Description:FIELD
The present disclosure relates to a rear frame of a vehicle, more particularly a rear cross member assembly of a rear frame of the vehicle.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
In electric vehicles or hybrid vehicles having rear wheel drive, rear frames are constructed for motor packaging to power the rear wheels. These rear frames are also known as rear subframes. The conventional rear subframe assembly is made up of two cross-member assemblies and longitudinal members connected to each other, and separate brackets are provided for other aggregate mounting like suspension linkage mounts and motor mounts. A few of the prior arts employ a rear cross member, which is designed with two piece panels those get connected to the side longitudinal members, suspension mounting is done with a separate bracket assembly that is welded on the longitudinal members or rear cross member, and motor mounting is provided with a separate bracket assembly that gets mounted on the rear cross member as shown in Fig. 1. The cross member is made up of two panels having a C-C Box section. Suspension mounting brackets are fabricated of three panels each side, and the motor mount bracket is fabricated of two panels which are connected with the cross member by welding.
The disadvantage of such an approach is misalignment of these many numbers of panel pieces when welded together. It is very difficult to maintain the close tolerance of suspension mounting due to the panel stacking up and weld distortion.
Since separate mounting brackets are welded to the frame members, these are usually manufactured with thicker sheet metal or metal plates, which leads to increase in overall weight, may also lead to alignment issues and increase overall process time.
Joining separate mounting brackets by welding may lead to stacking up of tolerances causing higher misalignment during the assembly. This misalignment must be accommodated or compensated by the insulator bushes in order to align the motor mounting face and motor axis during assembly, which would inevitably skew the rubber in the insulator bushes during assembly and torquing. Thus, the rubber insulator bushes experience a pre-compliance (a pre-compression to accommodate the skew) even in the static condition of the motor (before the motor is even operated).
Motor misalignment in such a type of construction in prior arts not only deteriorates the NVH performance of the vehicle but also demands a precise part and manufacturing process to control tolerance to the desired deviation range. This ultimately increases production costs and part costs. Further, weight addition to the vehicle due to the heavy frame impacts the vehicle's performance.
Therefore, there is felt a need to provide a rear cross member assembly of a rear frame of the vehicle that obviates the drawbacks mentioned hereinabove or at least provides an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative solution.
An object of the present disclosure is to provide a rear cross member assembly of a rear frame of a vehicle.
Another object of the present disclosure is to provide a rear cross member assembly that eliminates need of welding additional brackets for mounting vehicle aggregates such as suspension links.
Yet another object of the present disclosure is to provide a rear cross member assembly that eliminates need of welding additional brackets for mounting motor mounting bush.
Still another object of the present disclosure is to provide a rear cross member assembly that has reduced weight as compared to conventional rear cross member assemblies.
Another object of the present disclosure is to provide a rear cross member assembly that reduces misalignment issues while mounting vehicle aggregates such as suspension links and motor.
Yet another object of the present disclosure is to provide a rear cross member assembly that has higher positional precision while connecting it to longitudinal members of the rear frame of a vehicle.
Still another object of the present disclosure is to provide a rear cross member assembly that is easy to manufacture and improves manufacturing efficiency.
Yet another object of the present disclosure is to provide a rear cross member assembly that reduces overall material and manufacturing cost.
Another object of the present disclosure is to provide a vehicle having a rear frame comprising a rear cross member that eliminates need for welding additional brackets for mounting suspension links.
Yet another object of the present disclosure is to provide a vehicle having a rear frame comprising a rear cross member that eliminates need for welding additional brackets for mounting motor mounting bush.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a rear cross member assembly of a rear frame of a vehicle. The rear frame comprising plurality of longitudinal members, a front cross member and a rear cross member assembly. Plurality of longitudinal members spanning along the operative lengthwise direction of the vehicle and spaced apart from each other in the operative widthwise direction of the vehicle. The front cross member connecting the longitudinal members at an operative front end of the longitudinal members. The rear cross member assembly connecting the longitudinal members at an operative rear end of the longitudinal members. The rear cross member assembly comprising an integral construction configured for mounting atleast one suspension system component and at least one drive system component.
