Description:FIELD OF THE INVENTION
[001] The present invention relates to a frame assembly for a vehicle. More particularly, the present invention relates to the frame assembly for a saddle type vehicle.

BACKGROUND OF THE INVENTION
[002] Over last few years, with induction of new powertrain technologies concomitantly very substantial attention has been paid to improve ride comfort, utility, and safety. To this end, much attention has also been paid to development of efficient powertrains, advanced rider assist systems without compromising the storage volume. It is a challenge for the designers to accommodate various electrical and electronic subsystems in a compact saddle type vehicle.
[003] Typically, a frame assembly of the saddle type vehicle includes a mainframe member extending rearward and obliquely downward from a head pipe. A front wheel is mounted to the head pipe via one or more front fork. A rear wheel is mounted to the frame assembly via a swing arm. The mainframe member, which receives a force applied by the front and rear wheels, is required to have a high bending stiffness and an optimal twisting stiffness. Further, a pair of left and right seat rails extend rearwardly and upwardly from the said mainframe member. A seat assembly is mounted on the said pair of left and right seat rails. The seat assembly includes a rider’s seat and a pillion seat. The pillion seat is disposed of posterior to said rider’s seat.
[004] A typical body frame of the vehicle has a head tube, side tubes and a cross member for supporting various parts of the vehicle. The body frame also stiffens up the entire structure of the vehicle. Generally, the cross member connects one side tube to other side tube laterally. The cross member is usually mounted near the centre of the vehicle to support a utility box. Usually, a power unit is placed below the utility box. The cross member has proved to be a hinderance for packaging any additions component to the power unit or other new parts near that particular area around the cross member. So, there is need to modify the frame such that the above-mentioned limitations can be addressed.
[005] In addition to above, typically, various alignments of parts within the vehicle during the assembly process may be required, and misalignment due to component fault may result in catastrophic failure later. More specifically, the misalignment occurs due to the parts of dimensions outside the tolerance of the order of few millimeters. This occurs due to variation in manufacture and material. The few millimeters tolerances can be compensated by the sealing means to reduce the NVH (noise, vibration, and harshness) issues. This problem arises due to the usual method of reinforcing the frame and use of a plurality of brackets welded to mount storage box or other sub systems of the different coefficient of expansion. Further, any over-dimensioned or under dimensioned part poses a challenge to assemble in the assembly line during mass production especially while being assembled by hand. Furthermore, the uneven gap when one or more parts are deleteriously outside of a range of tolerance results in assembling of the vehicle and can also leads to a poor fit and finish.
[006] Further, if the cross member gets damaged may be during assembly or service, the entire frame will have to be replaced. This results in significant increase in cost of the vehicle and waste creation, which is undesirable. Furthermore, the area around the cross member is not efficiently utilized due to the hindrance created by cross member.
[007] Thus, there is a need in the art for a frame assembly for a saddle type vehicle which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] In one aspect, the present invention is directed towards a frame assembly for a vehicle. The frame assembly includes a pair of side frame members. The pair of side frame members is configured to have a front portion and a rear portion. The front portion of the pair of side frame members is connected to a main tube. The pair of side frame members includes a left side frame member and a right side frame member. The frame assembly includes a mounting assembly. The mounting assembly is connected to at least one of the left side frame member and the right side frame member. The mounting assembly is configured to support at least one sub system of the vehicle. The mounting assembly is positioned below a seat assembly.
[009] In an embodiment of the invention, the mounting assembly includes a left mounting assembly. The left mounting assembly is connected to the front portion of the left side frame member. The left mounting assembly is adapted to support the at least one sub system of the vehicle.
[010] In another embodiment of the invention, the mounting assembly includes a right mounting assembly. The right mounting assembly is disposed on a front portion of the right side frame member. The right mounting assembly is adapted to support at least the one sub systems of the vehicle.
[011] In a further embodiment of the invention, the frame assembly includes a left mounting assembly. The left mounting assembly includes a left primary arm which is mounted to a front portion of the left side frame member. The left primary arm extending forwardly in a front-rear direction of the saddle type vehicle and orienting inwardly towards the right side frame member when the left primary arm is mounted to the front portion. A left mounting bracket is connected to the left primary arm. The left mounting bracket is adapted to engage with the at least one sub system. A left secondary arm is mounted to the front portion of the left side frame member and to the left primary arm. The left secondary arm is adapted to support the left primary arm. A right mounting assembly includes a right primary arm mounted to the front portion of the right side frame member. The right primary arm is extending forwardly in a front-rear direction of the saddle type vehicle and orienting inwardly towards the left side frame member. A right mounting bracket is attached to the right primary arm. The right mounting bracket is adapted to engage with the at least one sub system. A right secondary arm is mounted to the front portion of the right side frame member and to the right primary arm. The right secondary arm is adapted to support the right primary arm.
