Note: Descriptions are shown in the official language in which they were submitted.
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FRAME ASSEMBLY FOR A VEHICLE
CROSS-REFERENCE
[0001] For
purposes of the United States of America, the present application is a
continuation of United States Patent Application No. 14/930,273, filed
November 2, 2015
which claims priority to United States Provisional Patent Application No.
62/073,602 filed on
October 31, 2014, and United States Provisional Patent Application No.
62/109,375 filed on
January 29, 2015.
FIELD OF THE TECHNOLOGY
[0002] The
present technology relates to frame assemblies for vehicles, and assembly
methods therefor.
BACKGROUND
[0003]
Vehicle frames are constructed of interconnected frame members of various
kinds, including tubular frame members, beams, solid rods, and different kinds
of brackets. In
order to achieve the desired precision and tolerances in the assembled frame
structure, the
frame members are generally pre-assembled in jigs designed to hold the frame
members in
their respective positions while they are connected together, for example, by
welding. A
significant factor in the ultimate precision achieved in the assembled frame
is the precision
and tolerance of the various parts of the pre-assembly jig itself. Jigs used
for pre-assembly of
the frame members, especially for tubular frame members, are often complicated
and
expensive to manufacture. Pre-assembly of the tubes in the jigs is often also
quite labor-
intensive and time-consuming.
[0004] There
is therefore a desire for a frame assembly and a method of assembling a
frame assembly for a vehicle that is reliable and convenient to use, effective
for achieving
desired precision and tolerances, and suitable for use in mass production.
SUMMARY
[0005] It is
an object of the present technology to ameliorate at least some of the
inconveniences present in the prior art.
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[0006] According to one aspect of the present technology, there is
provided a frame
assembly for a vehicle including a first frame member defining a first frame
member axis.
The first frame member also defines a slot and has a first frame member
connection portion
adjacent the slot. A second frame member defines a second frame member axis.
The second
frame member has a projection and a second frame member connection portion
adjacent the
projection. The projection is received in the slot. The first frame member
connection portion
is connected to the second frame member connection portion to form a
connection region.
The second frame member axis is disposed at a non-zero angle with respect to
the first frame
member axis in the connection region.
[0007] In some implementations, each of the first and second frame members
is tubular.
[0008] In some implementations, each of the first and second frame
members is
cylindrical.
[0009] In some implementations, the projection is linear, T-shaped or L-
shaped.
[0010] In some implementations, the slot is linear, T-shaped or L-
shaped.
[0011] In some implementations, the projection is disposed at a closed end
of the slot.
[0012] In some implementations, the slot is a first slot, the projection
is a first projection,
one of the first and second members has a second slot, and the other of the
first and second
members has a second projection being received in the second slot and being
spaced from the
first projection.
[0013] In some implementations, the projection includes a plurality of
projections spaced
apart from one another.
[0014] In some implementations, the first frame member connection
portion is welded to
the second frame member connection portion.
[0015] In some implementations, each of the slot and the projection is
formed by laser-
cutting.
[0016] In some implementations, the second frame member connection
portion and the
projection are disposed at an end of the second frame member.
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[0017] In some implementations, the second frame member connection
portion is an end
surface of the second frame member and the projection extends from the end
surface in a
direction parallel to the second frame member axis.
[0018] In some implementations, a portion of the first frame member is
disposed
between a portion of the projection and the end surface.
[0019] In some implementations, the second frame member connection
portion
circumscribes the slot of the first frame member.
[0020] In some implementations, the first frame member defines an
opening extending
therethrough, the second frame member connection portion circumscribing the
opening.
[0021] In some implementations, the slot is formed continuously with the
opening.
[0022] In some implementations, the slot is a first slot, the projection
is a first projection.
The first frame member has a second slot. The second frame member has a second
projection
being received in the second slot and disposed spaced from the first
projection. The second
frame member connection portion circumscribes the opening, the first slot and
the second
slot.
[0023] In some implementations, each of the first and second slots is
formed
continuously with the opening.
[0024] In some implementations, one of the first and second frame
members defines an
opening extending therethrough. The other of the first and second frame
members extends
through the opening.
[0025] In some implementations, the second frame member defines the
opening
extending therethrough. The projection of the second frame member extends into
the
opening. The slot of the first frame member extends from an end of the first
frame member.
The first frame member extends through the opening such that the projection is
received in
the slot, and a rim of the opening is connected to the first frame member.
[0026] In some implementations, the second frame member is tubular. The
opening is a
first opening. The second frame member defines a second opening extending
therethrough,
the first and second openings being disposed on opposite sides with respect to
the second
frame member axis. The first frame member extends through the first and second
openings.
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[0027] In some implementations, the first and second openings define an
opening axis,
the opening axis being disposed generally perpendicular to the second frame
member axis.
[0028] According to another aspect of the present technology, there is
provided a method
of assembling a frame assembly. The frame assembly includes a first frame
member having a
.. first frame member axis and a second frame member having a second frame
member axis.
The method includes inserting a projection of the second frame member into a
slot of the first
frame member, and contacting a first frame member connection portion of the
first frame
member with a second frame member connection portion of the second frame
member to
form a connection region. The first and second frame members are thereby
positioned for
connection with the second frame member axis disposed at a non-zero angle with
respect to
the first frame member axis in the connection region. After positioning the
first and second
frame members for connection, the first frame member connection portion is
connected to the
second frame member connection portion.
[0029] In some implementations, when the first frame member connection
portion is
connected to the second frame member connection portion, the second frame
member
connection portion circumscribes the slot.
[0030] In some implementations, when the first frame member connection
portion is
connected to the second frame member connection portion, the second frame
member
connection portion circumscribes an opening defined through the first frame
member.
[0031] In some implementations, the opening is formed continuously with the
slot.
Inserting the projection into the slot includes placing the projection in the
opening, and
moving the projection from the opening into the slot.
[0032] In some implementations, connecting comprises welding.
[0033] In some implementations, inserting the projection into the slot
comprises
engaging the first frame member with the second frame member.
[0034] In some implementations, after inserting the projection into the
slot and before
connecting the first frame member connection portion with the second frame
member
connection portion, the projection is moved along the slot.
[0035] In some implementations, the projection is moved along the slot
until the
.. projection is disposed at an end of the slot.
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[0036] In some implementations, the slot is a first slot, and the
projection is a first
projection. One of the first and second frame members includes a second slot
and the other of
the first and second frame members includes a second projection. The method
further
incudes, inserting the second projection into the second slot after moving the
first projection
5 along the first slot and before connecting the first frame member
connection portion with the
second frame member connection portion.
[0037] In some implementations, the slot is a first slot and the
projection is a first
projection. One of the first and second frame members includes a second slot
and an other of
the first and second frame members includes a second projection. The method
further
includes, after inserting the first projection into the first slot and before
connecting the first
frame member connection portion with the second frame member connection
portion, moving
the second frame member with respect to the first frame member to align the
second
projection with the second slot. After aligning the second projection with the
second slot, the
second projection is inserted through the second slot.
