FIELD OF THE INVENTION

[0001] The invention relates to the field of trucks. More specifically, the invention relates to a front box structure for an at least partially electrically operated truck.

BACKGROUND INFORMATION

[0002] At least partially electrically operated trucks with at least one electric drive system component are already known in the state of the art. The electrically operated truck therefore comprises a structure, wherein the at least one electric drive system component may be arranged inside the structure.

[0003] US 2009 236478 A1 discloses an instrument mount assembly comprising a pair of spaced apart L shaped brackets having a vertical leg and a horizontal flange extending outwardly from a bottom end thereof in a first direction and a hook at a top end thereof sized and configured to securely engage over a body rail of a truck, extending outwardly from the vertical leg in a direction opposite the flange, each flange being adapted to engage an end edge of an isolation plate sized and configured to support a corresponding instrument thereon, the brackets being engaged to one another by at least one cross rail, with the entire assembly being sized and configured to compactly hold the instrument to the body rail of the truck without interfering with any truck structures proximate thereto.

[0004] EP 2554420 discloses an electric drive module with an electric or hybrid drive unit with a battery pack rechargeable by an inverter. The battery pack is accommodated in a support frame, where the support frame is fastened to a motor vehicle assembly. The drive module is arranged as an independent unit with the battery pack and electric transducers, such as the inverter and a direct current converter, and an electric connection interface, a cooling system with a heat exchanger, a coolant line and a supply pump in the support frame.

[0005] There is a need in the art to provide a front box structure which allows for an easier packaging of electric drive system components. There is also a need in the art to provide a front box structure which allows for more versatility in mounting electric drive system components.

SUMMARY OF THE INVENTION

[0006] It is an object of the invention to provide a front box structure by which an easier way for packaging of components, plumbing and wiring is realized. It is also an object of the invention to provide a front box structure by which a more versatile mounting of components is realized.

[0007] This object is solved by a front box structure according to the independent claim. Advantageous embodiments are presented in the dependent claims.

[0008] One aspect of the invention relates to a front box structure for an at least partially electrically operated truck, wherein the front box structure is configured to be coupled to at least one electrical drive system component of the truck, wherein the front box structure comprises at least one lateral structure member, at least one longitudinal structure member and at least one vertical structure member, wherein the at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member at least partially surround an inside of the front box structure.

[0009] In an embodiment the at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member is/are made of sheet metal and the at least one lateral structure member and/or the at least one vertical structure member and/or the at least longitudinal structure member comprises/comprise a C profile. In an exemplary embodiment, sheet metal may be sheet steel or sheet aluminum. [0010] In an embodiment the front box structure takes up less volume for easier packaging of components, plumbing and wiring. In an embodiment, the front box structure can achieve better tolerance and easier manufacturing than a typical welded structure according to the state of the art because there is no deformation due to welding and reduced fixing requirements. In an embodiment, the C profile is more versatile for mounting components, plumbing and wiring and more easily adapted to change components or packaging because bolts and/or weld nuts are easily added and clamping bolts may not compress and collapse the structure as is the case with tubular structures. Finally, the C profile structure is lower in weight than a hollow tube structure according to the state of the art.

[0011] The at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member is/are made from flat pattern cut and bent sheet metal forming the C profile shapes, which are bolted together. Mounting of components, plumbing and wiring is made on horizontal trays bolted to the C profile structure and integrated tabs of the C profile flanges. Small common castings are used in places typical for weld gusset. In an embodiment, all structural members may be made from sheet metal of the same thickness and physical properties. Spot welding is used to capture weld nuts and studs, which does not require fixturing and is done by machines. These captive fasteners reduce takt time on the assembly line as only one fastener and fixturing to one side is required. Furthermore, ll-Nuts may be used which have more float than weld nuts for easier assembly of the trays where precise tolerance on position of the trays is not required.

[0012] Therefore, reduced costs due to one single material being used for all sheet metal parts, no manual welding, and reduced fixing requirements because of lacking structure welding is realized. Furthermore, increased design versatility from the flat pattern of the bent C profile, which allows for easy moving of mounting and clipping points, is realized. Furthermore, decreased takt time in assembly lines due to otherwise extensive use of captive fasteners is realized.

[0013] According to an embodiment, the at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member is a single gauge of sheet metal. In particular, all structural members are made from a single gauge of sheet metal, which reduces costs. In an exemplary embodiment, the sheet metal may be particularly sheet steel or sheet aluminum.

[0014] In another embodiment, an opening of the C profile of the at least one longitudinal structure member may face outwards away from the inside of the front box structure.

[0015] According to another embodiment, an opening of the C profile of the least one vertical structure member may face inwards towards the inside of the front box structure.

[0016] In another embodiment, an opening of the C profile of the at least one lateral structure member may face outwards away from the inside of the front box structure.