[012] In a further embodiment of the invention, the left primary arm is mounted onto the left side frame member through a left support bracket. The right primary arm is mounted onto the right side frame member through a right support bracket.
[013] In an embodiment of the invention, the left support bracket is fastened to a left stay member provided on the left side frame member. The right support bracket is fastened to the right stay member provided on the left side frame member.
[014] In another embodiment of the invention, each of the left mounting bracket and the right mounting bracket comprises a threaded bush for engagement with the at least one sub system.
[015] In a further embodiment of the invention, the left support bracket is fastened to the left side frame member. The right support bracket is fastened to the right side frame member.
[016] In a further embodiment of the invention, the left mounting assembly is separated by a distance (D) from the right mounting assembly.
[017] In a further embodiment of the invention, the distance (D) maintained between the left mounting assembly and the right mounting assembly is greater than the diameter of the main tube.
[018] In a further embodiment of the invention, the distance (D) ranges from 40 mm to 160 mm.
[019] In a further embodiment of the invention, the left mounting assembly is separated by the distance (D) from the right mounting assembly at a central plane (A-A’) of the saddle type vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[020] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a perspective view of a frame assembly of a saddle type vehicle with a mounting assembly, in accordance with an embodiment of the present invention.
Figure 2 illustrates a exploded view of the frame assembly with the mounting assembly, in accordance with an embodiment of the present invention.
Figure 3 illustrates a side exploded view of the frame assembly with the mounting assembly, in accordance with an embodiment of the invention.
Figure 4 illustrates a front view of the frame assembly depicting the mounting assembly in attached position, in accordance with an embodiment of the invention.
Figure 5 illustrates a side view of the frame assembly with the mounting assembly in attached position in accordance with an embodiment of the invention.
Figure 6 illustrates a side view of the frame assembly with the mounting assembly in detached position in accordance with an embodiment of the invention.
Figure 7 illustrates a side view of the frame assembly with the mounting assembly in attached position in accordance with an embodiment of the invention.
Figure 8 illustrates a sectional view of the frame assembly along the axis A-A depicted in Figure 7 with mounting assembly in attached position, in accordance with an embodiment of the invention.
Figure 9 illustrates a sectional view of the frame assembly along the axis B-B with the mounting assembly in attached position, in accordance with an embodiment of the invention.
Figure 10 illustrates a perspective view of the mounting assembly of the frame assembly of the saddle type vehicle in accordance with an embodiment of the invention.
Figure 11 illustrates an exploded view of the mounting assembly of the frame assembly of the saddle type vehicle in accordance with an embodiment of the invention.
Figure 12 illustrates a side view of the frame assembly of the saddle type vehicle with a support bracket and a stay member, in accordance with an alternate embodiment of the invention.
Figure 13 illustrates a front view of the frame assembly depicting a left mounting assembly separated by a distance (D) from a right mounting assembly, in accordance with an alternate embodiment of the invention.
Figure 14 illustrates an exploded view of the frame assembly having the mounting assembly with the support bracket and the stay member, in accordance with an alternate embodiment of the invention.
Figure 15 illustrates a schematic view depicting the left mounting assembly being mounted on the frame assembly of the saddle type vehicle and a right mounting assembly attached to the frame assembly, in accordance with an embodiment of the invention.
Figure 16 illustrates a schematic view depicting the right mounting assembly being mounted on the frame assembly of the saddle type vehicle and a left mounting assembly attached to the frame assembly in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[021] In one aspect, the present invention relates to a frame assembly for a vehicle. The frame assembly of the present invention is typically used in a saddle type vehicle. Generally, the frame assembly supports various components and sub frame parts of the vehicle. The frame may be manufactured in a shape of, but not limited to, tube or pipe or is in any other shape or form available in the art.
[022] Figure 1 illustrates a perspective view of a frame assembly 100 for a saddle type vehicle, in accordance with an exemplary embodiment of the present invention. The frame assembly 100 being configured to provide enhanced space and freedom for packaging mechanical and electrical/ electronic components of the saddle type vehicle (not shown). The frame assembly 100 is also adapted to enhance space availability in the saddle type vehicle (hereinafter referred to as vehicle) for packaging new parts.