[0038] In some implementations, inserting the projection of the second
frame member
into the slot of the first frame member includes moving the second frame
member with
respect to the first frame member in an insertion direction parallel to the
first frame member
axis or the second frame member axis.
[0039] Also, terms related to spatial orientation such as forward,
rearward, front, rear,
.. upper, lower, left, and right, are as they would normally be understood by
a driver of the
vehicle sitting thereon in a normal driving position with the vehicle being
upright and steered
in a straight ahead direction. Definitions of terms provided herein take
precedence over
definitions in the document incorporated herein by reference.
[0040] Implementations of the present technology have at least one of
the above-
.. mentioned object and/or aspects, but do not necessarily have all of them.
[0041] Additional and/or alternative features, aspects, and advantages of
implementations of the present technology will become apparent from the
following
description, the accompanying drawings, and the appended claims.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Further features and advantages of the present technology will
become apparent
from the following detailed description, taken in combination with the
appended drawings, in
which:
[0043] Figure 1 is a perspective view, taken from a front, right side of a
front portion of a
frame assembly of a side-by-side vehicle;
[0044] Figure 2A is a perspective view, taken from a top and front, of a
portion of the
frame assembly of Fig. 1 showing, in isolation, two frame members in an
assembled
configuration;
[0045] Figure 2B is a perspective view, taken from a left side, of the
portion of the frame
assembly of Fig. 2A with the two frame members shown in a disassembled
configuration;
[0046] Figure 2C is another perspective view, taken from a top and
front, of the frame
assembly of Fig. 2B;
[0047] Figure 2D is a perspective view, taken from a top and front, of
the portion of the
.. frame assembly of Fig. 2B, with the two frame members being disposed as in
one step of
assembly;
[0048] Figure 2E is a perspective view, taken from a top and front, of
the portion of the
frame assembly of Fig. 2B, with the first and second frame members being
disposed as in
another step of assembly after the step shown in Fig. 2D;
[0049] Figure 2F is a cross-sectional view, of the portion of the frame
assembly of Fig.
2E, taken along a line corresponding to the line 2F-2F shown in Fig. 2B;
[0050] Figure 2G is a cross-sectional view, of the portion of the frame
assembly of Fig.
2A, taken along a line corresponding to the line 2F-2F shown in Fig. 2B;
[0051] Figure 3A is a perspective view, taken from a top and front, of a
portion of the
.. frame assembly of Fig. 1 showing another implementation of one of the frame
members;
[0052] Figure 3B is a top plan view of a portion of another
implementation of a frame
member;
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[0053] Figure 3C is a top plan view of a portion of another
implementation of a frame
member;
[0054] Figure 4A is a perspective view, taken from a top and front, of
another portion of
the frame assembly of Fig. 1 showing, in isolation, two frame members in an
assembled
configuration;
[0055] Figure 4B is a perspective view, taken from a top and front, of
the portion of the
frame assembly of Fig. 4A, with the two frame members shown in a disassembled
configuration;
[0056] Figure 4C is a perspective view of one of the frame members of
the portion of the
frame assembly of Fig. 4A shown in isolation;
[0057] Figure 5A is a perspective view, taken from a top and front, of
another
implementation of the frame assembly of Fig. 4A showing, in isolation a first
frame member
thereof and a second frame member thereof in a disassembled configuration;
[0058] Figure 5B is a perspective view, taken from a top and front,
showing the frame
members of Fig. 5A in an assembled configuration;
[0059] Figure 5C is a perspective view, taken from a top and front, of
the first frame
member of Fig. 5A and another implementation of the second frame member of
Fig. 5A in a
disassembled configuration;
[0060] Figure 5D is a perspective view, taken from a top and front,
showing the frame
members of Fig. 5C in an assembled configuration;
[0061] Figure 6A is a perspective view, taken from a front and left
side, of a frame
assembly portion according to another implementation, showing a first frame
member thereof
and a second frame member thereof before assembly;
[0062] Figure 6B is a perspective view, taken from a front and left
side, of the frame
assembly portion of Fig. 6A showing the first and second frame members in an
assembled
configuration;
[0063] Figure 7A is a top plan view of a frame assembly portion
according to another
implementation, showing a first frame member thereof and a second frame member
thereof
before assembly;
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[0064] Figure 7B is a top plan view of the frame assembly portion of
Fig. 7A showing
the first and second frame members in an assembled configuration.
DETAILED DESCRIPTION
[0065] The present technology will be described below with respect to a
frame assembly
for a side-by-side vehicle (SSV) designed to accommodate two riders (driver
and passenger)
seated side-by-side in an open cockpit area. However, it is contemplated that
some aspects of
the technology could be adapted for frame assemblies of other kinds of
vehicles, such as a
single passenger off-road vehicle, two-, four- or more passenger SSVs, golf
carts, pickup
trucks, automobiles, and the like.
[0066] Figure 1 illustrates a front portion of a frame assembly 12 of an
SSV (not shown).
The SSV will not be described herein. The front frame assembly portion 12 is
configured to
support and have attached thereto, components of the SSV including but not
limited to, a roll
cage extending above a cockpit area of the SSV, a dashboard extending along
the front of the
cockpit area, a radiator, a left and a right front suspension assembly, and a
steering assembly.
Further details of the SSV, and the frame assembly 12 of the SSV, can be found
in United
States Provisional Patent Application No. 62/109,375, filed on January 29,
2015the entirety
of which is incorporated herein by reference.
[0067] The frame assembly 12 includes several interconnected frame
members including
tubular frame members and various kinds of brackets. The description is
provided herein
with respect to frame assembly portions 100, 100', 100", 100", 200, 300, 400,
500 and 600,
referred to hereinafter as frame assemblies 100, 100', 100", 100", 200, 300,
400, 500 and
600, for convenience.
[0068] The frame assembly 100 and a method of assembling the frame
assembly 100
will now be described with reference to Figs. 2A to 2G. The frame assembly 100
includes a
frame member 110 connected to another frame member 120. A frame member
connection
portion 126 (Figs. 2A and 2C) of the frame member 120 is connected to a frame
member
connection portion 116 (Fig. 2B) of the frame member 110, thereby defining the
connection
region 102 of the frame assembly 100.
[0069] With reference to Figs. 2A to 2G, the frame member 110 is tubular
and
cylindrical. The frame member 110 has a central axis 112, or a frame member
axis 112. The
frame member 110 has a rear right arrangement 190 of a first slot 130, a
second slot 132 and
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an opening 134. The rear right arrangement 190 is disposed on a rear right
side portion of the
frame member 110 when viewed from the top as in Fig. 2A. The rear right
arrangement 190
is used for the connection of the frame member 120 to the frame member 120.
Each of the
slots 130, 132 is formed continuously with the opening 134. It is contemplated
however that
one or both of the slots 130, 132 could be spaced apart from the opening 134.
The first slot
130 and the second slot 132 are both linear and extend parallel to the frame
member axis 112.