[0017] In another embodiment, an assembly is bolted to the at least one lateral structure member and/or the assembly is bolted to the at least one vertical structure member and/or the assembly is bolted to the at least one longitudinal structure member. Bolted assemblies minimize quality control requirements and costs involved with the welding process. Achieved assembly tolerances are also better controlled in this embodiment.

[0018] According to another embodiment, the at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member are produced by a flat pattern process, such as flat pattern cut or laser cut or waterjet cut or router milling or wire EDM (electrical discharge machining). This substantially lowers costs and mounting effort otherwise involved with stamping or forming processes.

[0019] In a yet further embodiment, the at least one lateral structure member and/or the at least one vertical structure member and/or the at least one longitudinal structure member are brake press formed. This substantially lowers costs and mounting effort otherwise involved with stamping or forming processes.

[0020] According to another embodiment, at least one plumbing line of the electrical drive system component is arranged in an opening of the C profile of the at least one lateral structure member and/or the at least one vertical structure member. In particular, the plumbing line is arranged in the opening of the at least one lateral structure member. The at least one lateral structure member allows for nesting the plumbing lines inside the opening of the C profile, reducing over a width and allowing more to fit in between chassis frame rails of the at least partially electrically operated truck.

[0021] In a further embodiment, the front box structure comprises at least two layers for arranging at least a first electric drive system component on the first layer and a second electric drive system component on the second layer. In particular, the front box structure may comprise three layers, wherein a third electric drive system component may be arranged on the third layer. An electric drive system component may be, for example, a low voltage battery, an electric air compressor, a pump, an electric heater, an electrical fixturing compressor, a chiller, an electric steering pump, and/or a DC/DC converter.

[0022] According to another embodiment, the at least one lateral structure member and/or the at least one longitudinal structure member and/or the at least one vertical structure member are configured for arranging at least one L casting on the at least one lateral structure member and/or the at least one vertical structure member. The L castings may be used in both up and down positions to allow for different tray heights to meet packing needs. The L castings may be threaded to reduce required fasteners.

[0023] A further aspect of the invention relates to an at least partially electrically operated truck comprising the front box according to the preceding aspect. In particular, the truck may be fully electrically operated.

[0024] Further advantages, features, and details of the invention derive from the following description of preferred embodiments as well as from the drawings. The features and feature combinations previously mentioned in the description as well as the features and feature combinations mentioned in the following description of the figures and/or shown in the figures alone can be employed not only in the respectively indicated combination but also in any other combination or taken alone without leaving the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The novel features and characteristic of the disclosure are set forth in the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and together with the description, serve to explain the disclosed principles. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described below, by way of example only, and with reference to the accompanying figures.

[0026] The drawings show in:

[0027] Fig. 1 a schematic perspective view according to an embodiment of a front box structure;

[0028] Fig. 2 another schematic perspective view according to an embodiment of a structure member;

[0029] Fig 3 another schematic front view of an embodiment of a front box structure;

[0030] Fig. 4 a schematic enlarged perspective view according to an embodiment of a front box structure;

[0031] Fig. 5 another schematic perspective view according to an embodiment of the front box structure;

[0032] Fig. 6 a schematic cross-sectional view according to an embodiment of the front box structure;

[0033] Fig. 7 another schematic perspective view of a front box structure; and

[0034] Fig. 8 a schematic front view according to an embodiment of the front box structure.

[0035] In the figures same elements or elements having the same function are indicated by the same reference signs.

DETAILED DESCRIPTION

[0036] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration". Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. [0037] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[0038] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion so that a setup, device or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus preceded by “comprises” or “comprise” does not or do not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

[0039] In the following detailed description of the embodiment of the disclosure, reference is made to the accompanying drawings that form part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. This embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[0040] Fig. 1 shows a schematic perspective view of an embodiment of a front box structure 10 for an at least partially electrically operated truck, which is not shown, wherein the front box structure 10 is configured to be coupled to at least one electric drive system component, which is also not shown, of the truck inside the front box structure 10, wherein the front box structure 10 comprises at least one lateral structure member 12, at least one longitudinal structure member 40 and at least one vertical structure member 14, wherein the inside 16 of the front box structure 10 is at least partially surrounded by the at least one lateral structure member 12 and/or the at least one longitudinal structure member 40 and/or the at least one vertical structure member 14. [0041] In an embodiment, the at least one lateral structure member 12 and/or the at least one longitudinal structure member 40 and/or the at least one vertical structure member 14 is made of sheet metal, and the at least one lateral structure member 12 and/or the at least one longitudinal structure member 40 and/or the at least one vertical structure member 14 comprise a C profile 18.

