Abstract: A vehicle has external bodywork including an upper surface and an under surface, the under surface having at least one aperture, and the vehicle comprising lower ducting located within the external bodywork and communicating with that aperture, the upper surface having at least one aperture, and the vehicle comprising upper ducting located within the external bodywork and communicating with that aperture, the upper ducting and the lower ducting leading to a fan adapted to selectively draw air through the respective ductings, the vehicle further comprising a control unit adapted to receive information as to the vehicle dynamic state and, in the light of that state, draw air through the lower ducting or through the upper ducting. Thus, a choice can be made between enhanced levels of downforce on the one hand, and low drag on the other.

Abstract: We disclose a chassis for a vehicle, comprising an interconnected framework comprising a plurality of tubular sections, and at least one sheet bonded to the framework, wherein the tubular sections are of a non-ferrous metallic composition. The non-ferrous tubular sections have a very thin wall; generally, these sections are made by extrusion, which currently allows for wall thicknesses no thinner than about 2.5 mm. We prefer the wall thickness to be about this level, and ideally no greater than 3 mm. Such a thin-walled tube would usually imply a lower resistance to buckling, but as part of the structural element defined above, we have found that the tube does not buckle and in fact has an impact response that is superior to other alternatives. We therefore prefer that the tubular sections have a profile for which the ratio of the minimum area moment of inertia of its cross section to the square of the unsupported length of the section is less than 2 mm2.

Abstract: A chassis and a method of forming the chassis comprising assembling a framework of interconnected tubular-section metallic members and a plurality of composite panels, each panel being adhesively bonded to a plurality of the metallic members, wherein at least one bond between a composite panel and a metallic member is formed by an arcuate formation integral with and extending from an edge of a planar section of the composite panel and fitting around an exterior of the metallic member, and providing a layer of adhesive along the gap there between extending substantially from the edge of the planar section across a part of but less than the complete angular extent of the arcuate section.

Abstract: A vehicle with a load space to provide a chassis comprising a framework (10) comprising a pair of spaced-apart elongate longitudinal members (12, 14) connected by a pair of spaced-apart elongate lateral members (20, 22) and bracing for the thus-defined framework, a rear suspension attached to the rearmost lateral member (20) and comprising a trailing-arm arrangement (52), and a front suspension attached to the front most lateral member (22) and comprising a leading-arm arrangement (58). This creates a rigid core for the chassis, which also provides all four suspension mounting points.

Abstract: We improve still further the crashworthiness of a tubular-frame chassis by providing a means for absorbing lower-energy impacts without deforming the tubular steel frame, The vehicle comprises a chassis structure including a load-bearing tubular chassis member extending longitudinally within the vehicle, at least one crush structure located laterally outside of the chassis member, the crush structure having an upper and a lower extent that overlap with an upper and lower extent of the chassis member. In this way, the crush structure is able to interact with the chassis member, transferring impact forces to the chassis member and thereby reducing the necessary size (and weight) of the crush structure. The crush structure is preferably removable, to allow replacement after an impact. Alternatively, the crush structure part of a door of the vehicle, positioned as necessary when the door is closed.

Abstract: A vehicle with a load space to provide a chassis comprising a framework (10) comprising a pair of spaced-apart elongate longitudinal members (12, 14) connected by a pair of spaced-apart elongate lateral members (20, 22) and bracing for the thus-defined framework, a rear suspension attached to the rearmost lateral member (20) and comprising a trailing-arm arrangement (52), and a front suspension attached to the front most lateral member (22) and comprising a leading-arm arrangement (58). This creates a rigid core for the chassis, which also provides all four suspension mounting points.

Abstract: In a structure such as that described in WO2009/122178, it is necessary to provide an adhesive bond between composite panels and the tubular framework. We describe a chassis comprising a framework of interconnected tubular-section metallic members and a plurality of composite panels, each panel being adhesively bonded to a plurality of the metallic members, wherein at least one bond between a composite panel and a metallic member is formed by an arcuate formation integral with and extending from an edge of a planar section of the composite panel and fitting around an exterior of the metallic member, and a layer of adhesive along the gap there between extending substantially from the edge of the planar section across a part of but less than the complete angular extent of the arcuate section.

Abstract: A kit for constructing a commercial vehicle supplied ex-works as a flat-pack package using the vehicle chassis as a pallet. The kit includes components comprising: a chassis, an engine attachable to the chassis, located within and supported by the chassis, and a plurality of upright chassis members attachable to the chassis thereby to define at least a cabin, placed flat over the chassis. The component making up the kit can be restrained in place, such as by wrapping or tying with suitable film, bands or cords. Body panels attachable to the chassis uprights can be supplied, placed flat over the chassis. Brake line, a wiring loom and major drivetrain items such as the engine, differential and propshaft may be pre-attached to the chassis in their final locations before shipping the kit. With suitable spacers, several such kits could be packed for transport in a single vehicle or container.

