Chassis frame module and method of use for same

• US 20040069556A1
• Filed: 10/15/2002
• Published: 04/15/2004
• Est. Priority Date: 10/15/2002
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (Motors Liquidation Co. GUC Trust)
• Inventors: Chernoff, Adrian B., White, Tommy E.
• Granted Patent: US 6,935,658 B2
• Time in Patent Office: Days
• US Class Current: 180/311
• CPC Class Codes: B60G 2206/011 Modular constructions
• CPC Class Codes: B60G 2206/0114 Independent suspensions on subframes
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: B62D 21/05 pinched frame type, i.e. formed of at least two longitudinal frame sections connected by other longitudinal frame sections of lesser transverse dimension
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A structural frame for a vehicle chassis includes transversely-oriented unitary structural members interconnecting at least three longitudinally-oriented elongated members. The use of unitary structural members and elongated members provides flexibility in assembling structural frames of differing configurations. Correspondingly, a method of assembling structural frames having transversely-oriented unitary structural members interconnecting at least three longitudinally-oriented elongated members is provided.

Claims

1. A component for a chassis structural frame having at least three longitudinally-oriented elongated members, at least one of the elongated members being vertically spaced from the other elongated members, the component comprising:

a unitary structural member configured to extend transversely and vertically between the at least three longitudinally-oriented elongated members, and configured to attach to, and thereby interconnect, the at least three longitudinally-oriented members.

2. The component of claim 1, wherein the unitary structural member includes at least three cavities configured to at least partially locate the at least three longitudinally-oriented elongated members for attachment to the unitary structural member.

3. The component of claim 1, wherein the unitary structural member includes an upper cross-member section portion, a lower cross member portion, and two vertically-oriented portions, the two vertically-oriented portions connecting the upper cross member portion and the lower cross-member portion, and wherein the upper cross member portion, the lower cross member portion, and the two vertically-oriented portions define an open space.

4. The component of claim 1, wherein the chassis structural frame has at least four longitudinally-oriented elongated members, and wherein the unitary structural member has at least four cavities configured to at least partially locate the at least four longitudinally-oriented members for attachment to the unitary structural member.

5. The component of claim 1, wherein a suspension system is mounted with respect to the structural frame, at least three wheels are mounted with respect to the structural frame, a steering system is mounted with respect to the structural frame and operably connected to at least one wheel, a braking system is mounted with respect to the structural frame and operably connected to at least one wheel, an energy conversion system is mounted with respect to the structural frame and operably connected to at least one wheel, and at least one load-bearing body-retention coupling is mounted with respect to the structural frame and engageable with a complementary coupling on a vehicle body;

and wherein the steering system, braking system, and energy conversion system are responsive to non-mechanical control signals.

6. A vehicle chassis comprising:

a structural frame having

at least three longitudinally-oriented elongated members, at least one of said elongated members being vertically spaced from the other elongated members; and

a unitary structural member extending transversely and vertically between the at least three longitudinally-oriented elongated members, and attached to, and thereby interconnecting, the at least three longitudinally-oriented members.

7. The vehicle chassis of claim 6, wherein the unitary structural member includes at least three cavities configured to at least partially locate the at least three longitudinally-oriented elongated members for attachment to the unitary structural member.

8. The vehicle chassis of claim 6, wherein the unitary structural member defines an open space.

9. The vehicle chassis of claim 6, further comprising at least four elongated members, and wherein the unitary structural member is attached to, and thereby interconnects, the at least four longitudinally-oriented elongated members.

10. The vehicle chassis of claim 9, further comprising:

a body attachment interface having body connection components including at least one load-bearing body-retention coupling mounted with respect to the structural frame;

a suspension system;

at least three wheels rotatably mounted with respect to the suspension system;

a braking system;

a steering system;

an energy conversion system; and

an energy storage system operably connected to the energy conversion system;

wherein the braking system, steering system, and energy conversion system are each operably connected to at least one wheel and configured to respond to non-mechanical control signals.

11. The vehicle chassis of claim 10, wherein the body connection components further include at least one control signal receiver connector mounted with respect to the structural frame and configured to convey control signals in non-mechanical form;

and wherein each of the steering system, braking system, and energy conversion system are operably connected to a control signal receiver connector.

12. The vehicle chassis of claim 11, wherein the body connection components are in a predetermined spatial relationship with one another, and sufficiently positioned, arranged, and unobstructed such that when a vehicle body having complementary components in the same predetermined spatial relationship as the body connection components is sufficiently positioned relative to the body attachment interface, each of the body connection components is adjacent to a complementary component.

13. The vehicle chassis of claim 11, wherein the structural frame includes at least eight elongated members, and wherein the unitary structural member is attached to, and thereby interconnects, the at least eight longitudinally-oriented elongated members.

