A frame side member profile

Abstract

A FRAME SIDE MEMBER PROFILE The present invention discloses a frame side member profile (P) suitable for use in a frame of at least one vehicle. Said frame side member profile (P) comprises at least one side wall (1); at least one lower wall (2) located at a lower portion of a first surface of the side wall (1); at least a first upper wall (3) located at an upper portion of the first surface of the side wall (1); and at least a second upper wall (4) located at a second surface of the side wall (1).

Description

[0001] 5945 / TR

[0002] DESCRIPTION

[0003] A FRAME SIDE MEMBER PROFILE

[0004] Technical Field

[0005] The present invention relates to a frame side member profile, particularly for use in heavy commercial vehicles.

[0006] Background of the Invention

[0007] Heavy commercial vehicles such as trucks, vans, trailers, and semi-trailers are used for transporting relatively heavy loads. In these heavy commercial vehicles, the heavy loads are primarily carried through the frame, which is also referred to as the vehicle's skeleton. For this reason, said frame must be durable enough to safely carry heavy loads.

[0008] In heavy commercial vehicles, the frame typically comprises two frame side members in the form of profiles, positioned with a certain distance between them. These frame side member profiles are connected to each other by means of connecting arms, also referred to as traverses, placed at specific intervals. This structure results in a frame design with high mechanical strength.

[0009] According to the applications in the prior art, in order to achieve high mechanical strength for frame side member profiles, these profiles are made of durable materials such as steel. However, such applications not only increase production costs but also lead to a high carbon footprint for the vehicles produced. Furthermore, since materials like steel have high density, frame side member profiles made of steel contribute to the increased weight of the frame. The increased weight of the frame leads to a heavier overall weight of the heavy commercial vehicle, which in turn reduces the vehicle's operational efficiency.

[0010] To reduce the carbon footprint during the vehicle manufacturing process, lower production costs, and improve vehicle efficiency, frame side member profiles made of materials other than steel are needed. However, in order to achieve these advantages, it is also essential that the frame side member profiles have sufficient mechanical strength without increasing

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[0012] Confidential 5945 / TR their weight. Therefore, there is a need for a frame side member profile that fulfills all of these advantages and criteria.

[0013] Brief Description of the Invention

[0014] The present invention discloses a frame side member profile suitable for use in a frame of at least one vehicle. Said frame side member profile comprises at least one side wall; at least one lower wall located at a lower portion of a first surface of the side wall; at least a first upper wall located at an upper portion of the first surface of the side wall; and at least a second upper wall located on a second surface of the side wall.

[0015] In the frame side member profile according to the present invention, the side wall, lower wall, first upper wall, and second upper wall are used together. The combined use of these structures ensures high mechanical strength for the frame side member profile even when the wall thicknesses of these structures are not high. Therefore, the frame side member profile achieves a design that is both lightweight and durable.

[0016] Object of the Invention

[0017] An object of the present invention is to provide a frame side member profile suitable for use in heavy commercial vehicles.

[0018] Another object of the present invention is to provide a frame side member profile with high mechanical strength.

[0019] A further object of the present invention is to provide a lightweight frame side member profile.

[0020] Still another object of the present invention is to provide a frame side member profile that is easy to produce, cost-effective, and reduces the carbon footprint.

[0021] Description of the Drawings

[0022] 2

[0023] Confidential 5945 / TR

[0024] Exemplary embodiments of the frame side member profile according to the present invention are illustrated in the attached drawings, in which:

[0025] Figure 1 is a cross-sectional perspective view of the frame side member profile according to the invention.

[0026] Figure 2 is a front view of the frame side member profile according to the invention.

[0027] Figure 3 is a front view of an alternative embodiment of the frame side member profile according to the invention.

