Frames for all-terrain vehicles

Details Frames for all-terrain vehicles Frames for all-terrain vehicles

2001-04-04

2004-10-05

Culbreth, Eric (Department: 3616)

Land vehicles

Wheeled

Running gear

C180S311000, C280S786000, C280S787000, C280S798000

Reexamination Certificate

active

06799781

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to frames for vehicles and, more particularly, to a frame for an all terrain vehicle.
BACKGROUND OF THE INVENTION
All-terrain vehicles (ATV's) are designed to traverse relatively rough terrain. As ATV's have outboard wheels, meaning at least one wheel is spaced laterally outwardly from the frame, the frame is subjected to substantially high torsional loads, as well as bending loads (both static and dynamic in nature). As such, ATV's demand relatively high bending and torsional strengths of their frames. High strength requirements generally require a substantial measure of elasticity of the frame. However, the frame must also have a relative rigidity so as to not damage components of the ATV and maintaining good dynamic vehicle behavior. Therefore, the strength of the frame (which requires and introduces elasticity) must be balanced with the rigidity thereof.
Previous frames, sometimes referred to as “space” frames, have been constructed with sufficient strength and rigidity for ATV applications. However, to impart the necessary strength and rigidity properties and the balanced nature thereof, these frames have been either highly complex (and, as such costly to manufacture) or have used a large amount of material (also costly to manufacture and disadvantageously adding weight), or both (greatly increasing manufacturing costs).
As such, manufacturers of ATV's generally design ATV frames with a trade-off of high strength and rigidity for a relatively lower complexity/weight (cost). In other words, frames have been typically constructed to have substantially sufficient strength/rigidity properties (relatively, for ATV applications) with the lowest complexity and/or weight (cost) possible. It is possible to construct the frame with high strength metal alloys to increase strength properties of the frame without relatively increasing weight. However, of course, these metal alloys are highly costly and some require additional processing steps (such as post-weld heat treatment) in the manufacture of the frame.
It is also known to rigidly mount the engine to the frame in order to provide additional strength/rigidity properties to the frame (i.e., with the rigidity of the engine itself). However, the engine then directly transmits engine vibration to the frame, which can dramatically affect rider comfort. Steps have been taken to reduce or damp vibration of the engine, so as to improve rider comfort. However, it has proved extremely costly to substantially decrease engine vibration so that the frame is not adversely affected by the vibration of the engine. As such, it is generally accepted in the ATV art to resiliently mount the engine to the frame (such as with elastomeric bushings) so as to reduce transmission of engine vibration to the frame.
FIG. 1A
shows a conventional space frame
800
for an ATV. This type of frame
800
generally includes a network of interconnected tubular members. As shown, the frame
800
is formed of spaced paired tubular members, such as upper members
802
,
804
and lower members
806
,
808
. Additionally, the frame
800
includes multiple spaced paired cross members
810
,
812
and
814
,
816
. Further, the frame
800
utilizes laterally extending cross members
818
between respective pairs of frame members. The frame
800
may demonstrate adequate strength properties for ATV application, however, as shown, demands a complex construction to do so.
The frame
800
utilizes a relatively complex plurality of tubular members (including the cross members), namely members
802
-
818
. The frame
800
is mainly characterized in that it includes a large number of parts, for example, upwards of one hundred (100) components. The manufacturing process for producing this type of frame is relatively time consuming due to the complex layout of the members. Additionally, since there are a relatively high number of parts and welded joints, manufacturing time is further slowed. Also, there is a relatively higher statistical probability of forming a low quality weld and introducing dimensional distortions since the number of welds used to produce the frame
800
is relatively numerous. Moreover, some welds may be required to hold a relatively large number of parts in complicated shape. When the weld cools, it may shrink, thereby distorting the complicated shape.
FIG. 1B
shows another conventional space frame
850
. The frame
850
includes a spaced pair of upper tubular members
852
,
854
and a spaced pair of lower tubular members
856
,
858
. The upper and lower members
852
-
858
are interconnected by respective spaced pairs of cross members
860
,
862
and
864
,
865
. Further, similarly with the frame
800
, respective pairs of the upper and lower members
852
,
854
and
856
,
858
are connected by laterally extending cross members
866
(connecting the upper members
852
,
854
) and cross members
868
(connecting the lower members
856
,
858
).
The frame
850
has several advantages over the frame
800
. The main advantage is that the frame
850
uses only about half as many parts as the frame
800
. Because there are less parts, the number of welds and interconnections is reduced, which in turn reduces the statistical probability of failure and the introduction of distortion.
The frame
850
reduces the number of parts by use of a connecting plate
870
. The plate
870
replaces a plurality of components from the frame
800
by making the plurality of components a single integral unit. The plate
870
is connected between the lower members
856
,
858
to thereby add additional rigidity between the lower members
856
,
858
. However, the plate
870
has little if any effect on the strength of the frame
850
. Furthermore, the plate
870
allows various components of the ATV to be connected thereto. As such, additional connecting members need not be joined to the frame members and components of the ATV may be more easily joined to the frame
850
. However, one disadvantage of the frame
850
is that it requires expensive tooling, especially for the plate
870
.
Yet another conventional space frame
900
is shown in FIG.
1
C. The frame
900
similarly includes upper frame members
902
,
904
interconnected by laterally extending cross members
906
and lower members
908
,
910
, interconnected by laterally extending cross members
912
. The upper members
902
,
904
and lower members
908
,
910
are interconnected by cross members
914
.
The frame
900
includes corner brackets
916
to reduce magnitudes of stress concentrations formed between interconnected frame members, which adds weight and complexity to the frame
900
. Further, the frame
900
includes a removably attachable rear frame section
920
. As shown, the rear frame section
920
is attachable to the remainder of the frame
900
with a plurality of mechanical fasteners
922
. The use of the rear frame section
920
allows the frame
900
to be constructed in a relatively decreased manufacturing time, since the frame may be constructed separately and in smaller sections and then joined separately, thus simplifying the manufacturing process. Further, because the frame
900
is a two part frame, field service in the event of failure can be improved. However, the connection of the rear frame section
920
is made with the mechanical fasteners
922
, which may be prone to failure in harsh operating conditions.
As described above, frames for ATVs presently have sufficient relative bending and torsional strengths, however have been complex, time-consuming, and costly to manufacture. As such, there is a need in the art to provide a relatively simpler ATV frame that is easier and more cost-effective to manufacture and has the proper strength/rigidity requirements for ATV applications.
SUMMARY OF THE INVENTION
One aspect of the present invention is to provide a frame for an all-terrain vehicle.
Another aspect of the present invention is to provide a frame which does not require expensive tooling to manufacture.
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