US-12618531-B2 - Air tank integrated front box structure

US12618531B2US 12618531 B2US12618531 B2US 12618531B2US-12618531-B2

Abstract

Embodiments herein relate to a front box structure for use on an at least partially electrically powered vehicle. The front box utilizes a first pair of air tank mounting brackets and a second pair of air tank mounting brackets as part of a middle structural layer. Each pair of air tank mounting brackets supports an air tank, as well as other structural components of the front box assembly. The middle structural may also include a first brace and a second brace extending between and coupled to the first and second pairs of air tank mounting brackets. The first pair of air tank mounting brackets are adapted to be coupled to a first air tank, and the second pair of air tank mounting brackets are adapted to be coupled to a second air tank that form a part of the middle structural layer.

Inventors

Trevor Takaro
Rajashekar Kalarasaiah
Tejas Amashi
Sushmitha Mallappa Somashekar

Assignees

DAIMLER TRUCK NORTH AMERICA, LLC

Dates

Publication Date: 20260505
Application Date: 20221222

Claims (16)

1 . A front box structure for use on an at least partially electrically powered vehicle, the front box structure comprising: at least a middle structural layer, the middle structural layer comprising: a first air tank mounting bracket and a second air tank mounting bracket forming a first pair of air tank mounting brackets; a third air tank mounting bracket and a fourth air tank mounting bracket forming a second pair of air tank mounting brackets spaced from the first pair of air tank mounting brackets; a first brace extending between and coupled to the first air tank mounting bracket and the third air tank mounting bracket; a second brace extending between and coupled to the second air tank mounting bracket and the fourth air tank mounting bracket, a first support extending upwardly from the first air tank mounting bracket; a second support extending upwardly from the second air tank mounting bracket; and a top layer, wherein at least a first portion of the top layer is supported by the first support and the second support; wherein the first pair of air tank mounting brackets are adapted to be coupled to a first air tank, and the second pair of air tank mounting brackets are adapted to be coupled to a second air tank.
2 . The front box structure of claim 1 , wherein the vehicle has a longitudinal vehicle axis extending from a front of the vehicle to a back of the vehicle, and wherein the first pair of air tank mounting brackets are aligned with a first air tank axis orthogonal to the longitudinal vehicle axis.
3 . The front box structure of claim 2 , wherein the second pair of air tank brackets are aligned with a second air tank axis orthogonal to the longitudinal vehicle axis and parallel to the first air tank axis.
4 . The front box structure of claim 1 , further comprising a lower layer below the middle structural layer and supported by the middle structural layer.
5 . The front box structure of claim 1 , further comprising: a first plurality of tray brackets extending from the first pair of air tank mounting brackets and the second pair of air tank mounting brackets; and at least one tray coupled to the first plurality of tray brackets, wherein the at least one tray supports components of the vehicle.
6 . The front box structure of claim 5 , further comprising a second plurality of tray brackets extending from the first brace and the second brace, wherein the at least one tray is coupled to the second plurality of tray brackets.
7 . The front box structure of claim 1 , further comprising at least a third support extending from the first brace and a fourth support extending from the second brace, wherein the third support and the fourth support are coupled to at least a second portion of the top layer.
8 . A front box structure on an at least partially electrically powered vehicle, the front box structure comprising: a first air tank mounting bracket and a second air tank mounting bracket forming a first pair of air tank mounting brackets; a first air tank coupled to and between the first pair of air tank mounting brackets; a third air tank mounting bracket and a fourth air tank mounting bracket forming a second pair of air tank mounting brackets spaced from the first pair of air tank mounting brackets; a second air tank coupled to and between the second pair of air tank mounting brackets; a first brace extending between and coupled to the first air tank mounting bracket and the third air tank mounting bracket; and a second brace extending between and coupled to the second air tank mounting bracket and the fourth air tank mounting bracket; wherein each of the first pair of air tank mounting brackets has at least one tray bracket coupled thereto, and extending downwardly therefrom, wherein the front box structure further comprises a first lower tray coupled to the at least one tray bracket extending from the first pair of air tank mounting brackets.
9 . The front box structure of claim 8 , wherein each of the second pair of air tank mounting brackets has at least one tray bracket coupled thereto, and extending downwardly therefrom, wherein the front box structure further comprises a second lower tray coupled to the at least one tray bracket extending from the second pair of air tank mounting brackets.
10 . The front box structure of claim 9 , further comprising at least one tray bracket coupled to and extending downwardly from each of the first brace and the second brace, wherein at least one of the first lower tray and the second lower tray are further coupled to and supported by the at least one tray bracket coupled to the first brace and the second brace.
11 . The front box structure of claim 8 , wherein each of the second pair of air tank mounting brackets includes a lifting bracket extending upwardly therefrom.
12 . The front box structure of claim 8 , further comprising a front cross member coupled to, and extending between, the first pair of air tank mounting brackets, the front cross member having a flange extending below and forwardly of the first pair of air tank mounting brackets.