[0028] All the parts illustrated in figures are individually assigned a reference numeral and the corresponding terms of these numbers are listed below:

[0029] Frame side member profile (P)

[0030] Side wall (1)

[0031] Recess (1a)

[0032] Lower wall (2)

[0033] First protrusion (2a)

[0034] First upper wall (3)

[0035] Second protrusion (3a)

[0036] Second upper wall (4)

[0037] Third protrusion (4a)

[0038] Hole (5)

[0039] Description of the Invention

[0040] Heavy commercial vehicles are used for transporting relatively heavy loads, so the frame used in these vehicles must be durable. However, these frame must also be relatively lightweight to keep the vehicle's weight as low as possible. Therefore, the present invention provides a frame side member profile that has mechanical strength and relatively lightweight, particularly for use in a frame of a heavy commercial vehicle.

[0041] The frame side member profile (P) according to the present invention, as illustrated in figures 1-3, is suitable for use in a frame of a vehicle (e.g. a heavy commercial vehicle), and comprises at least one side wall (1); at least one lower wall (2) located at a lower portion

[0042] 3

[0043] Confidential 5945 / TR

[0044] (preferably, at the lowest portion) of a first surface of the side wall (1); at least a first upper wall (3) located at an upper portion (preferably, at the top) of the first surface of the side wall (1); and at least a second upper wall (4) located at an upper portion (preferably, at the top) of a second surface (which is opposite to the first surface thereof) of the side wall (1). The second upper wall (4) facilitates the attachment of components (e.g., battery, superstructure bracket, fifth wheel, etc.) or component brackets to the frame side member profile (P).

[0045] In an exemplary embodiment of the invention, said frame side member profile (P) is used in the frame of a heavy commercial vehicle such as a truck. Here, two frame side member profiles (P) are positioned such that the first surfaces of their side walls (1) face each other. In each frame side member profile (P), the side walls (1) are located to extend along a vertical axis, while said lower wall (2), first upper wall (3), and second upper wall (4) extend along the side wall (1), on a horizontal axis, as protrusions. The frame side member profiles (P) are connected to each other by traverses attached at regular intervals to the side walls (1). Thus, the obtained frame structure can be durable. The form created through the side wall (1), lower wall (2), first upper wall (3), and second upper wall (4) in the frame side member profile (P) allows for high mechanical strength to be achieved using minimal wall thickness. The resistance to bending moment of profile structures is determined based on the RBM (Resistance to Bending Moment) value. The RBM value is determined according to the range set by each manufacturer. For high-tonnage (high GVM - Gross Vehicle Mass) vehicles, the RBM value needs to be higher. Considering other loads applied to the vehicle and types of vehicles, the highest RBM value regions in the frame side member profile are reinforced regions. This RBM value is determined based on parameters such as the moment of inertia, bending axis, and material yield strength. In the frame side member profile (P) according to the present invention, the form created by the side wall (1), lower wall (2), first upper wall (3), and second upper wall (4) ensures that the RBM value of the frame side member profile (P) is as high as possible without increasing the component's wall thicknesses and lengths. Thus, the frame side member profile (P), and therefore the frame in which it is used, remains both lightweight and durable.

[0046] In a preferred embodiment of the invention, said frame side member profile (P) comprises at least one hole (5) located on the side wall (1) and / or second upper wall (4). The hole (5) can be used, for example, to allow a fastening element such as a bolt to be inserted when a traverse is attached to the frame side member profile (P). The hole (5) is also provided on

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[0048] Confidential 5945 / TR areas of the side wall (1) and / or second upper wall (4) where relatively low pressure occurs, thereby reducing the weight of the frame side member profile (P) and enabling the frame side member profile (P) to be produced using less material.

[0049] In a preferred embodiment of the invention, said frame side member profile (P) comprises an aluminum material. Here, all of the components in the frame side member profile (P), such as the side wall (1), lower wall (2), first upper wall (3), and second upper wall (4), can be produced as a single piece of aluminum. In addition to being lightweight and durable, aluminum is a relatively easy-to-shape material, and therefore it is used as the raw material for the frame side member profile (P) according to the present invention. Aluminum is also preferred because it has a lower carbon footprint compared to materials like steel. Aluminum can be used alone or in an alloy form with different metals. In embodiments where aluminum is used for the frame side member profile (P), although the yield strength may be reduced due to the material used, the moment of inertia increases at least by the same proportion. Therefore, the RBM value of the frame side member profile (P) becomes high. In other words, the RBM value of the aluminum alloy-based frame side member profile (P) with the geometry described in the invention is made to be equal to or higher than the RBM value of the frame side member profiles of the prior art that are made of steel material.