14. A method of assembling chassis structural frames, the method comprising:

maintaining a first inventory of elongated members of various lengths and a second inventory of unitary structural members configured to at least partially define a structural frame with at least three of the elongated members;

assembling a first vehicle chassis structural frame having a first configuration and including

a first selection having a first quantity of at least three elongated members selected from the first inventory and oriented generally longitudinally, at least one of the elongated members of the first selection being vertically spaced from the other elongated members of the first selection, and at least one of the elongated members of the first selection being transversely spaced from the other elongated members of the first selection, and

a first set of at least two unitary structural members selected from the second inventory, the least two unitary structural members of the first set being oriented transversely, spaced a first distance apart, and attached to the first selection of elongated members to further define the first structural frame; and

assembling a second vehicle chassis structural frame having a second configuration and including

a second selection having a second quantity of at least three elongated members selected from the first inventory and oriented longitudinally, at least one of the elongated members of the second selection being vertically spaced from the other elongated members of the second selection, and at least one of the elongated members of the second selection being transversely spaced from the other elongated members of the second selection, and

a second set of at least two unitary structural members selected from the second inventory, the at least two unitary structural members of the second set being oriented transversely, spaced a second distance apart, and attached to the second selection of elongated members to further define the second structural frame; and

wherein the elongated members of the second selection are sufficiently differently dimensioned from the elongated members of the first selection, or the first quantity of elongated members differs from the second quantity of elongated members, such that the second configuration is differently-dimensioned from the first configuration.

15. The method of claim 14, wherein the second distance is different from the first distance.

16. The method of claim 14, wherein the quantity of unitary structural members in the first set is different from the quantity of unitary structural members in the second set.

17. The method of claim 14, wherein at least one of the unitary structural members includes at least three cavities configured to at least partially locate the at least three longitudinally-oriented elongated members for attachment to the unitary structural member.

18. The method of claim 14, wherein at least one of the unitary structural members defines an open space.

19. The method of claim 14, wherein the first set of elongated members and the second set of elongated members each include at least four elongated members, and wherein at least one of the unitary structural members in each of the first set of unitary structural members and the second set of elongated structural members includes at least four cavities configured to at least partially locate the at least four elongated members.

20. The method of claim 14, wherein the first set of elongated members and the second set of elongated members each include at least eight elongated members, and wherein at least one of the unitary structural members in each of the first set of unitary structural members and the second set of elongated structural members includes at least eight cavities configured to at least partially locate the at least eight elongated members.

21. A method comprising:

providing a first vehicle chassis structural frame having a first configuration and including

a first selection having a first quantity of at least three longitudinally-oriented elongated members, one of the longitudinally oriented members of the first selection being vertically spaced from the other elongated members of the first selection, and one of the elongated members of the first selection being transversely spaced from the other elongated members of the first selection, and

a first set of at least two unitary structural members oriented transversely and attached to the first selection of at least three longitudinally-oriented elongated members; and

providing a second vehicle chassis structural frame having a second configuration and including

a second selection having a second quantity of at least three longitudinally-oriented elongated members, one of the longitudinally oriented members of the second selection being vertically spaced from the other elongated members of the second selection, and one of the elongated members of the second selection being transversely spaced from the other elongated members of the second selection, and

a second set of at least two unitary structural members oriented transversely and attached to the second selection of at least three longitudinally-oriented elongated members;

wherein the elongated members of the second selection are sufficiently differently dimensioned from the elongated members of the first selection, or the first quantity of elongated members differs from the second quantity of elongated members, such that the second configuration is differently-dimensioned from the first configuration.

22. The method of claim 21, further comprising operably attaching a first steering system, a first energy conversion system, a first braking system, and a first load-bearing body-retention coupling with respect to the first structural frame;

and attaching a second steering system, a second energy conversion system, a second braking system, and a second load-bearing body-retention coupling with respect to the second structural frame;

wherein the first steering system, the first braking system, the first energy conversion system, the second steering system, the second braking system, and the second energy conversion system are each responsive to non-mechanical control signals.

23. The method of claim 22, wherein the first energy conversion system and the second energy conversion system each include a fuel cell.

24. A vehicle chassis comprising:

a structural frame having

four elongated members positioned longitudinally; and

at least two unitary structural members, each of the at least two unitary structural members having an upper cross-member portion and a lower cross-member portion, the upper and lower cross member portions connected by two vertically-oriented portions spaced a distance apart, the upper-cross member portion, lower cross member portion, and two vertically-oriented portions defining an open space configured to contain vehicle chassis hardware, and each of the at least two unitary structural members formed to have at least four cavities configured to at least partially retain the four elongated members in a rectangular arrangement relative to one another;

a body attachment interface having body connection components including at least one load-bearing body-retention coupling mounted with respect to the structural frame, and at least one control signal receiver connector configured to convey control signals in non-mechanical form;

a suspension system;

at least three wheels rotatably mounted with respect to the suspension system;

a braking system;

a steering system;

an energy conversion system; and

an energy storage system operably connected to the energy conversion system;

wherein the braking system, steering system, and energy conversion system are operably connected to at least one wheel, each operably connected to a control signal receiver connector, and each configured to respond to non-mechanical control signals.