US-20260124867-A1 - UNIBODY LOAD SUPPORT BRACKET ASSEMBLY

US20260124867A1US 20260124867 A1US20260124867 A1US 20260124867A1US-20260124867-A1

Abstract

The present invention provides a load support system for unibody vehicle frames, incorporating an upper load support bracket with a U-shaped configuration, including inner, center, and outer panels. The load support bracket enhances load distribution and structural integrity by improving conformance to the frame's contours. Mounting features align with pre-existing frame points and are longitudinally spaced from the air spring mounting location to enhance load distribution across the bracket. The upper bracket can feature asymmetrical vertical extension regions that accommodate various vehicle features and reinforce against transverse deflection. Air spring mounting features securely couple the bracket to the air spring. Overall, the load support system significantly reduces localized stress concentrations, improving vehicle stability and handling.

Inventors

Robert Bingle
Mark Symons
Lee Foster Hovey

Assignees

AIR LIFT COMPANY

Dates

Publication Date: 20260507
Application Date: 20250814

Claims (20)

1 . A load support system for installation on a unibody vehicle frame and for use with an air spring positioned between the unibody vehicle frame and a vehicle axle, the system comprising: an upper load support bracket configured to generally conform to the contour of the unibody vehicle frame, the upper load support bracket configured to couple to the air spring and distribute load forces across the unibody vehicle frame, thereby reducing localized stress concentrations; and a roll plate assembly configured to couple to a lower portion of the air spring and surround the vehicle axle.
2 . The load support system of claim 1 , wherein the upper load support bracket includes an inner panel, a center panel, and an outer panel arranged in a U-shaped configuration.
3 . The load support system of claim 2 , wherein the inner panel and outer panel each include unibody vehicle frame mounting features that align with pre-existing mounting features of the unibody vehicle frame to secure the upper load support bracket to the unibody vehicle frame.
4 . The load support system of claim 3 , wherein the unibody vehicle frame mounting features of the upper load support bracket are positioned longitudinally along the inner and outer panels, facilitating distribution of forces from the unibody vehicle frame across the upper load support bracket.
5 . The load support system of claim 3 , wherein the unibody vehicle frame mounting features on the inner and outer panels are vertically distributed to maintain alignment with the pre-existing mounting features on the unibody vehicle frame.
6 . The load support system of claim 3 , wherein the mounting features on the inner and outer panels of the upper load support bracket are shaped to conform to the pre-existing mounting features of the unibody vehicle frame.
7 . The load support system of claim 6 , wherein the mounting features of the inner and outer panels are spaced from the vicinity of the air spring mounting features to enhance load distribution across the upper load bracket.
8 . The load support system of claim 2 , wherein the inner panel and outer panel include vertical reinforcement sections adapted to reduce transverse deflection in the unibody vehicle frame during dynamic load conditions.
9 . The load support system of claim 2 , wherein the center panel of the upper load support bracket includes air spring mounting features configured for coupling the upper load support bracket to an upper portion of the air spring.
10 . The load support system of claim 9 , wherein the inner panel and center panel of the upper load support bracket include a notch configured to accommodate an air inlet for the air spring.
11 . The load support system of claim 2 , wherein the inner and outer panels include reinforcement regions extending vertically above and/or below the center panel to enhance load distribution against transverse forces or accommodate vehicle features.
12 . The load support system of claim 1 , wherein the upper load support bracket is composed of a high-strength, load-bearing material suitable for withstanding distributed load forces across the unibody vehicle frame.
13 . The load support system of claim 1 , wherein the upper load support bracket is configured to span a sufficient area of the unibody vehicle frame to enhance load distribution along the frame and improve overall vehicle stability and handling.
14 . The load support system of claim 1 , wherein the upper load support bracket is arranged to conform to the contour of the unibody vehicle frame to distribute load forces across a broader area of the frame than those directly above the vehicle axle.
15 . A load support system for installation on a unibody vehicle frame and for use with an air spring positioned between the unibody vehicle frame and a vehicle axle, the system comprising: an upper load support bracket having a U-shaped configuration that includes an inner panel, a center panel, and an outer panel, wherein: the inner and outer panels extend longitudinally along the unibody frame, incorporating mounting features that align with pre-existing mounting points to secure the upper load support bracket to the unibody vehicle frame; the center panel joins the inner and outer panels and generally follows a contoured portion of the bottom of the unibody vehicle frame, providing structural integrity to the upper load support bracket and a unified support structure; the inner and outer panels extend vertically above and/or below the center panel providing extension regions that accommodate various vehicle features; air spring mounting features located on the center panel are configured to securely couple the upper load support bracket to an upper portion of the air spring; whereby the upper load support bracket distributes load forces across the unibody vehicle frame reducing localized stress concentrations and improving overall vehicle stability and handling.