[0050] In another preferred embodiment of the invention, a width of the lower wall (2) (a distance from an end of the lower wall (2), which is farthest from the side wall (1), to the side wall (1)) is greater than or equal to a width (a distance from an end of the first upper wall (3) farthest from the side wall (1) to the side wall (1)) of the first upper wall (3). Furthermore, preferably, a width of the lower wall (2) is greater than a width of the second upper wall (4) (a distance from an end of the second upper wall (4), which is farthest from the side wall (1), to the side wall (1)). The height of the vehicle’s center of gravity from the ground is important for driving performance. A higher center of gravity from the ground increases the risk of rollover and energy consumption, so it is essential to keep the height of center of gravity from the ground as low as possible. With this design, the width of the lower wall (2) of the frame side member profile (P) being greater than the width of the upper walls (3, 4) ensures that the bending axis of the frame side member profile (P) remains at the center of the side wall (1) relative to the axis of the side wall (1) extending between the lower wall (2) and the upper walls (3, 4). This, in turn, helps keep the center of gravity of the heavy commercial vehicle with the

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[0052] Confidential 5945 / TR frame side member profile (P) closer to the ground, making the vehicle more stable and reliable.

[0053] By adjusting the width values in these embodiments, the loads applied to the frame side member profile (P) are more evenly distributed between the lower wall (2) and the first and second upper walls (3, 4).

[0054] In another preferred embodiment of the invention, a cross-sectional area of the lower wall (2) (the part of the section of the frame side member profile (P) shown in the shaded area in Figure 1 , belonging to the lower wall (2)) is greater than a cross-sectional area of the first upper wall (3) (the part of the section of the frame side member profile (P) shown in the shaded area in Figure 1 , belonging to the first upper wall (3)) and / or of the second upper wall (4) (the part of the section of the frame side member profile (P) shown in the shaded area in Figure 1 , belonging to the second upper wall (4)). Thus, while balancing the load between the lower wall (2) and the first and second upper walls (3, 4), the thicknesses of these components are maintained at an optimum value to minimize the weight of the frame side member profile (P).

[0055] In another preferred embodiment of the invention, a wall thickness (height) of the first upper wall (3) ranges between a wall thickness of the side wall (1) and twice the wall thickness of the side wall (1) (2 x wall thickness of the side wall (1) >= wall thickness of the first upper wall (3) >= wall thickness of the side wall (1)). Similarly, a wall thickness (height) of the second upper wall (4) ranges between a wall thickness of the side wall (1) and twice the wall thickness of the side wall (1) (2 x wall thickness of the side wall (1) >= wall thickness of the second upper wall (4) >= wall thickness of the side wall (1)). In this embodiment, a wall thickness of the lower wall (2) is at most twice the wall thickness of the thicker of the first and second upper walls (3, 4). In another preferred embodiment, the difference between the wall thickness of the side wall (1) and the wall thicknesses of the lower wall (2), first upper wall (3), and second upper wall (4) is at most half of the difference between the highest wall thickness among the lower wall (2), first upper wall (3), and second upper wall (4) and the wall thickness of the side wall (1).