[023] The frame assembly 100 for the vehicle comprises a headtube (not shown), a down tube and a pair of side frame tubes. In an embodiment, the down tube being configured to connect the head tube to the pair of side frame tubes. t. The pair of side frame members 102a, 102b are adapted to support a seat assembly (not shown) and a utility box (not shown) or a storage compartment (not shown) of the vehicle.
[024] Referring to Figures 2-4 in conjunction with Figure 1, the pair of side frame members 102a, 102b comprises a front portion 128a, 128b and a rear portion 130a, 130b. The front portion 128a, 128b of the pair of side frame members 102a, 102b is connected to a downtube through a connecting structure 132. The pair of side frame members 102a, 102b includes a left side frame member 102a and a right side frame member 102b. The frame assembly 100 includes a mounting assembly 104. As shown in figures 1 - 4, the mounting assembly 104 is connected to at least one of the left side frame member 102a and the right side frame member 102b. In other words, the mounting assembly 104 is mounted on the left side frame member 102a or the right side frame member 102b or both the left side frame member 102a and the right side frame member 102b. The mounting assembly 104 is positioned below the seat assembly and is adapted to support at least one sub system (not shown) of the vehicle. In an embodiment, the sub systems may be, but not limited to, one of a utility box, a storage compartment, an engine assembly, an induction system and an air cleaner. In an embodiment, the mounting assembly 104 is mounted on the front portion 128a, 128b of the pair of side frame members 102a, 102b as any alteration in construction or profile of any of the sub system is accommodated in the frame assembly 100 without need of modification in the frame assembly 100. In another embodiment, the mounting assembly 104 is mounted on the front portion 128a, 128b of the pair of side frame members 102a, 102b to facilitate alteration in profile or construction of powertrain components without need of modification in the frame assembly 100.
[025] Referring to Figures 5-7 in conjunction with Figures 1-4, the mounting assembly 104 comprises a left mounting assembly 104a. The left mounting assembly 104a is connected to the front portion 128a of the left side frame member 102a. The left mounting assembly 104a is adapted to support the at least one sub system of the vehicle. The left mounting assembly 104a comprises a left primary arm 110a (also shown in Figures 10 and 11) which is mounted to the front portion 128a of the left side frame member 102a through a left support bracket 108a. The left primary arm 110a extends forwardly in a front-rear direction of the vehicle and orienting inwardly towards the right side frame member 102b when the left primary arm 110a is mounted to the front portion 128a. A left mounting bracket 114a is connected to the left primary arm 110a. The left mounting bracket 114a is adapted to connect with the at least one sub system. As such, the left mounting bracket 114a acts as a support for engagement with the at least one sub system. Further, a left secondary arm 112a is mounted to the front portion 128b of the left side frame member 102a and to the left primary arm 110a. The left secondary arm 112a is adapted to support the left primary arm 110a.
[026] Further, the mounting assembly 104 comprises a right mounting assembly 104b. The right mounting assembly 104b is disposed on a front portion 128b of the right side frame member 102b. The right mounting assembly 104b is also adapted to support at least the one sub systems of the vehicle. In an embodiment, the left mounting assembly 104a and the right mounting assembly 104b is welded to the respective side frame members 102a, 102b. The right mounting assembly 104b comprises a right primary arm 110b is mounted to the front portion 128b of the right side frame member 102b through a right support bracket 108b. The right primary arm 110b extends forwardly in a front-rear direction of the saddle type vehicle and orienting inwardly towards the left side frame member 102a, when the right primary arm 110b is mounted onto the right side frame member 102b. A right mounting bracket 114b is attached to the right primary arm 110b. The right mounting bracket 114b is adapted to connect with the at least one sub system. A right secondary arm 112b is mounted to the front portion 128b of the right side frame member 102b and to the right primary arm 110b. The right secondary arm 112b is adapted to support the right primary arm 110b.
[027] In an embodiment, the left primary arm 110a and the right primary arm 110b are bashed or flattened at one end to engage with the at least one sub system. In another embodiment, the left primary arm 110a and the right primary arm 110b being provided with one or more left mounting brackets 114a right mounting bracket or one or more right mounting brackets 114b.
[028] In an embodiment, the left support bracket 108a is attached to the left side frame member 102a. The right support bracket 108b is attached to the right side frame member 102b. In another embodiment, the left support bracket 108a is welded to the left side frame member 102a. The right support bracket 108b is welded to the right side frame member 102b. The left and right support bracket (108a, 108b) being welded on the side faces. Such a construction reduces stress concentration in the mounting assembly 104.
[029] In an alternative embodiment, as shown in an exemplary figure 12-16, the left support bracket 108a is fastened to a left stay member 106a provided on the left side frame member 102a. Similarly, the right support bracket 108b is fastened to the right stay member 106b provided on the left side frame member 102b. In another embodiment, the left support bracket 108a is welded to a left stay member 106a provided on the left side frame member 102a. Similarly, the right support bracket 108b is welded to the right stay member 106b provided on the left side frame member 102b.