The opening 134 is generally circular as can be seen best in Fig. 5A. It is
contemplated that
the opening 134 could have a shape other than circular. The shape of the slots
130, 132 could
also be different than as shown herein. In the illustrated implementation of
the frame
assembly 100, the first and second slots 130, 132 generally have the same
dimensions and are
located on diametrically opposite sides of the opening 134. The slots 130, 132
are spaced
apart from each other in a direction parallel to the frame member axis 112. It
is contemplated
that the slots 130, 132 could be spaced from each other in a direction
disposed at an angle to
the frame member axis 112. It is also contemplated that the slots 130, 132
could be disposed
at locations that are not mutually diametrically opposite to one another with
respect to the
opening 134. The slot 130 could have a different shape and size compared to
the slot 132 as
in the implementations of Figs. 3A and 3B. The slots 130, 132 are
complementary
respectively to projection 140, 142 of the frame member 120 as will be
described below. The
opening 134 is formed in order to reduce the overall weight of the frame
member 110, and
thereby the overall frame 12. It is also contemplated that the opening 134
could be omitted as
in the implementations of Figs. 3A to 3C. It is also contemplated that one of
the slots 130,
132 could be omitted.
[0070] With reference to Fig. 2A, the frame member 110 has a rear left
arrangement 192
of two slots and one opening defined in a rear left portion of the frame
member 110 for
connection of a frame member 170 (Fig. 1) which is a mirror image of the frame
member
120. The rear left arrangement 192 is therefore formed as a mirror image of
the rear right
arrangement 190. Each of the slots 130, 132 and the opening 134 of the rear
right
arrangement 190 has a corresponding element in the rear left arrangement 192.
The
corresponding elements of the rear left arrangement 192 and the rear right
arrangement 190
have therefore been labeled with the same reference numbers. The frame member
110 also
has a front right arrangement 194 of slots and openings (not indicated)
defined in the front
right portion of the frame member 110 for connection of a frame member 180
(Fig. 1). The
frame member 110 similarly has a front left arrangement 196 of slots and
openings (not
indicated) defined in the front left portion of the frame member 110 for
connection of a fifth
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frame member 180 (Fig. 1). The front arrangements 194, 196 and the frame
members 170,
180, 182, and their connection to the frame member 110 will not be described
herein in any
further detail. Unless explicitly stated otherwise, all further references to
the slots 130, 132
and opening 134 refer to the rear right arrangement 190.
5 [0071] With reference to Figs. 2A to 2G, the frame member 120 is
tubular and
cylindrical. The frame member 120 has a central axis 122, or a frame member
axis 122. One
end 124 of the frame member 120 is disposed on the curved outer surface of the
frame
member 110 and welded thereto as will be described below. The end 124 is
therefore
configured to have a curved end surface 125 (Fig. 2B) that is congruous with
the curved outer
10 surface of the frame member 110. The end surface 125 would be planar for
connection to a
planar surface of the frame member.
[0072] As can be seen in Figs. 2A, 2E and 2G, the end surface 125 of the
frame member
120 is connected to the outer surface of the frame member 110 so as to
circumscribe the
opening 134, and slots 130, 132. In the illustrated implementation therefore,
the frame
member connection portion 126 is the curved end surface 125 of the frame
member 120. The
frame member connection portion 116 is the portion 116 (Fig. 2C) of the curved
outer surface
of the frame member 110 surrounding the slots 130, 132 and opening 134 onto
which the
curved end surface 125 is received. It is contemplated that the frame member
connection
portion 126 could be a portion of the end surface 125 and that the frame
member connection
portion 126 would not circumscribe the slots 130, 132 and the opening 134 but
would only
partially surround the slots 130, 132 and the opening 134.
[0073] In the illustrated implementation, each frame member axis 112, 122
extends in a
single continuous straight line throughout the entire length of the respective
frame member
110, 120. It is however contemplated that a portion of one or both of the
frame members 110,
120 could be curved or bent such that the respective frame member axis 112,
122 is curved or
bent along a section thereof.
[0074] In the illustrated implementation, the frame member axis 122 is
disposed at a
non-zero and non-perpendicular angle with respect to the frame member axis
112. Generally,
the frame member axis 122 is disposed at a non-zero angle with respect to the
frame member
axis 112 at least in the connection region 102 formed by the first and frame
member
connection portions 116, 126.
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[0075] The curved end surface 125 of the frame member 120 has a first
projection 140
and a second projection 142. The projections 140 and 142 are located on
diametrically
opposite sides with respect to the frame member axis 122. The first projection
140 is received
in the first slot 130 of the frame member 110. The second projection 142 is
received in the
second slot 132 of the frame member 110 as will be described below.
[0076] With reference to Figs. 2B to 2D, the first projection 140 is T-
shaped. An axial
portion 140a of the first projection 140 extends outwardly from the curved end
surface 125 in
a direction parallel to the frame member axis 122. A circumferential portion
140b of the T-
shaped projection 140 is connected to the end of the axial portion 140a spaced
from the end
surface 125. The circumferential portion 140b extends outwardly from each side
of the first
axial portion 140a in a circumferential direction of the frame member 120.
With reference to
Figs. 2F and 2G, in an assembled configuration of the frame assembly 100, the
axial portion
140a extends through the slot 130 at an end of the first slot 130 farthest
away from the
opening 134. The curved end surface 125 and the circumferential portion 140b
of the
projection 140 are disposed on opposite sides of the slot 130 so that the
cylindrical wall of the
frame member 110 adjacent to the end of the slot 130 is held between the
curved end surface
125 and the first projection circumferential portion 140b. The curvature of
the portion 140b
matches the curvature of the wall of the frame member 110 adjacent the slot
130. It is
contemplated that the first projection 140 could have a different shape than
as shown herein.
For example, the projection 140 could be linear with the circumferential
portion 140b being
omitted. The first projection could also be triangular, or L-shaped instead of
T-shaped. As
another example, the portion 140b could be in the form of a disc.
[0077] With reference to Fig. 2B, the second projection 142 is linear
and extends
outwardly from the curved end surface 125 in a direction parallel to the frame
member axis
122. With reference to Fig. 2G, in an assembled configuration of the frame
assembly 100,
the second projection 142 is positioned at an end of the second slot 132
farthest away from
the opening 134.
[0078] It is contemplated that one or both of the frame members 110, 120
could not be
cylindrical, and could have a cross-section (in a plane normal to the
respective axis 112, 122)
that is other than circular. For example, one or both of the frame members
110, 120 could
have a rectangular cross-section. It is also contemplated that one or both of
the frame
members 110, 120 could not be tubular. For example, one or both of the frame
members 110,
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120 could be in the form of a beam having a C-shaped cross-section, an I-
shaped cross-
section or the like.
[0079] The method of assembling the frame assembly 100 will now be
described with
reference to Figs 2A to 2G.