[0056] In another preferred embodiment of the invention, the frame side member profile (P) comprises at least a first protrusion (2a) located at a portion of the lower wall (2) farther

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[0058] Confidential 5945 / TR from the side wall (1) (e.g., at the furthest end). Said first protrusion (2a) is preferably located at an upper surface of the lower wall (2) (a surface closer to the first upper wall (3)). The first protrusion (2a) enhances the mechanical strength of the lower wall (2), thereby allowing the lower wall (2) to have a thinner wall thickness when necessary. In a similar embodiment, the frame side member profile (P) comprises at least a second protrusion (3a) located at a portion of the first upper wall (3) farther from the side wall (1) (e.g., at the furthest end). Said second protrusion (3a) is preferably located at a lower surface of the first upper wall (3) (a surface closer to the lower wall (2)). In another similar embodiment, the frame side member profile (P) comprises at least a third protrusion (4a) located at a portion of the second upper wall (4) farther from the side wall (1) (e.g., at the furthest end). Said third protrusion (4a) is preferably located at a lower surface of the second upper wall (4) (a surface closer to the lower wall (2)). In a preferred embodiment, a width of the first protrusion (2a) is greater than or equal to a width of the second protrusion (3a) and / or the third protrusion (4a). In another preferred embodiment, the total cross-sectional area of the lower wall (2) and the first protrusion (2a) is equal to or greater than the total cross-sectional areas of the first upper wall (3), second upper wall (4), second protrusion (3a), and third protrusion (4a). Thus, in an embodiment where said protrusion forms are used together, wall thicknesses of the lower wall (2), first upper wall (3), and second upper wall (4) are reduced while maintaining the load balance between these components. In other words, thanks to the protrusion forms, while the weight of the frame side member profile (P) is reduced, the geometric moment of inertia is higher, ensuring that the RBM value remains unchanged.

[0059] In another preferred embodiment of the invention, a height of said side wall (1) ranges between 250-300 mm. In this embodiment, these height values enable said frame side member profile (P) to be used in a vehicle such as a truck. This allows for the production of a frame side member profile (P) with a height similar to the side walls of frame side member profiles of the prior art that are made of steel. Thus, existing systems can be mounted onto the frame side member profile (P) without reducing the package space.

[0060] In another preferred embodiment of the invention, said side wall (1) comprises at least one recess (1a). The recess (1a) is formed in areas of the side wall (1) where relatively low pressure occurs, further reducing the weight of the side wall (1). However, while the weight of the side wall (1) is reduced, the mechanical strength of the side wall (1), and consequently the frame side member profile (P), is not adversely affected.

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[0062] Confidential 5945 / TR

[0063] In another preferred embodiment of the invention, the connection region where the lower wall (2) and the side wall (1) meet is rounded. This ensures a strong connection between the lower wall (2) and the side wall (1). Similarly, the connection region where the first upper wall (3) and the side wall (1) meet, and / or the connection region where the second upper wall (4) and the side wall (1) meet, is also rounded.

[0064] The present invention also discloses a heavy commercial vehicle frame which comprises said frame side member profile (P). Said frame comprises at least two (preferably only two) frame side member profiles (P) located side by side with a gap therebetween; and at least one traverse connecting said frame side member profiles (P) to each other.

[0065] In the frame side member profile (P) according to the present invention, the side wall (1), lower wall (2), first upper wall (3), and second upper wall (4) are used together. The combined use of these structures ensures high mechanical strength for the frame side member profile (P) even when the wall thicknesses of these structures are not high. Therefore, the frame side member profile (P) achieves a design that is both lightweight and durable.

[0066] Confidential

Claims

5945 / TRCLAIMS1. A frame side member profile (P) suitable for use in a frame of at least one vehicle, characterized by comprising: at least one side wall (1); at least one lower wall (2) located at a lower portion of a first surface of the side wall (1); at least a first upper wall (3) located at an upper portion of the first surface of the side wall (1); and at least a second upper wall (4) located at a second surface of the side wall (1).

2. A frame side member profile (P) according to claim 1 , characterized in that the frame side member profile (P) comprises at least one hole (5) located on the side wall (1) and / or second upper wall (4).

3. A frame side member profile (P) according to claim 1 or 2, characterized in that the frame side member profile (P) comprises an aluminum material.

4. A frame side member profile (P) according to any of the preceding claims, characterized in that a width of the lower wall (2) is greater than or equal to a width of the first upper wall (3).