[030] In an embodiment, each of the left mounting bracket 114a and the right mounting bracket 114b has a threaded bush 116 (shown in figure 11) for engagement with the at least one sub systems.
[031] In an embodiment, the left mounting assembly 104a is separated by a distance (D) (as shown in figure 4 and figure 13) from the right mounting assembly 104b. In another embodiment, the left mounting assembly 104a is separated by the distance (D) from the right mounting assembly 104b at a central plane (A-A’) of the saddle type vehicle. The distance (D) maintained between the left mounting assembly 104a and the right mounting assembly 104b is greater than the diameter of a main tube of the frame assembly 100. The distance (D) ranges from 40 milli meters to 160 milli meters. In an embodiment, the distance (D) is approximately 50 percent of a length of a cylinder head in an engine having a capacity of 125 cubic centimetres. The space created by the availability of distance (D) which can give more freedom while packaging various new components like increased air intake tube, larger cylinder head, addition of Variable Valve Actuation (VVA) solenoid etc in that region. The VVA solenoid which is usually placed near the cylinder head can be accommodated in the distance (D) between the mounting assemblies. The VVA is a mechanism which allow to vary the inlet and exhaust valve openings to achieve the best performance of engines.in another embodiment, in the distance (D) between the mounting assemblies, the utility box can be extended further downwards or forwardly in a vehicle longitudinal direction locally to improve the overall storage space. The distance “D” can also be used to extend laterally and slightly upwards the cylinder head. The distance “D” provide scope for more freedom and articulation of the engine. The intake tube can be made larger in size or the throttle body can be pushed upwards for better packaging due to the availability of the distance “D”. In an embodiment, in case of an electric vehicle, the distance “D” is used to accommodate a charger assembly. It can also be used to accommodate any extensions or additions to the battery pack.
[032] In an embodiment, the primary arm 110a, 110b has bigger diameter than the secondary arm 112a, 112b (as shown in Figures 7 and 8). Similarly, diameter of each of the left side frame member 102a and the right side frame member 102b is bigger than the primary arm 110a, 110b (as shown in Figures 7 and 9).
[033] In another embodiment, the mounting assembly 104 is a sheet metal part welded to the pair of side frame member 102a, 120b. In an embodiment, the mounting assembly 104 is extending from the pair of side frame member 102a, 120b towards the central plane A-A’ (shown in figure 4) of the frame assembly 100. In another embodiment, the sheet metal part is welded to a side face (not shown) of each of the pair of side frame member 102a, 120b. A supporting plate (not shown) is used which is welded to an opposite face (not shown) of each of the pair of side frame member 102a, 120b to provide additional strength to the frame assembly 100. In another embodiment, the mounting assembly 104 is made of a forged or a cast part and is adapted to be connected to the frame assembly 100 and the utility box.
[034] The claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies. Specifically, the claimed aspect of the the frame assembly has increased the space for packaging new parts and also improved the overall storage space. The claimed invention provides flexibility to change the design of cylinder head as there is no hinderance. Hence, it helps in increasing the overall performance of the vehicle. The claimed invention also enables the ease of assembly of other parts and improves the serviceability. The claimed invention requires minimum modification in the frame. Hence, reduces the cost of application of present invention in the vehicle. Further, if there is any damage in the mounting assembly of the claimed invention, the same can be replaced without replacing the entire body frame of the vehicle as the mounting assembly is detachably attached to the frame.
[035] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals
100 - Frame Assembly
102a - Left side frame member
102b - Right side frame member
104a - Left mounting assembly
104b - Right mounting assembly
106a - Left stay member
106b - Right stay member
108a - Left support bracket
108b - Right support bracket
110a - Left primary arm
110b - Right primary arm
114a - Left mounting bracket
114b - Right mounting bracket
112a - Left secondary arm
112b - Right secondary arm
116 - Threaded bush
128a, 128b – Front portion
128a – Front portion of the left side frame member
128b – Front portion of the right side frame member
130a, 130b – Rear portion
130a – Rear portion of the left side frame member
130b – Rear portion of the right side frame member
132 – Connecting structure , Claims:WE CLAIM:
1. A frame assembly (100) for a vehicle, the frame assembly (100) comprising:
a pair of side frame members (102a, 102b), the pair of side frame members (102a, 102b) being configured to have a front portion (128a, 128b) and a rear portion (130a, 130b),
wherein the front portion (128a, 128b) of the pair of side frame members being connected to a main tube;
wherein the pair of side frame members (102a, 102b) includes a left side frame member (102a) and a right side frame member (102b);
a mounting assembly, the mounting assembly being connected to at least one of the left side frame member (102a) and the right side frame member (102b),
wherein the mounting assembly being configured to support at least one sub system of the vehicle, wherein the mounting assembly being positioned below a seat assembly.