In an embodiment, the integral construction is configured for mounting at least two suspension links and at least one motor mounting bush.
In an embodiment, the suspension links are selected from group comprising a spring link, a toe link, a control arm and a camber link.
In an embodiment, the integral construction for mounting the suspension system component comprises an integral seating surface configured for mounting one end of the suspension system component and at least one hole configured for inserting a pivoting element or a fastening element. The pivoting element or the fastening element configured to connect the suspension system component with the rear cross member assembly.
In an embodiment, the rear cross member assembly integrally comprises plurality of components including a front panel, a back panel, a top panel, a connecting means, a right hand side mount bracket, a left hand side mount bracket and a lower cross panel.
The front panel spanning along length of the rear cross member assembly, the back panel spanning along length of the rear cross member assembly and positioned in the operative rearward direction of the vehicle with respect the front panel. The top panel spanning along length of the rear cross member assembly and positioned on the operative top of the front panel and the back panel. The connecting means with its longitudinal axis positioned perpendicular to length of the rear cross member assembly. The connecting means configured to connect the front panel and the back panel. The right hand side mount bracket attached at the operative right end of the front panel. The left hand side mount bracket attached at the operative left end of the front panel. The lower cross panel spanning along length of the rear cross member assembly and configured to connect the left hand side mount bracket and the right hand side mount bracket.
In an embodiment, the connecting means is a cylindrical sleeve, the cylindrical sleeve is configured to connect and pass through at least the front panel and the back panel. The cylindrical sleeve is configured to hold a motor mounting bush.
In an embodiment, the front panel and back panel comprise integral mounting arrangement for mounting a toe link.
In an embodiment, the right hand side mount bracket and left hand side mount bracket comprise integral mounting arrangement for mounting a control arm.
In an embodiment, the rear cross member assembly comprises at least a reinforcing element disposed between at least two panels of the rear cross member assembly.
In an embodiment, the rear cross member assembly comprises at least two reinforcing elements disposed between the back panel and the front panel.
In an embodiment, the rear cross member assembly comprises at least two reinforcing elements disposed between the front panel and the top panel.
According to another aspect of the present disclosure, a method of manufacturing a rear cross member assembly of the rear frame of a vehicle is disclosed. The method comprises manufacturing of subcomponents of rear cross member assembly separately; and joining of all sub components together using a metal joining process to form the rear cross member assembly.
In an embodiment, the manufacturing of the subcomponents of rear cross member assembly includes manufacturing of a front panel, a back panel, a top panel, a connecting means, a right hand side mount bracket, a left hand side mount bracket and a lower cross panel.
The front panel spanning along length of the rear cross member assembly, the back panel spanning along length of the rear cross member assembly and positioned in the operative rearward direction of the vehicle with respect the front panel. The top panel spanning along length of the rear cross member assembly and positioned on the operative top of the front panel and the back panel. The connecting means with its longitudinal axis positioned perpendicular to length of the rear cross member assembly. The connecting means configured to connect the front panel and the back panel. The right hand side mount bracket attached at the operative right end of the front panel. The left hand side mount bracket attached at the operative left end of the front panel. The lower cross panel spanning along length of the rear cross member assembly and configured to connect the left hand side mount bracket and the right hand side mount bracket.
In an embodiment, the connecting means is a cylindrical sleeve , the cylindrical sleeve is configured to pass through at least the front panel and the back panel.
In an embodiment, the method further comprises a step of press fitting a motor mounting bush into the cylindrical sleeve.
According to another aspect, the present disclosure envisages a vehicle with a rear frame, the rear frame of the vehicle comprising plurality of longitudinal members, a front cross member and a rear cross member assembly. The plurality of longitudinal members spanning along the operative lengthwise direction of the vehicle and spaced apart from each other in the operative widthwise direction of the vehicle. The front cross member connecting the longitudinal members at an operative front end of the longitudinal members. The rear cross member assembly connecting the longitudinal members at an operative rear end of the longitudinal members. The rear cross member assembly comprising an integral construction configured for mounting atleast one suspension system component and at least one drive system component.
