Pre-engineered frame portion and method of use therefor

Abstract

A vehicle chassis includes a structural frame having a frame portion that partially defines an open space and that has a predetermined configuration such that the open space maintains a predetermined amount of spatial integrity in the event of a horizontal impact to the vehicle chassis. The frame also includes a frame component operatively connected to the frame portion that further defines the structural frame. The open space provides a protected packaging space wherein certain critical chassis components are placed. The frame portion configuration provides a pre-engineered protected area that may be used in a variety of structural frame configurations. Accordingly, a method for using pre-engineered frame portions is provided.

1 . A vehicle chassis comprising: 
 a structural frame, the structural frame including: 
 a frame portion partially defining the structural frame, defining an open space, and having a predetermined configuration such that the open space maintains a predetermined amount of spatial integrity in the event of a horizontal impact to the vehicle chassis; and  
 at least one structural frame component operatively connected to the frame portion and further defining the structural frame.  
   
     
     
         2 . The vehicle chassis of  claim 1 , further comprising: 
 at least three wheels rotatably mounted with respect to the structural frame; an energy conversion system mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; a steering system mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; a braking system mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; and an energy storage system operatively connected to the energy conversion system and mounted with respect to the structural frame;    wherein at least one of the energy conversion system, energy storage system, steering system, and braking system is at least partially located within the open space.    
     
     
         3 . The vehicle chassis of  claim 2 , wherein the frame portion is a prefabricated module.  
     
     
         4 . The vehicle chassis of  claim 3 , wherein the prefabricated module includes a plurality of segments defining the open space therebetween, and at least one augmentation segment operatively connected to at least one of the plurality of segments defining the open space; and 
 wherein the at least one structural frame component is mounted to the at least one augmentation segment.    
     
     
         5 . The vehicle chassis of  claim 3 , wherein the prefabricated module is at least partially formed by hydroforming.  
     
     
         6 . The vehicle chassis of  claim 2 , wherein the braking system and the energy conversion system are responsive to non-mechanical control signals.  
     
     
         7 . The vehicle chassis of  claim 2 , wherein the energy conversion system includes a fuel cell.  
     
     
         8 . The vehicle chassis of  claim 7 , wherein the energy storage system is configured to store hydrogen.  
     
     
         9 . A method of assembling a plurality of vehicle chassis, the method comprising: 
 assembling a first vehicle structural frame having 
 a first frame portion defining a first open space, partially defining the first vehicle structural frame, and having a predetermined configuration such that the first open space maintains a predetermined amount of spatial integrity in the event of a load exerted on the first frame portion or a vehicle component operatively connected thereto, and  
 a first selection of at least one frame component further defining the first vehicle structural frame and operatively connected to the first frame portion such that the first vehicle structural frame has a first size and a first shape; and  
   assembling a second vehicle structural frame having 
 a second frame portion substantially identical to the first frame portion, defining a second open space, partially defining the second vehicle structural frame, and having a predetermined configuration such that the second open space maintains a predetermined amount of spatial integrity in the event of a load exerted on the second frame portion or a vehicle component operatively connected thereto, and  
 a second selection of at least one frame component further defining the second vehicle structural frame and operatively connected to the second frame portion such that the second vehicle structural frame has a second size and a second shape;  
 wherein the second size is different from the first size or the second shape is different from the first shape.  
   
     
     
         10 . The method of  claim 9 , wherein the first frame portion and the second frame portion are prefabricated modules.  
     
     
         11 . The method of  claim 10 , further comprising maintaining an inventory having a plurality of substantially identical prefabricated modules that each define an open space, and wherein the first frame portion and the second frame portion are prefabricated modules taken from the inventory.  
     
     
         12 . The method of  claim 11 , wherein each of the plurality of prefabricated frame modules in the inventory includes a plurality of segments defining the open space therebetween, and at least one augmentation segment operatively connected to at least one of the plurality of segments defining the open space; and 
 wherein at least one of the first selection of frame components is mounted to the at least one augmentation segment of the first frame portion, and wherein at least one of the second selection of frame components is mounted to the at least one augmentation segment of the second frame portion.    
     