Abstract: We improve still further the crashworthiness of a tubular-frame chassis by providing a means for absorbing lower-energy impacts without deforming the tubular steel frame, The vehicle comprises a chassis structure including a load-bearing tubular chassis member extending longitudinally within the vehicle, at least one crush structure located laterally outside of the chassis member, the crush structure having an upper and a lower extent that overlap with an upper and lower extent of the chassis member. In this way, the crush structure is able to interact with the chassis member, transferring impact forces to the chassis member and thereby reducing the necessary size (and weight) of the crush structure. The crush structure is preferably removable, to allow replacement after an impact. Alternatively, the crush structure part of a door of the vehicle, positioned as necessary when the door is closed.

Abstract: A vehicle suspension comprises an assembly of a hub carrier and a support arm, the support arm being attached to the hub carrier at two points spaced from each other in the direction of travel and extending inwardly therefrom to a support arm attachment point for fixing to a chassis, and a trailing link extending from the assembly in a direction transverse to that of the support arm, toward a trailing link attachment point for fixing to the chassis. The trailing link preferably extends from the assembly in a forward direction, and is preferably connected directly to the hub carrier. A strut can extend upwardly toward an attachment point for fixing to a chassis, to provide a spring and damper. The support arm can comprise a pair of arms extending divergently from the attachment point to each of the two points. The hub carrier can include a pivot pin extending in a fore/aft alignment, passing through two pivot points on the support arm thereby to define the two points.

Abstract: Electric vehicles usually inherit a chassis of a pressed steel construction from a conventional vehicle design. This imposes a substantial weight penalty on the vehicle. We disclose a chassis element for a vehicle, formed of an outer skin material, an inner core material enveloped by the outer skin material, and at least one array of aligned fibres, and comprising a restraint for an electrical battery adapted to locate the battery over the at least one array. There can be multiple arrays of aligned fibres, preferably disposed at a transverse angle relative to each other of less than 90°. We particularly prefer three arrays of aligned fibres, which can be disposed relative to each other at an angle of 60°. The fibres can be disposed within the skin material.

Abstract: A chassis for a vehicle has a locally narrower portion within which is mounted a wheel, and a rigid member extending from the chassis toward the quiescent position of the wheel and ending at a point which is spaced radially from the outer profile and located axially within the thickness of the wheel. Under an impact, the wheel itself will be crushed against the rigid member, absorbing some of the impact energy. The impact energy can also be transmitted via the rigid member to the remainder of the chassis, providing a load path to major mass concentrations elsewhere in the vehicle and allowing energy to be dissipated by the deformation of other structures elsewhere. This can then limit frontal damage to the vehicle and hence reduce the risk of intrusions into the passenger cell. The rigid member can be a column extending towards the wheel, and can end with a flat plate that is positioned tangentially to a local portion of the outer profile.

Abstract: A chassis (10) for a vehicle is disclosed which combines rigidity, speed of manufacture, and a small environmental footprint. Such a chassis comprises a framework of interconnected tubular sections (12, 14, 16, 18, 20, 22, 28) and at least one sheet (50) bonded to the framework. Laser cutting, CNC bending, and computer-controlled welding mean that the required production time can be kept to 120 seconds and the rigidity of the structure as a whole is sufficient. Such a chassis also has an exceptionally low carbon footprint. The sheet can be metallic, such as Aluminium or Aluminium honeycomb, or it can be a composite material such as one comprising a paper-based core and a fibre-reinforced plastics coating. The sheet can be non-flat, and is preferably a concave geometry such as a tub. It can be composed of a plurality of sections, ideally joined by a method allowing a positional tolerance so that any tolerance in the construction of the framework can be accommodated.

Abstract: A vehicle suspension comprises an assembly of a hub carrier and a support arm, the support arm being attached to the hub carrier at two points spaced from each other in the direction of travel and extending inwardly therefrom to a support arm attachment point for fixing to a chassis, and a trailing link extending from the assembly in a direction transverse to that of the support arm, toward a trailing link attachment point for fixing to the chassis. The trailing link preferably extends from the assembly in a forward direction, and is preferably connected directly to the hub carrier. A strut can extend upwardly toward an attachment point for fixing to a chassis, to provide a spring and damper. The support arm can comprise a pair of arms extending divergently from the attachment point to each of the two points. The hub carrier can include a pivot pin extending in a fore/aft alignment, passing through two pivot points on the support arm thereby to define the two points.