According to an embodiment of vehicle of the present disclosure, the integral construction is configured for mounting at least two suspension links and at least one motor mounting bush.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
FIGURE 1: illustrates a conventional rear frame and rear cross member assembly of a vehicle, wherein separate brackets are welded to rear frame for mounting suspension link and motor mounting bush.
FIGURE 2: illustrates isometric view of rear frame assembly according to present disclosure and the rear cross member assembly of the present disclosure.
FIGURE 3A: illustrates an isometric front view of the rear cross member assembly in accordance with the present disclosure.
FIGURE 3B: illustrates an isometric rear view of the rear cross member assembly in accordance with the present disclosure.
FIGURE 4: illustrates exploded isometric front view of the rear cross member assembly in accordance with the present disclosure showcasing its various subcomponents.
FIGURE 5: illustrates an isometric rear view of the rear cross member assembly in accordance with the present disclosure showcasing internal reinforcing elements.
FIGURE 6: illustrates isometric front view of the rear frame of the vehicle with the rear cross member assembly of the present disclosure.
FIGURE 7: illustrates isometric rear view of the rear frame of a vehicle with the rear cross member assembly of the present disclosure.
FIGURE 8A: illustrates an enlarged view of the rear frame assembly assembled with the rear cross member assembly of the present disclosure, showcasing integral mounting arrangement configured for mounting suspension link components.
FIGURE 8B: illustrates an enlarged view of the rear frame assembly assembled with the suspension links, showcasing how suspension links are connected to the rear cross member assembly of the present disclosure.
FIGURE 9: illustrates a rear view of the vehicle with rear frame in accordance with the present disclosure, showcasing how suspension links are connected to the rear cross member assembly of the present disclosure.
FIGURE 10A: illustrates a front view of the rear frame of the vehicle with the rear cross member assembly of the present disclosure.
FIGURE 10B: illustrates a sectional view of the rear cross member assembly of the present disclosure across the axis A-A as showcased in FIGURE 10A.
Figure 11: illustrates an isometric view of the rear frame of the vehicle along with the motor assembly (500).
LIST OF REFERENCE NUMERALS
100’ – conventional rear frame of vehicle
100 - rear frame of vehicle
200A’, 200B’ - longitudinal members of conventional rear frame
200A, 200B - longitudinal members
251 - motor mounting bush in longitudinal member
300 - front cross member
400’ - rear cross member of conventional rear frame
400 - rear cross member
410’ - motor mounting bracket of conventional rear frame
420’ - suspension link mounting bracket of conventional rear frame
440 - front panel
442 - back panel
444 - top panel
446A - right hand side mount bracket
446B - left hand side mount bracket
448 - lower cross panel
449A - reinforcing elements disposed between top and front panel
449B - reinforcing elements disposed between front and back panel
450 - cylindrical sleeve
451 - motor mounting bush in rear cross member
455 - lower control arm mounting arrangement
456 - lower control arm
460 - toe link mounting arrangement
461 - toe link
500 - motor assembly
F - operative front direction of vehicle
R - operative rear direction of vehicle

DETAILED DESCRIPTION
The present disclosure relates to a rear cross member assembly of a rear frame of a vehicle.
Embodiments of the present disclosure will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Figure 1 depicts a conventional rear subframe assembly (100’) of a vehicle. It incorporates a rear cross member (400’), which is designed with two-piece panels that get connected to the side longitudinal members (200A’, 200B’). In this configuration, the suspension mounting is done with a separate bracket assembly (420’) that is welded on the side members, and motor mounting is provided with a separate bracket assembly (410’) that gets mounted on the rear cross member (400’). The cross member is made up of two panels with a C-C box section.
