extending rearwardly in the vehicle front-rear direction; and one or more cross members (104) extending in a vehicle width direction (Wl), each of the one or more cross members (104) comprising one or more recessed portions (120a, 120b), each of the recessed portions (120a, 120b) adapted to receive and support the one or more long members (102).

2. The frame structure (100) as claimed in claim 1, wherein the frame structure (100) comprises a load deck (106) mounted on the one or more long members (102) and the one or more cross members (104).

3. The frame structure (100) as claimed in claim 1, wherein the load deck (106) comprises a floor member (108) disposed on the one or more long members (102) and the one or more cross members (104).

4. The frame structure (100) as claimed in claim 3, wherein the floor member (108) being welded to at least one of the one or more long members (102) and the one or more cross members (104).

5. The frame structure (100) as claimed in claim 1, wherein the one or more cross members (104) being coupled to the one or more long members (102).

6. The frame structure (100) as claimed in claim 1, wherein the one or more cross members (104) being welded to the one or more long members (102).

7. The frame structure (100) as claimed in claim 1, wherein at least one of the cross members (104) comprises a first portion (104a), a central portion (104b) and a second portion (104c), wherein the first portion (104a) and the second portion (104c) being disposed adjacent to ends of the central portion (104b).

8. The frame structure (100) as claimed in claim 4, wherein each of the first portion (104a), the central portion (104b), the second portion (104c) comprises a bottom wall ( 104g, 104d, 1041), a pair of sidewalls (104h,104i,104e, 104f, 104j, 104k) extending from both opposite side edges of the bottom wall (104d), one or more flanges (112a, 112b) extended from ends of the bottom wall (104d) and ends of the pair of sidewalls (104h, 104i, 104e, 104f, 104j, 104k), and wherein the one or more flanges (112a, 112b) being adapted to be in contact with the one or more long members (102).

9. The frame structure (100) as claimed in claim 4, wherein the first portion (104a) and the second portion (104c) are provided with a tapered profile.

10. The frame structure (100) as claimed in claim 1, wherein a top surface of each of the one or more cross members (104) being arranged in a same plane of a top surface of the one or more long members (102).

11. The frame structure (100) as claimed in claim 1, wherein the one or more long members (102) comprises a first long member (102a) and a second long member (102b), the first long member (102a) being spaced apart from the second long member (102b), wherein a central portion (104b) of each of the one or more cross members (104) being attached to the first long member (102a) and the second long member (102b) in the vehicle width direction (Wl), a first portion (104a) of the cross member (104) being attached to the first long member (102a), and a secondportion (104c) of the cross member (104) being attached to the second long member (102b).

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