16 . The load support system of claim 15 , wherein the vertical extension regions reinforce the upper load support bracket to reduce transverse deflection during dynamic loading conditions and improve structural rigidity.
17 . The load support system of claim 15 , wherein the extension regions of the inner and outer panels that extend vertically above and/or below the center panel are asymmetrical, tailored to accommodate various vehicle features, and enhance load distribution across the upper load support bracket.
18 . The load support system of claim 15 , wherein the mounting features of the inner and outer panels include contours that conform to the shape of the pre-existing mounting points on the unibody vehicle frame, facilitating secure attachment.
19 . A unibody load support bracket for installation on a unibody vehicle frame, comprising: an upper bracket having a U-shaped configuration that includes an inner panel, a center panel, and an outer panel, wherein: the inner and outer panels extend longitudinally along the unibody frame and incorporate mounting features that align with pre-existing mounting points for secure attachment; the center panel joins the inner and outer panels and generally follows a contoured portion of the bottom of the unibody vehicle frame, enhancing structural integrity; vertical extension regions of the inner and outer panels extend above and/or below the center panel.
20 . The unibody load support bracket of claim 19 , wherein the mounting features on the inner and outer panels are contoured to conform to the shape of the pre-existing mounting points on the unibody vehicle frame, thereby facilitating secure attachment and enhancing load distribution.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application 63/715,742, filed Nov. 4, 2024, the disclosure of which is incorporated by reference in its entirety. BACKGROUND OF THE INVENTION The present invention pertains to vehicle load support systems, specifically for unibody-frame vehicles. More particularly, it relates to a bracket assembly that effectively distributes and mitigates load stresses on unibody vehicle frames, optimizing load capacity while maintaining structural integrity. Vehicles featuring a unibody frame design, such as the Mercedes Sprinter van, are known for their advantages in safety and fuel efficiency. Unlike body-on-frame constructions, where the body is mounted on a separate chassis, unibody frames integrate the body and structural support into a single unit. While unibody frames provide certain benefits, they are generally less suited to carrying heavy loads, as the frame structure lacks the robustness needed to handle high load stress. When traditional load support mechanisms are applied to unibody vehicles, localized stress points can compromise the frame, causing bending, flexing, or, in extreme cases, structural failure. Conventional load support brackets, for example as shown in FIG. 2, typically use an upper bracket 200 with two standoffs 205 as primary contact points with the unibody frame 250. Each standoff 205 includes a contact surface 210 where it meets the unibody frame 250, creating concentrated load points that result in localized stress. This bracket design lacks adequate distribution of forces along the frame, making it prone to deformation over time, especially under dynamic loading conditions. An air spring 230 is positioned between the frame 250 and axle 260, but the limited surface area of contact surfaces 210 at each standoff 205 restricts the system's ability to manage varying load forces effectively. Specifically, as illustrated in FIG. 3, the prior art bracket 200 creates high-pressure points at the contact areas 210 of the standoffs 205, which interface directly with the unibody frame 250. The grayscale stress analysis 300 in FIG. 3 visually represents how these concentrated load points generate elevated stress levels (PSI) at each standoff 205. These high-stress zones indicate that the prior art's bracket design, with its limited contact area at the standoffs, inadequately distributes load forces. Over time, this concentrated loading may deform or damage the unibody frame 250, particularly under dynamic loading conditions when vehicle movement amplifies the stress on these contact areas 210. This significant limitation highlights the need for an improved load support bracket that distributes forces more uniformly across a broader area of the frame, thereby preserving structural integrity under a range of load conditions. SUMMARY OF THE INVENTION The present invention provides a load support system for unibody vehicles, addressing the challenges of load distribution on unibody frames, such as those in the Mercedes Sprinter van. The system features an upper load support bracket with a U-shaped configuration comprising an inner panel, a center panel, and an outer panel. This bracket engages pre-existing mounting points on the unibody vehicle frame, ensuring secure attachment. The upper load support bracket improves load distribution by conforming to the contours of the unibody structure. This reduces localized stress concentrations and mitigates issues such as bending and flexing of the unibody frame, thus preserving the structural integrity of the frame under dynamic loading conditions. Vertical extension regions of the inner and outer panels provide higher reinforced mounting features that align with mounting holes for the factory suspension. These areas of the frame are reinforced to handle loads, accordingly by mounting the bracket at these locations additional reinforcement can be provided, enhancing overall structural rigidity. Air spring mounting features are integrated into the center panel, allowing for secure coupling to the upper portion of the air spring, thus facilitating effective load management. Overall, the load support system enhances vehicle stability and handling by effectively distributing load forces across a broader area of the unibody frame while maintaining compatibility with different vehicle models. These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings. Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alt