Since separate mounting brackets are welded to the frame members, these are usually manufactured with thicker sheet metal or metal plates, which leads to an increase in overall weight and may also lead to alignment issues. Additionally, these configurations are typically prone to a variety of problems, including motor misalignment, poor positional precision, poor NVH performance, increased production costs, and inefficient manufacturing.
The present disclosure aims to alleviate the aforementioned drawbacks. The present disclosure envisages an improved rear cross member assembly (400) of a rear frame (100) of a vehicle.
Referring to Figure 2, the rear frame (100) of the vehicle comprises a plurality of longitudinal members (200A, 200B), a front cross member (300), and a rear cross member assembly (400). The longitudinal members (200A, 200B) span along the operative lengthwise direction of the vehicle and are spaced apart from each other in the operative widthwise direction of the vehicle. The front cross member (300) connects the longitudinal members at the operative front end of the longitudinal members (200A, 200B). The rear cross member assembly (400) connects the longitudinal members (200A, 200B) at the operative rear end of the longitudinal members (200A, 200B). The rear cross member assembly (400) comprises an integral construction (455, 460, 450) configured for mounting at least one suspension system component (456, 461) and atleast one drive system component (450, 451).
In a preferred embodiment, the integral construction (455, 460, 450) is configured for mounting at least two suspension links (456, 461) and at least one motor mounting bush (451). The suspension links (456, 461) are selected from a group comprising a spring link, a toe link, a control arm, and a camber link. The integral construction (455,460) comprises an integral seating surface configured for mounting one end of the suspension system component (456, 461) and at least one hole configured for inserting a pivoting element or a fastening element. The pivoting element, or fastening element, is configured to connect the suspension system component (456, 461) with the rear cross member assembly (400). Such integral construction eliminates the need for welding additional brackets for mounting suspension links to the rear cross member assembly (400).
Figures 2-5 illustrate various views of the rear cross member assembly (400) in accordance with the present disclosure showcasing its various subcomponents. Referring to figures 2-8, rear cross member assembly integrally comprises plurality of components including a front panel (440), a back panel (442), a top panel (444), a connecting means (450), a right hand side mount bracket (446A), a left hand side mount bracket (446B) and a lower cross panel (448).
The front panel (440) span along length of the rear cross member assembly (400). The back panel (442) span along length of the rear cross member assembly and positioned in the operative rearward direction of the vehicle with respect the front panel (440). The top panel (444) span along length of the rear cross member assembly and positioned on the operative top of the front panel (440) and the back panel (442). The connecting means (450) is positioned with its longitudinal axis positioned perpendicular to length of the rear cross member assembly (400). The connecting means is configured to connect the front panel (440) and the back panel (442). The right hand side mount bracket (446A) attached at the operative right end of the front panel and the left hand side mount bracket (446B) attached at the operative left end of the front panel (440). The lower cross panel (448) span along length of the rear cross member assembly. The lower cross panel configured to connect the left hand side mount bracket (446B) and the right hand side mount bracket (446A).
In a preferred embodiment, the connecting means is a cylindrical sleeve (450). The cylindrical sleeve (450) is configured to pass through at least the front panel (440) and the back panel (442). The cylindrical sleeve (450) is configured to hold a motor mounting bush (451). The motor mounting bush (451) is a rubber bush isolator configured to provide flexible interface between a motor assembly (500) and rear cross member assembly (400). The motor mounting bush (451) functions as a vibration isolator by damping the energy transmitted through the bushing. This arrangement comprising rear cross member assembly (400) with integral cylindrical sleeve (450) press fitted with the motor mounting bush (451) eliminates the need for welding additional brackets for mounting motor mounting bush to the rear cross member assembly (400).
The rear cross member assembly (400) comprises at least a reinforcing element (449A, 449B) disposed between at least two panels of said rear cross member assembly. In a preferred embodiment, the rear cross member assembly comprises at least two reinforcing elements (449B) disposed between said front panel (440) and said top panel (444). In another embodiment, rear cross member assembly (400) comprises at least two reinforcing elements (449B) disposed between said front panel (440) and said top panel (444). In another embodiment, additional reinforcing elements may be placed between the front panel (440) and left hand/ right hand mounting brackets (446A, 446B). Such reinforcing arrangement helps in selectively strengthening of the rear cross member assembly (400) in required areas while selecting thinner metal panels for manufacturing the rear cross member assembly (400). This helps in reducing weight of the rear cross member assembly (400) without compromising the strength.
