An air tube structural member for a vehicle chassis

Abstract

An air tube structural member (4) for a vehicle chassis (1) of the invention comprises a hollow body configured to store compressed air; a left half (6a) of an air tube structural member and a right half (6b) of an air tube structural member that are joined to form the hollow body; assembly region (8) for connecting the air tube structural member (4) to the side members (2); at least one air inlet hole (10a) and one air outlet hole (10b) for inlet or outlet of the air; a welding region (7) joining 10 the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member.

Description

[0001] 8343.1172

[0002] DESCRIPTION AN AIR TUBE STRUCTURAL MEMBER FOR A VEHICLE CHASSIS

[0003] Field of the Invention

[0004] The present invention generally relates to structural members between side members for vehicle chassis frames, and specifically to structural members between air tube and side members which integrate the function of compressed air storage with the chassis structural support.

[0005] Background of the Invention

[0006] Vehicle chassis frames, particularly those used in heavy-duty trucks and commercial vehicles, are designed to provide a strong and stable platform to support the vehicle's components and load. These frames typically consist of two parallel side members connected by a plurality of traverses forming a ladder-like structure. Traverses are essential for maintaining the structural integrity of the chassis by distributing loads and resisting torsional forces.

[0007] In conventional chassis designs, frames are made of steel or cast iron, usually manufactured from sheet metal, serving primarily a structural function. However, the increasing demand for fuel efficiency and load-carrying capacity has led to an increasing interest in multi-functional chassis components. European patent application no. EP3378739B1, known in the state of the art, discloses an integrated storage container and a structural component for a vehicle frame and exhibits the potential for combining structural and functional members within the chassis.

[0008] One of the challenges in the design of heavy-duty vehicles is the efficient use of limited space within the chassis. Compressed air systems, which are necessary for various vehicle functions such as air brakes and suspension systems, typically8343.1172

[0009] require separate air reservoir mounted on the chassis frame. These reservoirs occupy valuable space and add weight to the vehicle, potentially reducing its loadcarrying capacity.

[0010] Furthermore, the design of such chassis structural members to contribute to the chassis assembly process is of great importance in terms of automotive mass production processes. However, in the developed structures, the chassis member also functioning as a high-pressure reservoir can lead to sealing problems. This may pose serious safety risks for vehicle users.

[0011] It is understood that a traverse serving as a multi-functional air tube is required, which addresses one or more of the above problems.

[0012] Summary of the Invention

[0013] The objective of the invention is to provide a structural member between multifunctional side members for vehicle chassis frames, which addresses challenges of limited space utilization and component integration in heavy-duty vehicles.

[0014] The objective of the invention is to eliminate the inefficiencies associated with conventional chassis designs where the traverse and air reservoirs are separate components, thereby preventing increased weight, reduced load-carrying capacity, and manufacturing complexity.

[0015] The objective of the invention is to create a chassis component which combines the structural support function of a traverse with the air storage capacity of a compressed air reservoir, thereby increasing space efficiency, reducing the overall vehicle weight, and simplifying manufacturing and assembly processes in heavy-duty vehicle manufacturing.8343.1172

[0016] The objective of the invention is to provide a chassis member which not only reduces the overall vehicle weight but also serves as a structural member between the side members and at the same time providing a chassis structural member which allows ease of assembly thanks to the segmented structure of this structural member and solves the sealing problem in segmented structures.

[0017] Brief Description of the Drawings

[0018] A brief description of the drawings is as follows:

[0019] Figure 1 - A perspective view of a vehicle chassis according to an embodiment of the invention.

[0020] Figure 2 - A perspective view of an air tube structural member according to an embodiment of the invention.

[0021] Figure 3 - A bottom view of the air tube structural member of Figure 2.

[0022] Figure 4 - A perspective view of the right half of the air tube structural member according to an embodiment of the invention.

[0023] Figure 5 - A perspective view of the left half of the air tube structural member according to an embodiment of the invention.

[0024] Figure 6 - A cross-sectional view of the welding region between the right and left halves of the air tube structural member according to an embodiment of the invention.

[0025] The components shown in the figures are given the following reference numbers:

[0026] 1. Vehicle chassis

[0027] 2. Side members

[0028] 3. Traverse

[0029] 4. Air tube structural member

[0030] 5. Suspension V-arm

[0031] 6a. Left half of the air tube structural member8343.1172

[0032] 6b. Right half of the air tube structural member

[0033] 7. Welding region

[0034] 8. Structural member assembly region

[0035] 9. Protrusions

[0036] 10a. Air inlet hole

[0037] 10b. Air outlet hole

[0038] 11. Suspension V-arm connection region

[0039] 12a. First mechanical connection surface

[0040] 12b. Second mechanical connection surface

[0041] Detailed Description of the Invention

[0042] An air tube structural member (4) for a vehicle chassis (1) of the invention comprises a hollow body configured to store compressed air; a left half (6a) of an air tube structural member and a right half (6b) of an air tube structural member that are joined to form the hollow body; an assembly region (8) for connecting the air tube structural member (4) to the side members (2), at least one air inlet hole (10a) and one air outlet hole (10b) for inlet or outlet of the air, a welding region (7) for joining the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member.

[0043] An air tube structural member (6) of the invention ensures the structural integrity of the vehicle chassis (1) while also serving the function of storing compressed air. The hollow body safely stores compressed air, and the air is supplied to or discharged from the system through the air inlet hole (10a) and air outlet hole (10b). The left half (6a) and the right half (6b) of the air tube structural member are joined along the welding region (7) to form a sealed structure. Thanks to the assembly regions (8), the air tube structural member (4) is securely connected to the side members (2). This design combines the structural function of conventional structural members with compressed air storage capability, reducing vehicle weight, optimizing space utilization, and increasing overall vehicle efficiency.8343.1172

[0044] In an embodiment of the invention, the air tube structural member (4) comprises an assembly region (8) with a flat and curved structure. This design of the flat and curved assembly region (8) provides a more rigid and stable connection of the air tube structural member to the side members, maintaining structural integrity even under high load and vibration conditions.

[0045] In an embodiment of the invention, the air tube structural member (4) comprises a suspension V-arm connection region (11) extending from the hollow body. The integrated suspension V-arm connection region (11) enhances the multi-functional structure of the air tube structural member (4), simplifying vehicle design and accelerating the assembly process while improving the performance and reliability of the suspension system.

[0046] In an embodiment of the invention, the air tube structural member (4) comprises a left half (6a) of an air tube structural member comprising a first mechanical connection surface (12a) and a right half (6b) of an air tube structural member comprising a second mechanical connection surface (12b). The recess on the first mechanical connection surface (12a) and the protrusion on the second mechanical connection surface (12b) are designed to engage with each other and facilitate the assembly process by ensuring precise alignment of the left (6a) and right (6b) halves of the air tube structural member, while enhancing structural integrity and improving sealing performance. Conversely, these recesses and protrusions may be positioned on the right (6b) and left (6a) parts of the air tube structural member.

[0047] In an embodiment of the invention, the air tube structural member (4) comprises protrusions (9) which allow the mounting of additional components. The strategically positioned protrusions (9) allow various additional components to be mounted flexibly and modularly onto the air tube structural member (4).8343.1172

[0048] In an embodiment of the invention, the vehicle comprises an air tube structural member (4). The integration of the air tube structural member (4) into the vehicle design redefines the conventional chassis structure, reducing vehicle weight, increasing fuel efficiency, and at the same time optimizing the space required for compressed air systems.

[0049] A method for manufacturing an air tube structural member (4) for a vehicle chassis (1) of the invention comprises the steps of forming the left half (6a) of an air tube structural member (4) and the right half (6b) of an air tube structural member; joining the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member to form a hollow body configured to store compressed air; forming an air-tight sealing between the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member; and forming at least one air inlet hole (10a) and one air outlet hole (10b) in the hollow body for inlet or outlet of the air.