5. A frame side member profile (P) according to any of the preceding claims, characterized in that a width of the lower wall (2) is greater than a width of the second upper wall (4).

6. A frame side member profile (P) according to any of the preceding claims, characterized in that a wall thickness of the first upper wall (3) ranges between a wall thickness of the side wall (1) and twice the wall thickness of the side wall (1).

7. A frame side member profile (P) according to any of the preceding claims, characterized in that a wall thickness of the second upper wall (4) ranges between a wall thickness of the side wall (1) and twice the wall thickness of the side wall (1).9Confidential5945 / TR8. A frame side member profile (P) according to any of the preceding claims, characterized in that a wall thickness of the lower wall (2) is at most twice the wall thickness of the thicker of the first and second upper walls (3, 4).

9. A frame side member profile (P) according to any of the preceding claims, characterized in that the difference between the wall thickness of the side wall (1) and the wall thicknesses of the lower wall (2), first upper wall (3), and second upper wall (4) is at most half of the difference between the highest wall thickness among the lower wall (2), first upper wall (3), and second upper wall (4) and the wall thickness of the side wall (1).

10. A frame side member profile (P) according to any of the preceding claims, characterized in that the frame side member profile (P) comprises at least a first protrusion (2a) located at a portion of the lower wall (2) farther from the side wall (1).

11. A frame side member profile (P) according to claim 10, characterized in that the first protrusion (2a) is located at an upper surface of the lower wall (2).

12. A frame side member profile (P) according to any of the preceding claims, characterized in that the frame side member profile (P) comprises at least a second protrusion (3a) located at a portion of the first upper wall (3) farther from the side wall (1).

13. A frame side member profile (P) according to claim 12, characterized in that the second protrusion (3a) is located at a lower surface of the first upper wall (3).

14. A frame side member profile (P) according to any of the preceding claims, characterized in that the frame side member profile (P) comprises at least a third protrusion (4a) located at a portion of the second upper wall (4) farther from the side wall (1).

15. A frame side member profile (P) according to claim 14, characterized in that the third protrusion (4a) is located at a lower surface of the second upper wall (4).10Confidential5945 / TR16. A frame side member profile (P) according to claim 14 or 15, characterized in that a width of the first protrusion (2a) is greater than or equal to a width of the second protrusion (3a).

17. A frame side member profile (P) according to any of the claims 14 to 16, characterized in that a width of the first protrusion (2a) is greater than or equal to a width of the third protrusion (4a).

18. A frame side member profile (P) according to any of the claims 14 to 17, characterized in that the total cross-sectional area of the lower wall (2) and the first protrusion (2a) is equal to or greater than the total cross-sectional areas of the first upper wall (3), second upper wall (4), second protrusion (3a), and third protrusion (4a).

19. A frame side member profile (P) according to any of the preceding claims, characterized in that the frame side member profile (P) has a bending axis remaining at the center of the side wall (1) relative to the axis of the side wall (1) extending between the lower wall (2) and the upper walls (3, 4).

20. A frame side member profile (P) according to any of the preceding claims, characterized in that a height of the side wall (1) ranges between 250-300 mm.

21. A frame side member profile (P) according to any of the preceding claims, characterized in that the side wall (1) comprises at least one recess (1a).

22. A frame side member profile (P) according to any of the preceding claims, characterized in that the connection region where the lower wall (2) and the side wall (1) meet is rounded.

23. A frame side member profile (P) according to any of the preceding claims, characterized in that the connection region where the first upper wall (3) and the side wall (1) meet is rounded.11Confidential5945 / TR24. A frame side member profile (P) according to any of the preceding claims, characterized in that the connection region where the second upper wall (4) and the side wall (1) meet is rounded.

25. A heavy commercial vehicle frame which comprises a frame side member profile (P) according to any of the preceding claims.

26. A heavy commercial vehicle frame according to claim 25, characterized in that the heavy commercial vehicle frame comprises at least two frame side member profiles (P) located side by side with a gap therebetween; and at least one traverse connecting said frame side member profiles (P) to each other.12Confidential

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