Figures 6-8 illustrate various views of the rear frame (100) with a rear cross member assembly (400) in accordance with the present disclosure. The rear cross member assembly (400) comprises integral mounting arrangement (455,460) configured for mounting suspension links (456,461).
In a preferred embodiment, the front panel (440) and the back panel (442) of the rear cross member assembly (400) comprises integral mounting arrangement (460) for mounting a toe link (461). The right hand side mount bracket (446A) and left hand side mount bracket (446B) comprise integral mounting arrangement (455) for mounting a control arm (456). Figure 8A illustrates an enlarged portion of the rear frame (100) with the rear cross member assembly (400) of the present disclosure, showcasing integral mounting arrangement (455, 460) configured for mounting toe link and the control arm. The integral construction (455,460) comprises an integral seating surface configured for mounting one end of the suspension system component (456, 461) and at least one hole configured for inserting a pivoting element or a fastening element. The pivoting element or the fastening element configured to connect the suspension system component (456, 461) with the rear cross member assembly (400). Figure 8b illustrates an enlarged portion of the rear frame (100) assembled with the suspension links including the toe link (461) and the control arm (456), showcasing how suspension links are connected to the rear cross member assembly (400) of the present disclosure. Figure 9 showcases another view to illustrate how the toe link (456) and the control arm (456) are connected to the rear cross member assembly of the present disclosure.
Such integral mounting arrangement (455,460) for mounting suspension link (456,461) eliminates the need for welding additional brackets for mounting suspension links to the rear cross member assembly (400). This helps in reducing overall number of components in the rear frame which reduces tolerance stack up and reduces misalignment issues.
Figure 10B, illustrates a sectional view of the rear cross member assembly of the present disclosure across the axis A-A as showcased in figure 10A. Referring to figure 10B, the cylindrical sleeve (450) is configured to pass through at least the front panel (440) and the back panel (442). The cylindrical sleeve (450) is configured to hold a motor mounting bush (451). There is additional motor mounting intermediate bracket (510) which is pre-assembled on the motor assembly (500). The motor assembly along with pre-assembled intermediate bracket (510) is placed from the top as shown in Figure 11 and assembled on the motor mounting bush (451) of rear cross of the rear sub frame assembly. Additionally, the longitudinal members (200A,200B) of the rear frame (100) may also include motor mounting bush (251) as shown in figure 6.
According to another aspect, the present disclosure discloses a method of manufacturing rear cross member assembly (400) of a rear frame (100) of a vehicle. The method comprises manufacturing of subcomponents (440, 442, 446A, 446B, 448, 449A, 449B, 450) of rear cross member assembly (400) separately; and joining of all sub components together using a metal joining process to form said rear cross member assembly(400).
The manufacturing of the subcomponents includes separate manufacturing of a front panel (440), a back panel (442), a top panel (444), a connecting means (450), a right hand side mount bracket (446A), a left hand side mount bracket (446B) and a lower cross panel (448). In a preferred embodiment, the connecting means is a cylindrical sleeve (450). The cylindrical sleeve (450) is configured to pass through at least the front panel (440) and the back panel (442). The method further comprises a step of press fitting a motor mounting bush (451) into said cylindrical sleeve (450). The cylindrical sleeve (450) is configured to hold a motor mounting bush (451).
According to an embodiment of present invention, the front panel (440), the back panel (442) and the cylindrical sleeve (450) connecting the front panel (440) and the back panel (442) are welded together to form a bottom sub assembly. Subsequently, the top panel (444) is placed on operative top surface of the bottom sub assembly and welded. The right hand side mount bracket (446A) and the left hand side mount bracket (446B) are welded to the respective sides of the bottom sub assembly. Finally, the lower cross panel (448) connecting the left hand side mount bracket (446B) and the right hand side mount bracket (446A) is welded to form the rear cross member assembly (400).