[0080] As can be seen in Figs. 2C to 2D, the frame member 120 is moved with
respect to
the frame member 110 to insert the first projection 140 of the frame member
120 into the
opening 134 of the frame member 110. As can be seen in Figs. 2E to 2F, the
frame member
120 is then moved with respect to the frame member 110 to move the axial
portion 140a of
the first projection 140 into the first slot 130. In the illustrated
implementation therefore, the
frame member 120 is moved in the direction parallel to the frame member axis
112 to insert
the first projection 140 into the first slot 130. The first projection 140 is
moved along the slot
130 (i.e. in a direction away from the opening 134) until the axial portion
140a abuts the wall
of the frame member 110 adjacent the closed end of the first slot 130 farthest
from the
opening 134 as can be seen in Fig. 2F. With the first projection 140 disposed
in the closed
end of the slot 130, the frame member 120 is lowered towards the frame member
110 so as to
insert the second projection 142 into the second slot 132 as can be seen in
Fig. 2G. The
frame member 120 may also need to be rotated with respect to the frame member
110 in
order to align the second projection 142 with the second slot 132. In the
illustrated
implementation, the slots 130, 132 are configured such that, when the first
projection 140 is
positioned at the end of the first slot 130, the second projection 142 is
aligned with the end of
the second slot 132 farthest away from the opening 134. In this
implementation, the second
projection 142 cannot be inserted into the second slot 132 until the first
projection 140 is
positioned at the end of the first slot 130.
[0081] When the projections 140, 142 are received in the respective ends
of
corresponding slots 130, 132, the frame member connection portion 126 is
disposed on the
frame member connection portion 116 so as to circumscribe the slots 130, 132
and the
opening 134. In this position, the first and frame members 110, 120 are locked
to each other.
The first and frame members 110, 120 cannot be rotated with respect to each
other when the
projections 140, 142 are received in the corresponding slots 130, 132. Since
the projections
140, 142 are received in the respective ends of corresponding slots 130, 132,
the frame
member 120 is also prevented from moving with respect to the frame member 110
in a
direction parallel to the longitudinal direction of the slots 130, 132 (and
the frame member
axis 112 in the illustrated implementation). The width of the first projection
axial portion
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140a disposed in the first slot 130 and the second projection 142 disposed in
the second slot
132 further limits movement of the frame member 120 with respect to the frame
member 110
in the lateral direction of the slot 130 (circumferential direction of the
frame member in the
illustrated implementation). When the projections 140, 142 are received in the
respective
ends of corresponding slots 130, 132, the wall of the frame member 110 is held
between the
end surface 125 and the circumferential portion 140b of the first projection
140 such that the
frame member 120 cannot be completely pulled away from the frame member 110 in
the
direction parallel to the frame member axis 122. The frame member 110 is thus
engaged
with the frame member 120.
[0082] If the first projection 140 is linear similar to the second
projection 142 however,
the frame member 110 is not engaged with the frame member 120 when both
projections 140,
142 are received in the corresponding slots 130, 132. The frame member 120 is
then not
prevented from being pulled away from the frame member 110 in a direction
parallel to the
frame member axis 122. In this case where the projections 140, 142 are both
linear, the
projections 140, 142 could be inserted into the corresponding slots 130, 132
simultaneously,
or the second projection 142 could be inserted onto the second slot 132 before
inserting the
first projection 140 into the first slot 130.
[0083] When the projections 140, 142 are received in the corresponding
slots 130, 132,
the frame members 110, 120 are held in position for connection to each other
with their
respective axes 112, 122 disposed at an angle to each other in the connection
region 102. The
frame member connection portion 116 is then welded to the frame member
connections
portion 126 with the frame members 110, 120 being held in position for
connection to each
other. It is contemplated that the frame members 110, 120 could be fixed to
each other using
fasteners, adhesives or the like, instead of being welded together. The frame
assembly 100
described above does not need the use of a jig for positioning and holding the
frame members
110, 120 in their respective positions before they are connected to each
other.
[0084] In the illustrated implementation, the weld (connection portion
116)
circumscribes the slots 130, 132 and the opening 134 such that stress risers
that may be
caused by the slots 130, 132 and opening 134 are disposed inside the weld in a
relatively
lower stress area. In addition, the weld is formed so as to circumscribe the
slots 130, 132 and
the opening 134, the weld formed is continuous without any gaps which
contributes to the
rigidity and strength of the frame assembly 100. It is contemplated that the
opening 134
could be omitted as in the implementations of Figs. 3A to 3C described below.
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[0085] Fig. 3A shows an alternate implementation 100' of the frame
assembly 100.
Corresponding and similar elements of the implementations 100, and 100', have
been labeled
herein with the same reference labels and will not be discussed again herein
in detail.
[0086] With reference to Fig. 3A, the frame member 120 of the frame
assembly 100' is
identical to the frame member 120 of the frame assembly 100. The frame member
110 of the
frame assemblies 100' is similar to the frame member 110 of the frame assembly
100 except
for the rear left arrangement 192' and rear right arrangement 190'. As in the
frame assembly
100, the rear left arrangement 192' is a mirror image of the rear right
arrangement 190' in the
frame assemblies 100'. However, the rear left arrangement 192' of each of the
frame
assemblies 100' is different from the rear left arrangement 192 of the frame
assembly 100 as
will be described below. The following discussion of Fig. 3A is being provided
with
reference to the rear left arrangement 192' since the rear right arrangement
190', being
circumscribed by the frame member 120 connected to the frame member 110,
cannot be seen
in this figure.
[0087] With reference to Fig. 3A, the opening 134 of the frame assembly 100
has been
omitted from the arrangement 192' in the frame assembly 100'. The first and
second slots
130', 132 are therefore formed as two separate spaced apart slots 130' and
132. The first slot
130' is T-shaped instead of linear. The T-shaped slot 130' has a first arm
130a and a second
arm 130b extending perpendicular thereto. In the frame assembly 100', the
first projection
circumferential portion 140b of the frame member 120 is inserted through the
arm 130b of
the T-shaped slot 130' so that the first projection axial portion 140a is
disposed in the slot
portion 130b. The first projection axial portion 140a is then moved from the
arm 130a of the
first slot 130' and into the other arm 130a of the first slot 130', thereby
disposing the
cylindrical wall of the frame member 110 between the first projection
circumferential portion
140b and the end surface 125 of the frame member 120. The first slot 130' is
configured
such that the second projection 142 is aligned with the second slot 132 when
the projection
portion 140a is disposed at the end of the slot portion 130a farthest from the
slot portion
130b. It is also contemplated that the slot 130' could be L-shaped instead of
T-shaped as in
the implementation of Fig. 3B described below.
[0088] Fig. 3B illustrates another implementation 110" of the frame member
110.
Corresponding and similar elements of the frame members 110 and 110" have been
labeled
herein with the same reference labels and will not be discussed again herein
in detail.
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[0089] With reference to Fig. 3B, the frame member 110" is not a
cylindrical tubular
member but a tubular member having a rectangular cross-section. The frame
member 110"
has an arrangement 190" similar to the rear right arrangement 190 of the frame
member 110
(Fig. 2B). The opening 134 of the frame assembly 100 has been omitted from the
5 arrangement 190" in the frame member 110". The first and second slots
130, 132 are
therefore formed as two separate spaced apart linear slots 130 and 132. The
arrangement
190" of slots 130, 132 is defined in a planar wall of the rectangular tubular
member 110".