13 . A support structure for a front box of an at least partially electric vehicle, comprising: a first pair of axially aligned air tank mounting brackets; a second pair of axially aligned air tank mounting brackets; a pair of elongated braces coupled to and extending between the first pair of air tank mounting brackets and the second pair of air tank mounting brackets; a first plurality of supports extending upwardly from the first pair of air tank mounting brackets; a second plurality of supports extending upwardly from the pair of elongated braces, wherein at least a portion of a top layer is coupled to the second plurality of supports; and the top layer coupled to the first plurality of supports and extending above the first pair of air tank mounting brackets.
14 . The support structure of claim 13 , further comprising: a first air tank coupled to and extending between the first pair of air tank mounting brackets; and a second air tank coupled to and extending between the second pair of air tank mounting brackets; wherein the first air tank and the second air tank form a portion of a structural member.
15 . The support structure of claim 13 , further comprising a side casting extending outwardly from each of the second pair of air tank mounting brackets in a direction aligned with an axis of the second pair of air tank mounting brackets.
16 . The support structure of claim 13 , further comprising a lower layer extending below the first pair of air tank mounting brackets and the second pair of air tank mounting brackets, the lower layer being coupled to and supported by at least one of the first pair of air tank mounting brackets and the second pair of air tank mounting brackets.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63/293,895 (filed Dec. 27, 2021), entitled Air Tank Integrated Front Box Structure, which is incorporated herein by reference in its entirety. TECHNICAL FIELD Aspects herein relate to a front box structure for an electric vehicle. BACKGROUND Traditional vehicles, such as semi-trucks, have an internal combustion engine that is generally located at the front of the vehicle. An electric vehicle typically has one or more electric motors that receive power from a battery assembly. The battery assembly and electric motors are supplemented with other necessary components, such as a radiator, other cooling components such as cooling pumps and surge tanks, heating components and air compressor(s) among other things. These components require space, and may be housed in the space typically occupied by the internal combustion engine of traditional vehicles. There is a need to house the components within a front box of an electric vehicle in a way that efficiently utilizes space, allows for easy installation and that is structurally sound. BRIEF DESCRIPTION OF THE DRAWINGS Examples of aspects herein are described in detail below with reference to the attached drawings figures, wherein: FIG. 1 illustrates a front perspective view of a middle layer of a front box structure in accordance with aspects herein; FIG. 2 illustrates a perspective view of a bottom layer added to the middle layer of FIG. 1, in accordance with embodiments herein; FIG. 3 illustrates a perspective view of the structure of FIG. 2, and adding an air compressor in a top layer, in accordance with embodiments herein; FIG. 4 illustrates a perspective view similar to FIG. 3, but adding additional components in the top layer, in accordance with embodiments herein; FIG. 5 illustrates a perspective view showing the radiator assembly added to the structure of FIG. 4, in accordance with embodiments herein; and FIG. 6 illustrates a perspective view of the structure of FIG. 5 added to a frame of an electric vehicle, in accordance with embodiments herein. DETAILED DESCRIPTION The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” might be used herein to identify different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated. At a high level, aspects of the present invention relate to a front box structure for use on an at least partially electrically powered vehicle. The front box utilizes a first pair of air tank mounting brackets and a second pair of air tank mounting brackets as part of a middle structural layer. The first pair of air tank mounting brackets are spaced from, and coupled to, the second pair of air tank mounting brackets by a pair of elongated braces. Each pair of tank mounting brackets support an air tank. In other embodiments, the front box structure comprises at least a middle structural layer. The middle structural layer comprises a first air tank mounting bracket and a second air tank mounting bracket forming a first pair of air tank mounting brackets; and a third air tank mounting bracket and a fourth air tank mounting bracket forming a second pair of air tank mounting brackets spaced from the first pair of air tank mounting brackets. The middle structural layer further comprises a first brace extending between and coupled to the first air tank mounting bracket and the third air tank mounting bracket; and a second brace extending between and coupled to the second air tank mounting bracket and the fourth air tank mounting bracket. The first pair of air tank mounting brackets are adapted to be coupled to a first air tank, and the second pair of air tank mounting brackets are adapted to be coupled to a second air tank. In some embodiments, the vehicle has a longitudinal vehicle axis extending from the front of the vehicle to the back of the vehicle, and the first pair of air tank mounting brackets are aligned with a first air tank axis that is orthogonal to the longitudinal vehicle axis. In some embodiments, the second pair of air tank mounting brackets are aligned with a second air tank axis that is also orthogonal to the longitudinal vehicle axis and that is parallel to the first air tank axis. In some embodiments, the front box structure also comprises a lower layer below the middle structural layer and