[0042] In an embodiment, the at least one lateral structure member 12 and/or the at least one longitudinal structure member 40 and/or the at least one vertical structure member 14 is/are made from a single gauge of sheet steel. Furthermore, the at least one longitudinal structure member 40 is facing outwards away from the inside 16 of the front box structure 10 with an opening 20 of the C profile 18. Furthermore, the at least one vertical structure member 14 is facing inwards towards the inside 16 of the front box structure 10 with the opening 20 of the C profile 18. In an alternative embodiment, the at least one lateral structure member 12 and/or the at least one longitudinal structure member 40 and/or the at least one vertical structure member 14 is/are made from a single gauge of sheet aluminum.

[0043] According to the embodiment shown in Fig. 1 , all structural members are made from a single gauge of sheet steel, which reduces the costs. An assembly 22 is bolted to the at least one lateral structure member 12 and/or the assembly 22 is bolted to the at least one vertical structure member 14 and/or the assembly 22 is bolted to the at least one longitudinal structure member 40. In particular, the bolted assembly 22 minimizes quality control requirements and the costs of welding process. The achieved assembly tolerances are also better controlled. The longitudinal structure members 40 and/or lateral structural members 12 in this embodiment are facing outwards with the C profile 18. The vertical structure members 14 are facing inwards with the C profile 18.

[0044] Fig. 2 shows another schematic view of an embodiment of the vertical structure member 14. In particular, it is shown that the C profile 18 and the opening 20 may face towards the inside 16 of the front box structure 10. Furthermore, a spot welded nut 24 is shown. In particular, all structural members are made from sheet steel, and may be flat pattern cut, laser cut or water jet cut, and brake-press formed. This involves substantially lower costs and mounting effort than otherwise required by stamping or forming processes. [0045] Fig. 3 shows another schematic front view of the front box structure 10.

According to the shown embodiment, longitudinal members 40 comprising the C profile 18 and vertical structure members 14 comprising the C profile 18 are allowed to mount without inserts or welding as would be needed in a tubular structure.

[0046] The frame mounting sits inside the longitudinal C profile 18 and spot welded nuts 24 may be directly arranged through the longitudinal and vertical C profile 18. The lateral C profile 18 and/or the longitudinal C profile 18 may be mounted to the vertical C profile 18 at the same point.

[0047] The lateral structure members 12 may comprise C profile channels 18 facing away from the inside 16 towards a front/rear of the front box structure 10, and the spot welded nut 24 directly faces towards the flanges of the vertical structure members 14.

[0048] Fig. 4 shows another schematic perspective view of an embodiment of the front box structure 10. In particular, it is shown that the C profile 18 of the lateral structure members 12 allows for easy mounting of trays for components. Spot welded nuts 24 allow for the attachment between the structural members with a single tool. Furthermore, ll-Nuts 42 may be used which have more float than weld nuts for easier assembly of the trays where precise tolerance on position of the trays is not required.

[0049] Fig. 5 shows another perspective view according to an embodiment of the front box structure 10. Fig. 5 shows that the use of the C profile 18 with the spot welded nuts 24 that facilitates moving of the mounting points, wherein merely new holes and weld nuts are needed instead of inserts and welding. This is desirable in the under hood environment where there is a lot of plumbing and wiring requiring mounting brackets 26, as shown in Fig. 5. Furthermore, a lifting eye bracket 44 is shown.

[0050] Fig 6 shows a schematic front view according to an embodiment of the front box structure 10. According to the shown embodiment, the longitudinal C profile 18 allows for an arranging of a plumbing line 28, in particular, a plurality of plumbing lines 28, inside the C profile 18. This reduces the overall width of the front box structure 10 and allows for more elements to fit in between the chassis frame rails.

[0051] Fig 7 shows another schematic view according to an embodiment of the front box structure 10. In particular, a plurality of castings at key interfaces are shown. On each side of the front box structure 10 there are four L castings 30 shown. Furthermore, the front box structure 10 in this embodiment comprises one rear engine mounting 32 and one rear front box mounting 46. The front box structure 10 comprises two radiator mount castings 34 and one front cross member 36, which may comprise a cooling module drop casting 38 which is mounted to the front frame and may hold a cooling module.

[0052] Fig 8 shows a schematic front view according to another embodiment of the front box structure 10. Fig. 8 shows that the L castings 30 are used in both up and down positions to allow for different tray heights to meet packing needs. The L castings 30 are threaded to reduce required fasteners.

[0053] As is further shown, the front box structure 10 may comprise at least two layers for arranging electric drive system components. More particularly, the front box structure 10 may comprise three layers for arranging electric drive system components.

Reference Signs

10 front box structure

12 lateral structure member

14 vertical structure member

16 inside

18 C-profile

20 opening

22 assembly

24 spot welded nut

26 mounting brackets

28 plumbing line

30 L-castings

32 rear engine mountings

34 radiator mount castings

36 front cross member

38 cooling module drop casting

40 longitudinal structure member

42 U-Nut

44 lifting eye bracket

46 rear front box mountings