[0090] With reference to Fig. 3B, the arrangement 190" of the frame
member 110" is
configured for connection of a cylindrical tubular frame member (not shown)
similar to the
10 frame member 120 of the frame assembly 100. The tubular cylindrical
frame member (not
shown) connected to the frame member 110" is similar to the frame member 120
(Fig 2B)
except that instead of having the curved end surface 125, the frame member
(not shown)
connected to the frame member 110" has a planar end surface that is congruous
with the
planar outer surface of the planar wall of the tubular member 110". The frame
member 110"
15 thus has a connection portion 116" that is elliptical in shape. It is
contemplated that the frame
member 110" could be any other type of frame member having at least one planar
outer
surface. It is contemplated that the frame member connected to the frame
member 110"
could be any type of frame member, including a tubular frame member having a
non-circular
cross-section, a C-shaped beam, a solid rod and the like.
[0091] With reference to Fig. 3B, the frame member 120 is positioned for
connection
with the frame member 110", by inserting the T-shaped projection 140 into the
first slot 130"
with the circumferential projection portion 140b aligned with the longitudinal
direction of the
linear first slot 130. The projection 140 is inserted into the slot 130 such
that the
circumferential portion 140b is inserted past the slot 130 and the axial
portion 140a is
disposed in the slot 130. The second projection 142 is then aligned with the
second slot 132
by rotating the frame member 120 with respect to the frame member 110", and
translating the
frame member 120 in the longitudinal direction of the first slot 130 to move
the first
projection 140 to the closed end of the first slot 130. When the frame member
120 is rotated,
the second portion 140b is disposed at an angle with respect to the
longitudinal direction of
the first slot 130, thereby engaging the frame member 110" (i.e. the wall of
the frame
member 110" is held between the first projection circumferential portion 140b
and the end
surface 125 of the frame member 120).
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[0092] Fig. 3C illustrates yet another frame member 110" similar to the
frame member
110" of Fig. 3B. Corresponding and similar elements of the frame members 100,
110" and
100" have been labeled herein with the same reference labels and will not be
discussed again
herein in detail.
[0093] With reference to Fig. 3C, the frame member 110" is a tubular member
having a
rectangular cross-section. The frame member 110" has an arrangement 190"
similar to the
arrangement 190" of the frame member 110" (Fig. 3B). The arrangement 190" has
a single
linear slot 198 with opposite end portions 130'", 132" instead of the spaced
apart slots 130
and 132 of the arrangements 190 and 190". One or both of the end portions
130'", 132"
could be marked so as to be able to distinguish therebetween.
[0094] With reference to Fig. 3C, the frame member 120" is positioned
for connection
with the frame member 110" in a similar manner as described above with respect
to the
frame assembly 100" of Fig. 3B. The T-shaped projection 140 is first inserted
through the
slot 198 with the circumferential portion 140b being aligned with the
longitudinal direction of
the slot 198. The circumferential portion 140b is inserted past the slot 198
and the axial
portion 140a is disposed in the slot 198. The frame member 120 is then rotated
with respect
to the frame member 110" and translated along the longitudinal direction of
the slot 198
such that the projection 140 is disposed in the end portion 130" and the
second projection
142 is aligned with the end portion 132". The second projection 142 is then
inserted into the
aligned slot portion 132" before welding the frame member 110" to the frame
member
120'".
[0095] With reference to Fig. 3C, the arrangement 190" of the frame
member 110" is
configured for connection of a rectangular tubular frame member (not shown)
having a planar
end surface congruous with the planar outer surface of the planar wall of the
tubular member
.. 110" and projections 140, 142 extending therefrom. The frame member 110"
thus has a
connection portion 116" that is rectangular in shape. It is contemplated that
the frame
member 110" could be any other type of frame member having at least one planar
outer
surface. It is contemplated that the frame member connected to the frame
member 110"
could be any type of frame member, including a tubular frame member having a
circular or a
non-circular cross-section, a C-shaped beam, a solid rod and the like.
[0096] Although in the illustrated implementations of Figs 2A to 3C,
both of the slots
130 and 132, 130' and 132', 130" and 132", 130" and 132'", are formed in the
frame
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member 110, 110', 110", 110", and both of the projections 140, 142 are formed
in the frame
member 120, 120", it is contemplated that each of the slots 130 and 132, 130'
and 132',
130" and 132", 130" and 132'"could be formed in any one of the members 110 and
120,
110' and 120, 110" and 120'", and the corresponding projection 140, 142 would
be formed
in the other one of the members 110 and 120, 110' and 120, 110" and 120'". It
is
contemplated that there could be more than two projections, and that each of
the projections
could be received in a corresponding slot, or a corresponding portion of a
single slot.
[0097] The slots 130, 132, the projections 140, 142 and the opening 134
described
above are created by laser-cutting the corresponding shapes into a tubular
cylindrical frame
member. Laser cutting allows for greater precision on dimensions than that
would be
achieved by stamping the corresponding structures into the tubular frame
members. The
opening 134 can be created before or after the creation of the slots 130, 132
and projections
140, 142. It is however contemplated that any one of slots 130, 132, the
projections 140, 142,
and the opening 134 could be created by other suitable methods.
[0098] With reference to Figs. 4A to 4C, the frame assembly 200 and a
method of
assembling the frame assembly 200 will now be described. The frame assembly
200 includes
a frame member 210 connected to a frame member 220 in a connection region 202.
A frame
member connection portion 218 of the frame member 210 is connected to the
frame member
connection portion 256 of the frame member 220, thereby defining the
connection region 202
of the frame assembly 200.
[0099] With reference to Fig. 4C, the frame member 210 is tubular and
cylindrical. The
frame member 210 has a central axis 212, or a frame member axis 212. A slot
230 extends
from an end 214 of the frame member 210. The slot 230 is linear and extends
parallel to the
frame member axis 212.
[00100] With reference to Fig. 4B, the frame member 220 is tubular and
cylindrical, with
a central axis 222, or a frame member axis 222. The diameter of the frame
member 220 is
greater than that of the frame member 210. The frame member 220 has two
openings 250,
252 defined in its cylindrical wall. Each of the openings 250, 252 is
configured to receive the
cylindrical frame member 210 therethrough. The respective centers of the
openings 250, 252
are disposed diametrically opposite each other with respect to the frame
member axis 222.
The openings 250, 252 define an openings axis 251 passing through the frame
member axis
222 and the respective centers of both openings 250, 252. A projection 242 of
the frame
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member extends into the opening 252. The projection 242 is formed continuously
with the
cylindrical wall of the frame member 220. The projection 242 extends radially
with respect
to the opening axis 251.
[00101] With reference to Fig. 4A, the frame member extends through the
openings 250,
252 such that the frame member axis 212 is disposed coaxially with the opening
axis 251 and
the projection 242 of the frame member 220 is received in the slot 230 of the
frame member
210. The projection 242 is disposed at the closed end of the slot 230. The
portion 218 of the
curved outer surface of the frame member 210 disposed adjacent the end of the
slot 230 abuts
the rim 256 of the opening 252 and is welded thereto. The rim 254 of the
opening 250
(shown schematically in dotted lines) is also welded to the frame member 210
at a portion
216 of the curved outer surface abutting the rim 254. The portions 216, 218 of
the frame
member 210 form the frame member connection portions. The rims 254, 256 of the
openings
250, 252 respectively of the frame member 220 form the frame member connection
portions.
[00102] In the illustrated implementation of the frame assembly 200, the
axes 212 and 251
are disposed perpendicular to the frame member axis 222 in the connection
region 202. It is
however contemplated that the axes 212, 252 could be disposed at an angle
other than
perpendicular to the frame member axis 222. In this case, the centers of the
openings 250,
252 would be disposed on opposite sides of the frame member axis 222 but not
diametrically
opposite each other with respect to the frame member axis 222.
[00103] In the illustrated implementation, the frame members 210, 220
extend generally
straight throughout the entire length. In other words, the entire length of
the respective frame
member axes 212, 222 forms a single straight line. It is however contemplated
that a portion
the frame member 220 could be curved or bent such that the frame member axis
222 is
curved or bent along a section thereof.
[00104] It is contemplated that one or both of the frame members 210, 220
could not be
cylindrical, and have a cross-section that is other than circular. For
example, one or both of
the frame members 210, 220 could have an elliptical or a rectangular cross-
section. It is also
contemplated that one or both of the frame members 210, 220 could not be
tubular. For
example, one or both of the frame members 210, 220 could be in the form of a
beam having a
C-shaped cross-section, an I-shaped cross-section or the like.
[00105] The method of assembling the frame assembly 200 will now be
described with
reference to Figs 4A to 4C.
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[00106] The end 214 of the frame member 210 is inserted through the frame
member 220
through the opening 250, and then out through the opening 252. The frame
member 210 is
thus inserted along the direction of the opening axis 251 and the frame member
axis 212.
Before the end 214 is inserted through the opening 252, the frame member 210
is rotated
about the frame member axis 212 to align the slot 230 with the projection 242.
When the
projection 242 is received in the slot 230, the frame member 210 is prevented
from rotating
about the frame member axis 212. The insertion of the frame member 210 along
the opening
axis direction is limited by the projection 242 abutting the end of the slot
230. When the
projection 242 abuts the end of the slot 230, the frame member 210 is
positioned for
connection with respect to the frame member 220. The frame member connection
portion
216 is then welded to the frame member connection portion 254, and the frame
member
connection portion 218 is welded to the frame member connection portion 256.
It is
contemplated that the frame members 210, 220 could be fixed to each other
using fasteners,
adhesives or the like, instead of being welded together. The frame assembly
200 described
above does not need the use of a jig for positioning the frame members 210,
220 before they
are connected to each other.
[00107] In the illustrated implementation, the opening 250 does not have
a projection
similar to the projection 242 of the opening 252. It is contemplated that the
slot 230 could be
longer than as shown herein, and that the end 214 of the frame member 210
could be inserted
into the frame member 220 through the opening 252 and out thereof through the
opening 250
such that the end 215 without the slot 230 is disposed near the end 250 having
the projection
242.
[00108] It is contemplated that the opening 250 could have a projection
similar to the
projection 242 of the opening 252. It is contemplated that the projections of
both openings
250, 252 could be aligned with each other in the circumferential direction
with respect to the
opening axis 251 and frame member axis 212. The circumferentially aligned
projections of
the openings 250, 252 would be received in the slot 230 which would be longer
than that
shown in Figs. 4A and 4C. It is also contemplated that the frame member 210
could have
two slots extending from the end 214 and spaced apart from each other in a
circumferential
direction of the frame member 210, with each slot receiving a corresponding
one of the
projections of a corresponding one of the openings 250, 252. The
circumferentially spaced
slots of the frame member 210 and the corresponding circumferentially spaced
projections of
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the opening 250, 252 would ensure that the frame member 210 could be inserted
through the
frame member 220 only in one direction along the axis 251.
[00109] It is contemplated that, instead of having the slot 230, the
frame member 210
could have a flat machined onto the outer cylindrical surface and at least one
of the openings
5 250, 252 would accordingly have a straight edge portion corresponding the
flat of the frame
member 210.
[00110] It is also contemplated that a projection 242 could be formed on
the frame
member 210, and that a corresponding complementary slot 230 could be formed
adjacent the
opening 250 and/or 252 in the frame member 220. For example, the projection
242 could be
10 formed extend radially outward from the outer surface of the frame
member 210.
[00111] In the illustrated implementation, the frame member 210 is a
cylindrical member
having a uniform diameter along its entire length from the end 214 to the
opposite end 215.
It is also contemplated that a portion of the frame member 210 adjacent one of
ends 214, 215
could have a smaller diameter than the portion adjacent the other of the ends
214, 215. The
15 openings 150, 152 would be configured accordingly to receive
therethrough the smaller or
larger diameter portion of the frame member 210. It will also be understood
that the frame
member 210 would then be inserted into the frame member 220 through the one of
the
openings 250 or 252 that is configured to receive therethrough the larger
diameter portion of
the frame member 210.
20 [00112] It is further contemplated that the opening 250 could be
omitted and that the
frame member 220 could have only the opening 252 having the projection 242. In
this case,
the frame member 210 would be inserted into the frame member 220 by inserting
the end 214
into the frame member 220 via the opening 252.
[00113] With reference to Figures 5A and 5B, a frame assembly 300 similar
to the frame
assembly 200, and a method of assembling the frame assembly 300, will now be
described.
[00114] The frame assembly 300 includes a first frame member 310 similar
to the frame
member 210, and a second frame member 320 similar to the frame member 220.
Features of
the frame assembly 300 that are similar to the corresponding features of the
frame assembly
200 have been labeled with the same reference numbers as in the frame assembly
200 except
that, in the place of the first digit, "2" has been replaced with "3". The
frame assembly 300
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will only be discussed in detail below with regard to differences with the
frame assembly
200.
[00115] The slot 330 has a first portion 332 extending inwardly from the
end 314 and a
second portion 334 extending inwardly from the first portion 332 in a
direction away from
the end 314. The width 336 of the first portion 332 is greater than the width
338 of the
second portion 334. The width of the slot 330 changes discontinuously between
the first
portion 332 and the second portion 334 so as to form a shoulder 340. The
presence of the two
separate portions 332, 334 allows the frame member 310 to be used with the
second frame
member 320 of the frame assembly 300 and the second frame member 420 of the
frame
assembly 400 as will be described below.
[00116] The frame members 310, 320 are assembled similarly and also
without a jig as
the frame members 210, 220 of the frame assembly 200. The projection 342 of
the second
frame member 320 is received in the narrower second portion 334 of the slot
330 so as to
abut the end of the slot 330. The portion 344 of the curved outer surface of
the frame
member 310 disposed adjacent the end of the slot 330 abuts the rim 356 of the
opening 352
and is welded thereto. The rim 354 of the opening 350 (shown schematically in
dotted lines)
is welded to the frame member 310 at a portion 348 of the curved outer surface
abutting the
rim 354. The portions 344, 348 form the frame member connection portion of the
frame
member 310 and the rims 354, 356 form the frame member connection portion of
the frame
member 320.
[00117] With reference to Figures 5C and 5D, a frame assembly 400 similar
to the frame
assembly 300, and a method of assembling the frame assembly 400, will now be
described.
The frame assembly 400 includes the first frame member 310 described above,
and a second
frame member 420 similar to the frame member 220, 320. Features of the frame
member 420
that are similar to the corresponding features of the frame member 320 have
been labeled
with the same reference numbers as in the frame assembly 300 except that, in
the place of the
first digit, "3" has been replaced with "4". The frame assembly 400 will only
be discussed in
detail below with regard to differences with the frame assembly 300.
[00118] The projection 442 of the second frame member 420 is wider (width
measured in
a circumferential direction) than the projection 342 of the frame member 320.
The width of
the projection 442 is greater than the width 338 of the second portion 334 of
the slot 330 and
smaller than the width 336 of the first portion 332.
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[00119] In the illustrated implementation, the frame members 320, 420 are
both tubular
and cylindrical and have the same diameter, but it contemplated that the frame
members 320,
420 could have different diameters, and that one or both of the members 320,
420 could not
be cylindrical and/or tubular.
[00120] The frame members 310, 420 are assembled similarly as the frame
member 310,
320 of the frame assembly 300. The projection 442 of the second frame member
420 is
received in the wider first portion 332 of the slot 330 so as to abut the
shoulder 340. Thus, in
the frame assembly 300, the end 314 of the first frame member 310 extends
further past the
rim 356 than in the frame assembly 400 with respect to the rim 456. The rim
456 of the
opening 452 abuts the portion 342 of the curved outer surface of the frame
member 310
disposed adjacent the shoulder 340 and is welded thereto. The rim 454 of the
opening 450
(shown schematically in dotted lines) is welded to the frame member 310 at a
portion 346 of
the curved outer surface abutting the rim 454. The portions 342, 346 form the
frame member
connection portion of the frame member 310 and the rims 454, 456 form the
frame member
connection portion of the frame member 420. As will be understood, the
relative positions of
the connection portions 346 and 348 could be different than as shown herein
and would
depend in general on the relative diameter of the tubular frame members 320,
420, and the
angle of insertion of the frame member 310, 410.
[00121] The slot 330 having two separate portions 332, 334 allows the
frame member 310
to be used with the second frame member 320 of the frame assembly 300 as well
as the
second frame member 420 of the frame assembly 400. Each of the second frame
members
320, 420 can of course also be used with a respective first frame member
similar to the frame
member 210 having a slot 230 that is dimensioned to accommodate the
corresponding
projection 342 or 442. However the frame member 310 having the slot 330 allows
for a
reduction of the number of different types of parts manufactured by
eliminating the need for
manufacturing two different types of frame members 210. Manufacturing a single
frame
member 310 usable with both frame members 320, 420 results in a reduction of
complexity,
time and cost in manufacture and assembly compared to the manufacture and
assembly of
two separate types of frame members 210, one usable with the frame member 320,
and the
other usable with the frame member 420.
[00122] It is contemplated that the slot 330 could have more than two
portions 332, 334.
It is also contemplated that the slot 330 could be formed to have a
progressively decreasing
width in a direction proceeding further away from the end 314. A slot 330
having more than
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two slot portions, or having a slot having a progressively decreasing width,
would enable the
frame member 310 to be usable with more than two types of frame members, each
type
having a corresponding width of projection. It is also contemplated that any
of the frame
members 310, 320, 420 could be other than tubular and/or cylindrical frame
members.
[00123] To achieve greater precision than would be obtained by stamping,
the slots 230,
330 the projections 242, 342, 442 and the openings 250, 252, 350, 352
described above are
created by laser-cutting the corresponding shapes into the tubular cylindrical
frame member.
It is however contemplated that any of these above-mentioned structures could
be created by
other suitable methods.
[00124] With reference now to Figures 6A and 6B, a frame assembly 500, and
a method
of assembling the frame assembly 500 will now be described.
[00125] The frame assembly 500 includes a frame member 510 connected to
another
frame member 520. A frame member connection portion 526 of the frame member
520 is
connected to a frame member connection portion 516 of the frame member 510,
thereby
defining the connection region 502 of the frame assembly 500.
[00126] The frame member 510 is tubular and cylindrical. The frame member
510 has
two slots 530 and a circular opening 535 for connection of the frame member
520. Each of
the slots 530 extends in a circumferential direction. The slots 530 are spaced
from each other
in an axial direction of the frame member 510, and the opening 535 is spaced
from both slots
530 in a circumferential direction. In the axial direction, the position of
the opening 535 is
centered between the two slots 530.
[00127] The frame member 520 is a U-shaped bracket having two arms 540
connected
together by a generally planar portion 542. One end 524 of the frame member
520 is disposed
on the curved outer surface of the frame member 110 and welded thereto as will
be described
below. Each of the arms 540 therefore forms a curved end surface 525 at the
end 524 that is
congruous with the curved outer surface of the frame member 510. The end
surfaces 525
would be planar for connection to a planar surface of the frame member.
[00128] As can be seen in Fig. 6B, the end surfaces 525 of the frame
member 520 extend
in a circumferential direction when disposed on the outer surface of the frame
member 510.
The left end surface 525 is connected to the frame member 510 along a
circumferentially
extending connection portion 544 adjacent the left slot 530, and the right end
surface 525 is
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connected to the frame member 510 along a circumferentially extending
connection portion
544 adjacent the right slot 530. The end portion of the inward facing surface
(surface facing
towards the arms 540) of the planar portion 542 is disposed on the outer
surface of the frame
member 510. The edge 527 of the planar portion 542 is connected to the frame
member 510
along an axially extending connection portion 544 of the frame member 510. In
the
illustrated implementation therefore, as can be seen in Fig. 6A, the frame
member connection
portion 526 of the second frame member 520 is formed by the two curved end
surfaces 525
of the arms 540 and the edge 527 of the planar portion 542. As can be seen in
Fig. 6A, the
frame member connection portion 516 of the first frame member 510 is formed by
the left
circumferentially extending portion 544, the axially extending portion 546,
and the right left
circumferentially extending portion 544.