In another embodiment, the bottom sub assembly is welded to the longitudinal members (200A, 200B) of the rear subframe assembly (100) before performing the subsequent welding operations for joining the top panel (444), the right hand side mount bracket (446A) and the left hand side mount bracket (446B).
The manufacturing method according to the present disclosure allows the manufacturing of a rear cross member assembly (400) as a single component that can be joined to the longitudinal members (200A, 200B) with higher positional precision. Hence, higher positional precision and tight tolerances can be achieved with simple tools and manufacturing processes. Further, it eliminates additional step of welding brackets for mounting suspension links or motor mounting bush since these mounting arrangements are integrally provided while manufacturing of rear cross member assembly (400) of the present disclosure.
According to another aspect, the present disclosure discloses a vehicle with a rear frame (100). The rear frame (100) of the vehicle comprises plurality of longitudinal members (200A, 200B), the front cross member (300) and a rear cross member assembly (400). The longitudinal members (200A, 200B), span along the operative lengthwise direction of the vehicle and spaced apart from each other in the operative widthwise direction of the vehicle. The front cross member (300) connects the longitudinal members at an operative front end of the longitudinal members (200A,200B). The rear cross member assembly (400) connect the longitudinal members (200A, 200B) at an operative rear end of the longitudinal members (200A, 200B). The rear cross member assembly (400) of the vehicle comprises an integral construction (455,460,450) configured for mounting atleast one suspension system component (456, 461) and at least one drive system component (450,451).
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a rear cross member assembly of a rear frame of a vehicle that;
• eliminates need of welding additional brackets for mounting suspension links;
• eliminates need of welding additional brackets for mounting motor mounting bush;
• has reduced weight as compared to conventional rear cross member assemblies;
• reduces misalignment issues while mounting suspension links;
• is easy to manufacture and improves manufacturing efficiency;
• reduces overall material and manufacturing cost;
• offers higher positional precision while attaching it to the longitudinal members of the rear frame
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM
1. A rear cross member assembly (400) of a rear frame (100) of a vehicle, said rear frame (100) comprising:
• plurality of longitudinal members (200A, 200B) spanning along the operative lengthwise direction of the vehicle and spaced apart from each other in the operative widthwise direction of the vehicle;
• a front cross member (300) connecting said longitudinal members at an operative front end of said longitudinal members (200A,200B);
• a rear cross member assembly (400) connecting said longitudinal members (200A, 200B) at an operative rear end of said longitudinal members (200A, 200B);
said rear cross member assembly (400) comprising:
an integral construction (455,460,450) configured for mounting atleast one suspension system component (456, 461) and at least one drive system component (450,451).
2. The rear cross member assembly (400) as claimed in claim 1, wherein said integral construction (455,460,450) is configured for mounting at least two suspension links (456, 461) and at least one motor mounting bush (451).
3. The rear cross member assembly (400) as claimed in claim 2, wherein said suspension links (456, 461) are selected from group comprising a spring link, a toe link, a control arm and a camber link.
4. The rear cross member assembly (400) as claimed in claim 1, said integral construction (455,460) for mounting said suspension system component (456, 461) comprises:
• an integral seating surface configured for mounting one end of said suspension system component (456, 461); and
• at least one hole configured for inserting a pivoting element or a fastening element, said pivoting element or said fastening element configured to connect said suspension system component (456, 461) with said rear cross member assembly (400).
5. The rear cross member assembly (400) as claimed in claim 1, wherein said rear cross member assembly integrally comprises plurality of components including:
• a front panel (440) spanning along length of said rear cross member assembly (400),
• a back panel (442) spanning along length of said rear cross member assembly and positioned in the operative rearward direction of the vehicle with respect said front panel (440);
• a top panel (444) spanning along length of said rear cross member assembly and positioned on the operative top of said front panel (440) and said back panel (442);
• a connecting means (450) with its longitudinal axis positioned perpendicular to length of said rear cross member assembly (400), said connecting means configured to connect said front panel (440) and said back panel (442) ,
• a right hand side mount bracket (446A) attached at the operative right end of said front panel,
• a left hand side mount bracket (446B) attached at the operative left end of said front panel (440); and
• a lower cross panel (448) spanning along length of said rear cross member assembly, said lower cross panel configured to connect said left hand side mount bracket and said right hand side mount bracket.