2. The frame assembly (100) as claimed in claim 1, wherein the mounting assembly includes a left mounting assembly (104a), the left mounting assembly (104a) being connected to the front portion (128a) of the left side frame member (102a), the left mounting assembly (104a) being adapted to support the at least one sub system of the vehicle.

3. The frame assembly (100) as claimed in claim 1, wherein the mounting assembly includes a right mounting assembly (104b), the right mounting assembly (104b) being disposed on a front portion (128b) of the right side frame member (102b), the right mounting assembly (104b) being adapted to support at least the one sub systems of the vehicle.

4. The frame assembly (100) as claimed in claim 1 comprises:
a left mounting assembly (104a) comprising:
a left primary arm (110a) being mounted to a front portion (128a) of the left side frame member (102a), the left primary arm (110a) extending forwardly in a front-rear direction of the saddle type vehicle and orienting inwardly towards the right side frame member (102b) when the left primary arm (110a) is mounted to the front portion (128a),
a left mounting bracket (114a) connected to the left primary arm (110a), the left mounting bracket (114a) being adapted to engage with the at least one sub systems, and
a left secondary arm (112a) mounted to the front portion (128b) of the left side frame member (102a) and to the left primary arm (110a), the left secondary arm (112a) being adapted to support the left primary arm (110a), and
a right mounting assembly (104b) comprising:
a right primary arm (110b) mounted to the front portion (128a) of the right side frame member (102b), the right primary arm (110b) extending forwardly in a front-rear direction of the saddle type vehicle and orienting inwardly towards the left side frame member (102a);
a right mounting bracket (114b) attached to the right primary arm (110b), the right mounting bracket (114b) being adapted to engage with the at least one sub systems, and
a right secondary arm (112b) mounted to the front portion (128b) of the right side frame member (102b) and to the right primary arm (110b), the right secondary arm (112b) being adapted to support the right primary arm (110b).

5. The frame assembly (100) as claimed in claim 4, wherein the left primary arm (110a) is mounted onto the left side frame member (102a) through a left support bracket (108a), while the right primary arm (110b) is mounted onto the right side frame member (102b) through a right support bracket (108a).

6. The frame assembly (100) as claimed in claim 5, wherein
the left support bracket (108a) being fastened to a left stay member (106a) provided on the left side frame member (102a);
the right support bracket (108b) being fastened to the right stay member (106b) provided on the left side frame member (102b).

7. The frame assembly (100) as claimed in claim 4, wherein each of the left mounting bracket (114a) and the right mounting bracket (114b) comprises a threaded bush (116) for engagement with the at least one sub systems.

8. The frame assembly (100) as claimed in claim 5, wherein the left support bracket (108a) being fastened to the left side frame member (102a), the right support bracket (108b) being fastened to the right side frame member (102b).

9. The frame assembly (100) as claimed in claim 4, wherein the left mounting assembly (104a) is separated by a distance (D) from the right mounting assembly (104b).

10. The frame assembly (100) as claimed in claim 9, wherein the distance (D) maintained between the left mounting assembly (104a) and the right mounting assembly (104b) is greater than the diameter of the main tube.

11. The frame assembly (100) as claimed in claim 9, wherein the distance (D) ranges from 40 milli meters to 160 milli meters.

12. The frame assembly (100) as claimed in claim 9, wherein the left mounting assembly (104a) is separated by the distance (D) from the right mounting assembly (104b) at a central plane (A-A’) of the saddle type vehicle.

Dated this 19 day of July 2023

TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471