     
         13 . The method of  claim 9 , further comprising: 
 assembling a first vehicle chassis having the first vehicle structural frame, a first set of at least three wheels rotatably mounted with respect to the first vehicle structural frame, a first steering system, a first braking system, a first energy conversion system, and a first energy storage system; wherein the first steering system, first braking system, and first energy conversion system are mounted with respect to the first vehicle structural frame and operatively connected to at least one of the at least three wheels in the first set; wherein the first energy storage system is operatively connected to the first energy conversion system and mounted with respect to the first vehicle structural frame; and wherein at least a portion of at least one of the first energy conversion system, first energy storage system, first steering system, and first braking system is located within the open space of the first frame portion; and    assembling a second vehicle chassis having the second structural frame, a second set of at least three wheels rotatably mounted with respect to the second vehicle structural frame, a second steering system, a second braking system, a second energy conversion system, and a second energy storage system; wherein the second steering system, second braking system, and second energy conversion system are mounted with respect to the second vehicle structural frame and operatively connected to at least one of the at least three wheels in the second set; wherein the second energy storage system is operatively connected to the second energy conversion system and mounted with respect to the second vehicle structural frame; and wherein at least a portion of at least one of the second energy conversion system, second energy storage system, second steering system, and second braking system is located within the open space of the second frame portion.    
     
     
         14 . The method of  claim 13 , wherein the first energy conversion system and the second energy conversion system include a fuel cell.  
     
     
         15 . The method of  claim 14 , wherein the first energy storage system and the second energy storage system are configured to store hydrogen.  
     
     
         16 . The method of  claim 13 , wherein the first steering system, first braking system, first energy conversion system, second steering system, second braking system, and second energy conversion system are responsive to nonmechanical control signals.  
     
     
         17 . A method of assembling vehicle chassis, the method comprising: 
 providing a first vehicle structural frame, the first vehicle structural frame including a first frame portion and a first selection of at least one frame component operatively connected to the first frame portion such that the first vehicle structural frame has a first size and first shape, the first frame portion defining a first open space and configured such that the first open space maintains a predetermined amount of spatial integrity in the event of an impact load on the first frame portion; and    providing a second vehicle structural frame, the second vehicle structural frame including a second frame portion being substantially identical to the first frame portion and defining a second open space, and a second selection of at least one frame component operatively connected to the second frame portion such that the second vehicle structural frame has a second size and shape, the second size being different from the first size or the second shape being different from the first shape.    
     
     
         18 . The method of  claim 17 , further comprising: 
 assembling a first vehicle chassis having the first vehicle structural frame, a first set of at least three wheels rotatably mounted with respect to the first vehicle structural frame, a first steering system, a first braking system, a first energy conversion system, and a first energy storage system; wherein the first steering system, first braking system, and first energy conversion system are mounted with respect to the first vehicle structural frame and operatively connected to at least one of the at least three wheels in the first set; wherein the first energy storage system is operatively connected to the first energy conversion system and mounted with respect to the first vehicle structural frame; and wherein at least a portion of at least one of the first energy conversion system, first energy storage system, first steering system, and first braking system is located within the open space of the first frame portion; and    assembling a second vehicle chassis having the second structural frame, a second set of at least three wheels rotatably mounted with respect to the second vehicle structural frame, a second steering system, a second braking system, a second energy conversion system, and a second energy storage system; wherein the second steering system, second braking system, and second energy conversion system are mounted with respect to the second vehicle structural frame and operatively connected to at least one of the at least three wheels in the second set; wherein the second energy storage system is operatively connected to the second energy conversion system and mounted with respect to the second vehicle structural frame; and wherein at least a portion of at least one of the second energy conversion system, second energy storage system, second steering system, and second braking system is located within the open space of the second frame portion.    
     
     
         19 . The method of  claim 18 , wherein the first energy conversion system and the second energy conversion system include a fuel cell, and the first energy storage system and the second energy storage system are configured to store hydrogen.  
     
     
         20 . The method of  claim 18 , wherein the first steering system, first braking system, first energy conversion system, second steering system, second braking system, and second energy conversion system are responsive to nonmechanical control signals.  
     
     
         21 . A vehicle chassis comprising: 
 a structural frame, the structural frame including: 
 a prefabricated frame module partially defining the structural frame and defining an open space, the prefabricated frame module being configured such that the open space maintains a predetermined amount of integrity in the event of an impact to the vehicle chassis; and  
 at least one structural component rigidly mounted with respect to the prefabricated frame module and further defining the structural frame;  
   at least three wheels rotatably mounted with respect to the structural frame; a by-wire energy conversion system including a fuel cell mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; a by-wire steering system mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; a by-wire braking system mounted with respect to the structural frame and operatively connected to at least one of the at least three wheels; and an energy storage system including storage tanks configured to store compressed hydrogen gas operatively connected to the energy conversion system and mounted with respect to the structural frame;    wherein at least a portion of at least one of the energy conversion system, energy storage system, steering system, and braking system is at least partially located within the open space.