6. The rear cross member assembly (400) as claimed in claim 5, wherein said connecting means is a cylindrical sleeve (450), said cylindrical sleeve (450) is configured to connect and pass through at least said front panel (440) and said back panel (442), wherein said cylindrical sleeve (450) is configured to hold a motor mounting bush (451).

7. The rear cross member assembly (400) as claimed in claim 5, wherein said front panel (440) and said back panel (442) comprises integral mounting arrangement (460) for mounting a toe link (461), said right hand side mount bracket (446A) and left hand side mount bracket (446B) comprise integral mounting arrangement (455) for mounting a control arm (456) and wherein said rear cross member assembly (400) comprises at least a reinforcing element (449A, 449B) disposed between at least two panels of said rear cross member assembly.
8. The rear cross member assembly (400) as claimed in claim 5, wherein said rear cross member assembly comprises at least two reinforcing elements (449A) disposed between said back panel (442) and said front panel (440).
9. The rear cross member assembly (400) as claimed in claim 5, wherein said rear cross member assembly comprises at least two reinforcing elements (449B) disposed between said front panel (440) and said top panel (444).
10. A method of manufacturing a rear cross member assembly (400) of a rear frame of a vehicle (100), said method comprising the steps of:
manufacturing of subcomponents (440, 442, 446A, 446B, 448, 449A, 449B, 450) of said rear cross member assembly (400); and
joining of all sub components together using a metal joining process to form said rear cross member assembly(400).
11. The method as claimed in claim 10, said subcomponents of rear cross member assembly (400) includes:
• a front panel (440) spanning along length of said rear cross member assembly,
• a back panel (442) spanning along length of said rear cross member assembly and positioned in the operative rearward direction of the vehicle with respect said front panel (440);
• a top panel (444) spanning along length of said rear cross member assembly and positioned on the operative top of said front panel (440) and said back panel (442);
• a connecting means with its longitudinal axis positioned perpendicular to length of said rear cross member assembly, said connecting means configured to connect said front panel (440) and said back panel (442) ,
• a left hand side mount bracket attached at the operative left end of said front panel (440),
• a right hand side mount bracket attached at the operative right end of said front panel (440); and
• a lower cross panel (448) spanning along length of said rear cross member assembly, said lower cross panel configured to connect said right hand side mount bracket (446A) and said left hand side mount bracket (446B).
12. The method as claimed in claim 11, wherein said connecting means is a cylindrical sleeve (450), said cylindrical sleeve (450) is configured to pass through at least said front panel (440) and said back panel (442) .

13. The method as claimed in claim 12, wherein said method comprises a step of press fitting a motor mounting bush (451) into said cylindrical sleeve (450).
14. A vehicle with a rear frame (100), said rear frame (100) of said vehicle comprising:
• plurality of longitudinal members (200A, 200B) spanning along the operative lengthwise direction of the vehicle and spaced apart from each other in the operative widthwise direction of the vehicle;
• a front cross member (300) connecting said longitudinal members at an operative front end of said longitudinal members (200A,200B);
• a rear cross member assembly (400) connecting said longitudinal members (200A, 200B) at an operative rear end said longitudinal members (200A, 200B);
said rear cross member assembly (400) comprising:
an integral construction (455,460,450) configured for mounting atleast one suspension system component (456, 461) and at least one drive system component (450,451).
15. The vehicle as claimed in claim 14, wherein said integral construction (455, 460, 450) is configured for mounting at least two suspension links (456,461) and at least one motor mounting bush (451).

Dated this 30th day of October, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI