Off-Road Vehicle Frame and Door Sealing for Load and Noise Control

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Solution Overview

Problem

Off-road vehicles face challenges in transferring loads efficiently, protecting frame components from damage, managing fluid lines, reducing noise from the powertrain, and ensuring effective sealing and locking of vehicle components.

Innovation Solution

The vehicle frame is designed with specific configurations that include a lower frame portion, front and rear ground engaging members, a powertrain, and a seating area, incorporating features like a routing tray for fluid lines, passive duct acoustical attenuation devices, and sealed doors with angled seals and independent actuating mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the frame is designed with multiple frame members and braces to transfer loads, then the frame strength and load transfer capability are improved, but the device complexity increases

Engineering Contradiction:

Improveframe strengthVSAvoidframe complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The frame is divided into multiple discrete members including front frame portions, longitudinally-extending frame members, laterally-extending frame members, and braces. Each segment is optimized for specific load paths, allowing the complex loading environment to be managed through modular structural elements that can be independently designed and manufactured.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple frame members and braces are combined into an integrated lower frame assembly where load paths are continuously transferred through welded or rigidly connected joints. The merging of these components creates a unified structural system that distributes forces efficiently across the entire frame while maintaining manageable complexity through standardized connection methods.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If fluid lines are routed across the vehicle, then the vehicle functionality is improved, but the lines may interfere with other portions of the vehicle

Engineering Contradiction:

Improvevehicle functionalityVSAvoidinterference with vehicle components

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Fluid lines are extracted from the general vehicle space and routed through dedicated pathways such as along frame members or through designated channels. This separation removes the harmful interference potential by confining fluid lines to specific locations where they cannot contact moving parts or other sensitive components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Protective coverings or routing trays act as intermediary elements between fluid lines and other vehicle components. These intermediaries prevent direct contact and potential interference while allowing the fluid lines to maintain their routing across the vehicle for functional purposes.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If the powertrain produces significant noise, then the power output is maintained, but the rider's experience is degraded

Engineering Contradiction:

Improvepower outputVSAvoidnoise

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The frame structure and body panels are configured to channel and redirect noise away from the operator area. Structural elements that would normally just support powertrain components are also designed to act as acoustic barriers, converting the powertrain housing into a noise management feature that protects riders while maintaining full power output capability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Object-affected harmful factors

If doors are added to seal the operator area, then protection from noise and debris is improved, but the sealing and locking mechanism complexity increases

Engineering Contradiction:

Improveprotection from noise and debrisVSAvoidsealing and locking mechanism complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Sealing features are applied locally at critical interfaces where doors meet the frame, rather than requiring complete sealing systems across entire door surfaces. Gaskets or seal strips are positioned specifically at gaps and joints, providing adequate protection from noise and debris while minimizing the complexity of the sealing mechanism.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Door seals and locking mechanisms are pre-configured in the door and frame structures during manufacturing. Seal channels, compression surfaces, and locking receptacles are built into the basic door and frame components, so that the actual sealing and locking actions require minimal additional complexity when the doors are operated.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12479508B2Off-road vehicle

Publication Date: 2025.11.25 POLARIS IND INC

AI summary

A vehicle shown herein is a side by side utility vehicle having frame configured to effectively transfer various loads throughout the frame as whole. The vehicle may further or alternatively include a routing tray configured to retain various fluid lines of the vehicle, a transmission including a passive duct acoustical attenuation device, a door seal configured to allow the frame to contact the seal at an angle, a modular door actuating mechanism, and/or a modular skid plate.