[00129] As can be seen in Fig. 6A, each end surface 525 of the frame
member 520 has a
corresponding hook-like projection 550 (only the left projection 550 being
seen in the
Figures) that is received in a corresponding one of the slots 530 of the frame
member 510
when assembled together (as in Fig. 6B). In the illustrated implementation,
the right
projection (not shown) is similar to the left projection 550. As such, only
the left projection
550 will be described herein. The projection 550 is L-shaped. A first portion
550a of the
projection 550 extends outwardly away from the end surface 525 to a second
portion 550b,
and the second portion 550b extends away from the first portion 550a in a
direction generally
parallel to the end surface 525. The second portion 550b of the projection 550
is thus spaced
from the end surface 525. The projection 550 extends through the slot 530 such
that the first
portion 550a is disposed in the slot 530, and the curved end surface 525 and
the second
portion 550b of the projection 550 are disposed on opposite sides of the
cylindrical wall of
the frame member 510 adjacent the end of the slot 530 so as to retain
therebetween the
cylindrical wall of the frame member 510 adjacent the end of the slot 530. The
curvature of
the second portion 550b of the projection 550 matches the curvature of the
wall of the frame
member 510 adjacent the slot 530. It is contemplated that the projection 550
could have a
different shape than as shown herein. For example, the projection 550 could be
T-shaped
instead of L-shaped.
[00130] As can be seen in Fig. 6A, the planar portion 542 has a circular
opening 555 near
the edge 527. When each projection 550 is received in the corresponding slot
530, the
opening 555 is aligned with the opening 535 of the frame member 510. The frame
assembly
500 also includes a rivet 560 used to assemble the members 510, 520 as will be
described
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below. The rivet 560 is a removable blind rivet but it is contemplated that
the rivet 560 could
be any suitable rivet or other fastener.
[00131] The method of assembling the frame assembly 500 will now be
described with
reference to Figs. 6A and 6B. The frame member 520 is moved with respect to
the frame
5 member 510 to insert the projections 550 of the frame member 520 into the
corresponding
slots 530 of the frame member 510. The frame member 520 is then moved with
respect to
the frame member 510 to place the end portion of the planar portion 542 on the
curved
surface of the frame member 510. The frame members 510, 520 are now in place
for
connection to each other. A portion of the wall of the frame member 510
adjacent each slot
10 530 is held between second projection portion 555b and the end surface 525
of the
corresponding arm 540 to hold the frame members 510, 520 in place for
connection. A rivet
560 is then inserted through the aligned openings 535, 555 to lock the frame
members 510,
520 to each other. The curved end surface 525 and the edge 527 of the frame
member 520
(which form the frame member connection portion 526) are then welded to the
frame member
15 connections portions 544, 546 with the frame members 510, 520 being held
locked in
position by the rivet 560 and the projections 550 received in the slots 530.
In the illustrated
implementation, the rivet 560 is removed after the frame members 510, 520 are
welded
together but it is contemplated that the rivet 560 could be left in place
after the frame
members 510, 520 are welded to each other. It is also contemplated that a
fastener other than
20 the rivet 560 could be used to lock the frame members 510, 520 in place
for welding.
[00132] The frame assembly 500 described above does not need the use of a
jig for
positioning and holding the frame members 510, 520 in their respective
positions before they
are connected to each other. The rivet 560 secures the frame members 510, 520
together in
place for connection and thereby provides accurate alignment. In the
illustrated
25 implementation, the slots 530 are each covered by the end surfaces of
the corresponding arm
540. The weld is formed continuously along the regions 546, 544 without any
gaps along the
weld contributing to the rigidity and strength of the frame assembly 500.
[00133] With reference now to Figures 7A and 7B, a frame assembly 600,
and a method
of assembling the frame assembly 600 will now be described.
[00134] The frame assembly 600 includes a first frame member 610 connected
to another
frame member 620. A frame member connection portion 626 of the frame member
620 is
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connected to a frame member connection portion 616 of the frame member 610,
thereby
defining the connection region 602 of the frame assembly 600.
[00135] The frame member 610 is tubular and cylindrical. The frame member
610 has a
neutral axis 612. The neutral axis 612 is an axis in the body of the frame
member 610 along
which there is no stress or strain. The frame member 620 is in the form of a
generally planar
and triangular bracket. An edge 624 of the planar surface of the frame member
620 is
disposed on the curved outer surface of the frame member 610 and connected
thereto along
the neutral axis 612. The connection portion 616 of the frame member 610 is
therefore
disposed along the neutral axis 612 except in two small regions 618 as will be
described
below. The connection portion 626 of the frame member 620 is formed by the
edge 624.
[00136] As can be seen in Fig. 7A, the tubular frame member 612 has two
circular
openings 630, each opening 630 being disposed along the neutral axis 612.
[00137] The edge 624 of the frame member 620 is generally straight except
in two spaced
apart portions 640 that protrude outwardly away from the opposite edge of the
frame member
620. The frame member 620 has an opening 642 disposed just inwardly of each
edge portion
640. Each opening 642 is in alignment with the straight portion of the edge
624 (i.e. a straight
line containing the straight portions of the edge 626 would pass through the
openings 642).
The distance between the openings 642 corresponds to the distance between the
openings 630
so that the frame member 620 can be disposed on the frame member 610 such that
each
opening 642 is aligned with a corresponding one of the openings 630.
[00138] The frame members 610, 620 are assembled without a jig. For
assembling the
frame assembly 600, the frame member 620 is disposed along the tubular frame
member 610
so as to align the openings 642 with the openings 630. A first rivet 650 is
inserted through the
left one of the aligned openings 630, 642 and a second rivet 650 is inserted
through the right
one of the aligned openings 630, 642 to lock the frame members 610, 620 to
each other in
place for connection. The entirety of the edge 624 including both portions 640
is then welded
to the frame member connection portion 616.
[00139] A majority of the weld (frame member connection portion 616)
extends along the
neutral axis 612. Each portion 618 of the connection portion 616 which is
welded to a
corresponding one of the edge portions 640 is disposed outside the neutral
axis 612. The
majority of the weld is disposed along the neutral axis 612 to reduce the
amount of stress and
strain that the weld is subjected to and so that the portion of the frame
member 610 that has
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the weld formed therein, is not a portion subjected to large compression or
tension forces
during use, thereby increasing the robustness and strength of the frame
assembly 600. In
addition, the openings 630 are disposed along the neutral axis to reduce the
probability of a
fracture starting at the location of either of the openings 630. The weld
extends slightly away
from the neutral axis 612 around the openings 630 in order to be formed
continuously
without any gaps. The continuously formed weld also contributes to the
strength and
robustness of the frame assembly 600.
[00140] It is contemplated that the frame member 620 could be connected to
two (or
more) frame members such as the frame member 610. For example, the portion of
the edge
624 around one of the openings 642 could be connected to a first frame member
610, and the
portion of the edge 624 around the other opening 642 could be connected to a
second frame
member (not shown). The frame member 620 could thus be used to connect the
first frame
member 610 to the second frame member (not shown).
[00141] Modifications and improvements to the above-described
implementations of the
present technology may become apparent to those skilled in the art. The
foregoing description
is intended to be exemplary rather than limiting. The scope of the present
technology is
therefore intended to be limited solely by the scope of the appended claims.
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