[0050] The method for manufacturing an air tube structural member (4) of the invention comprises a multi-step process. First, the left half (6a) and right half (6b) of the air tube structural member are manufactured separately. These halves can be formed using precision casting or advanced metal forming techniques. Air inlet holes (10a) and air outlet holes (10b) are opened at precise locations on these parts. These holes can be formed using high-precision drilling or laser cutting techniques. Then, these two halves are brought together along their specially designed joining surfaces. The joining process can be performed using welding, bonding, or mechanical connection methods. Then, they can be equipped with special connection members or valves.

[0051] The recess of the first mechanical connection surface (12a) and the protrusion of the second mechanical connection surface (12b), which engage with each other, precisely align the halves (6a, 6b) of the air tube structural member, while their square cross-section provides mechanical resistance against torsional loads and8343.1172

[0052] prevents this region from rotating. This structure enhances structural integrity through the welding process applied along the welding region (7), increases the strength of the welding region, and optimizes high-compressed air storage capacity by improving sealing.

[0053] In an embodiment of the invention, the method comprises the step of forming a series of protrusions (9) on the outer surface of at least one of the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member. The protrusions (9) on the outer surface increase the structural strength of the air tube structural member (4) while providing various connection points for mounting additional components.

[0054] Figure 1 shows a vehicle chassis (1). The vehicle chassis (1) comprises a pair of side members (2) extending over the length of the vehicle. The side members (2) are connected with a plurality of traverses (3) to form a ladder-frame structure.

[0055] An air tube structural member (4) is arranged between the side members (2) and serves both as a structural member and compressed air reservoir. The air tube structural member (4) is connected to the suspension V-arms (5) and is integrated with the traverse (3) to improve the overall strength of the vehicle chassis (1). This multifunctional design allows the air tube structural member (4) to contribute to the chassis strength while also providing storage for compressed air used in vehicle systems.

[0056] Figure 2 shows an air tube structural member (4). The air tube structural member (4) comprises a right half (6b) of an air tube structural member and a left half (6a) of an air tube structural member. The right half (6b) of an air tube structural member and the left half (6a) of an air tube structural member are joined in a welding region (9).8343.1172

[0057] The air tube structural member has a square cross-section with rounded comers which maximizes internal volume while ensuring structural integrity. With this rounded square cross-section, the air tube pressure is increased by using the area to the maximum extent. At the same time, the strength of the part is increased by creating mechanical resistance against the loads applied in the welding region. With this geometry, resistance to both bending and torsional loads is increased.

[0058] A plurality of protrusions (9) is visible along the body of the air tube structural member, which serve as mounting points for additional components. The two-piece structure of the air tube structural member maintains the required strength and functionality for its role as both a structural member and an air storage container, while allowing efficient manufacturing and assembly.

[0059] Figure 3 shows a bottom view of an air tube structural member (4). The air tube structural member comprises an assembly region (8) with extended portions at each end designed for connection to the vehicle chassis. A plurality of protrusions (9) on the surface of the air tube structural member serves as protrusions for other components to be attached.

[0060] The air tube structural member further comprises an air inlet hole (10a) and an air outlet hole (10b) positioned along the middle portion. These openings allow compressed air to enter and exit. A suspension V-arm connection region (11) extends from structure and provides a mounting point for the suspension V-arm. Thus, no additional part is required for connecting the V-arm, and the loads from the suspension are received by the air tube structural member. Thanks to rounded square cross-section of the structural member, both bending and torsional loads from the suspension are carried. The overall design of the air tube structural member (4) shows a symmetrical arrangement integrated with various mounting points and structural reinforcements.8343.1172

[0061] Figure 4 shows the right half (6b) of an air tube structural member. Figure 5 shows the left half (6 a) of an air tube structural member.

[0062] Figure 6 shows the welding region (7) and connection mechanism between the two halves of the air tube structural member (4). The connection mechanism comprises a first mechanical connection surface (12a) on one half and a corresponding second mechanical connection surface (12b) on the other half. Such properties create a mechanical locking joint when the two halves are brought together.

[0063] The air tube connection recess (12a) and the air tube connection protrusion (12b) are designed with complementary geometries which exactly match each other. When assembled, the joining region of the two halves forms a V-shaped groove. This V-shaped groove serves as preparation for welding, providing an ideal area for welding the two halves together. The combination of the mechanical locking feature and the welding groove provides a strong and secure connection between the two halves of the air tube structural member (4). This mechanical connection supports the welding region against torsional loads from the vehicle, thereby increasing the strength of the part.

Claims

8343.1172CLAIMS1. An air tube structural member (4), which serves as a structural member between the vehicle side members (2) and functions as compressed air storage thereby improving efficiency in the vehicle's package area, characterized in that c it comprises:a left half (6a) of an air tube structural member and a right half (6b) of a structural member, which incorporates an air tube feature, that are joined together to form a hollow body,an assembly region (8) for connecting the air tube structural member (4) to the side members (2),at least one air inlet hole (10a) and at least one air outlet hole (10b) for inlet or outlet of the air,a welding region (7) for joining the left half (6a) of an air tube structural member and the right half (6b) of an air tube structural member.

2. An air tube structural member (4) according to Claim 1, characterized by the assembly region (8) with a flat and curved structure.

3. An air tube structural member (4) according to any one of the preceding claims, characterized by a suspension V-arm connection region (11) extending from the hollow body.

4. An air tube structural member (4) according to any one of the preceding claims, characterized by the left half (6a) of the air tube structural member comprising a first mechanical connection surface (12a) which functions as a mechanical connection surface and the right half (6b) of the air tube structural member comprising a first mechanical connection surface (12a) which functions as a mechanical connection surface, wherein the said first and second mechanical8343.1172connection surfaces (12a, 12b) have a square cross-section geometry with rounded corners.

5. An air tube structural member (6) according to any one of the preceding claims, characterized by a left half (6a) of an air tube structural member comprising a first mechanical connection surface (12a) and a right half (6b) of an air tube structural member comprising a second mechanical connection surface (12b), and characterized in that the first mechanical connection surface (12a) comprises a recessed structure, and the second mechanical connection surface (12b) comprises a protrusion which engages with the recess.

6. An air tube structural member (4) according to Claim 5, characterized in that a V-shaped welding space is created in the said connection region by joining the recess on the first mechanical connection surface (12a) and the protrusion on the second mechanical connection surface (12b).

7. An air tube structural member (4) according to any one of the preceding claims, characterized by the protrusions (9) allowing the mounting of additional components.

8. A vehicle, comprising an air tube structural member (4) according to any one of the preceding claims.

9. A method of manufacturing an air tube structural member (6) for a vehicle chassis (1) according to any one of the preceding claims, comprising the steps of• forming a left half (6a) and a right half (6b) of an air tube structural member (6),• joining the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member to form a hollow body configured to store compressed air,8343.1172• forming an air-tight region between the left half (6a) of an air tube structural member and the right half (6b) of an air tube structural member, and• forming at least one air inlet hole (10a) and at least one air outlet hole (10b) in the hollow body for inlet or outlet of the air.

10. A method according to Claim 9, characterized by the steps ofassembling a first mechanical connection surface (12a) on the left half (6a) of the air tube structural member and a second mechanical connection surface (12b) on the right half (6b) of the air tube structural member, and welding the left half (6a) of the air tube structural member to the right half (6b) of the air tube structural member along a welding region (7).

11. A method according to Claim 9 or 10, characterized in that it comprises the step of forming a series of protrusions (9) on the outer surface of at least one of the left half (6a) of the air tube structural member and the right half (6b) of the air tube structural member.

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