Description:FIELD OF THE INVENTION
[001] The present invention relates to a vehicle, and more particularly to disposition of an ignition coil assembly in the vehicle.

BACKGROUND OF THE INVENTION
[002] Ignition coil assembly is one of the essential components in an Internal Combustion (IC) engine of a vehicle. The ignition coil assembly is coupled to a spark plug of the IC engine and to a battery pack in the vehicle. The ignition coil assembly comprises a coil unit and a suppressor cap, that are adapted to route ignition current or voltage to the spark plug, for igniting an air-fuel mixture in the IC engine for combustion.
[003] Generally, disposition of the ignition coil assembly in a vehicle, such as a saddle-type vehicle, is of utmost importance. Based on disposition of the ignition coil assembly, a layout of the vehicle may be categorized into two structures. A first type of vehicle layout may be a vehicle structure comprising a mainframe extending from a headtube of the vehicle. In such vehicle layouts, the suppressor cap is readily accessible to a user of the vehicle, owing to the conspicuous location of the engine in the vehicle. A second type of vehicle layout may be an adventure type vehicle, wherein a trellis type frame structure is provided owing to a higher torque and speed requirements. Conventionally, the trellis type frame structure comprises the head tube, with a left and right main frame extending from the head tube. A plurality of cross members may be connecting the pair of left and right main frame. The trellis type frame improves the overall vehicle rigidity and sturdiness to suit the vehicle torque and speed requirements. In the trellis frame, the engine is disposed between the left and right main frame members, hence accessibility of the engine is readily unavailable to the user or the user may be required to employ specialised tools for accessing the suppressor cap.
[004] A common instance of interaction with the ignition coil assembly is in the event of non-startability of the vehicle. At this juncture, a general practice is to remove the suppressor cap from the engine and blow off carbon soot accumulated. In the trellis frame structure, as the engine is located between the left and right main frame, the suppressor cap is readily inaccessible to the user of the vehicle. As such, the vehicle is required to be moved to a dealer’s location, wherein the dealer with specialised tools may dismantle body panels in the vehicle for accessing the suppressor cap.
[005] Further, as the ignition coil assembly is a high current generating instrument for igniting the air fuel mixture, a High Tension (HT) cable connects the coil unit with the spark plug. Typically, the HT cable is prone to fire safety risks due to supply of ignition current or voltage, if routed improperly in the vehicle. Particularly, the fire safety risks enhances if the HT cable is in contact with any metal part and sharp objects on the frame of the vehicle. Also, current leakage and spark leakage may be higher in case of improper routing of the HT cable. As such, locating the IG coil by considering the HT cable routing is important to avoid fire risk in the vehicle.
[006] In view of the above, there is a need for a vehicle that addresses at least some of the limitations mentioned above.

SUMMARY OF THE INVENTION
[007] In one aspect, a vehicle is provided. The vehicle has at least one ignition coil assembly. The vehicle also comprises a frame assembly having a headtube, a left main tube extending rearwardly from the headtube, a right main tube extending rearwardly from the headtube and a cross member. The cross member connects the left main frame and the right main frame in a front portion of the vehicle. Each of the at least one ignition coil assembly comprises a coil unit mounted to the cross member and a suppressor cap. The suppressor cap is disposed in a cylinder head of an engine and is electrically coupled to the coil unit.
[008] In an embodiment, the coil unit is mounted to the cross member through a detachable bracket.
[009] In an embodiment, the coil unit is positioned below the cross member and a fuel tank of the vehicle.
[010] In an embodiment, the coil unit overlaps with an engine control unit mounting bracket and an engine control unit in a side view of the vehicle.
[011] In an embodiment, the coil unit is located above the cylinder head of the engine.
[012] In an embodiment, the coil unit is located behind a cooling duct in a front-rear direction of the vehicle, and above the cooling duct in a top-down direction of the vehicle.
[013] In an embodiment, the suppressor cap is spaced apart from the cross member by a distance about a top-down direction of the vehicle.
[014] In an embodiment, the suppressor cap is electrically coupled to the coil unit through a high tension cable.
[015] In an embodiment, the high tension cable that connects the suppressor cap and the coil unit, is provided with a bending radius (R).
[016] In an embodiment, the high tension cable with the bending radius (R) is oriented towards one of the left main tube and the right main tube.

BRIEF DESCRIPTION OF ACCOMAPNYING DRAWINGS
[017] 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 is a left-side view of a front portion of a frame assembly in a vehicle, in accordance with an exemplary embodiment of the present invention.
Figure 2 is a bottom view of the front portion of the frame assembly, in accordance with an exemplary embodiment of the present invention.
Figure 3 is a top perspective view of the front portion of the frame assembly, in accordance with an exemplary embodiment of the present invention.
Figure 4 is a perspective view of an ignition coil assembly mounted to the frame assembly, in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[018] Present invention discloses a vehicle. Particularly, the present invention relates to disposition of an ignition coil assembly in the vehicle. The ignition coil assembly comprises a coil unit adapted to generate an ignition current to be supplied to a spark plug of an engine of the vehicle. The coil unit is positioned on a cross member connecting a left main tube and a right main tube of a frame assembly in the vehicle. A suppressor cap is electrically coupled to the coil unit and to the spark plug through a High Tension (HT) cable. Such a disposition of the ignition coil assembly ensures easy serviceability and accessibility to the spark plug of the engine. Also, the coil unit is protected from damage in the event of a sideward fall of the vehicle. Moreover, disposition of the ignition coil assembly makes the packaging in the vehicle compact, while also ensuring easy access to the coil unit during a service requirement.
[019] In the present disclosure, arrow indications provided in Figures pertain to directional indications of the vehicle. As such, the terms “top side”, “bottom side”, “left side” and “right side” respectively correspond to top, bottom, left and right sides of the vehicle, until and unless specified otherwise.
[020] Figure 1 is a left-side view of a front portion of a frame assembly 102 in a vehicle 100, in accordance with an exemplary embodiment of the present invention. The vehicle 100 can be a two-wheeled vehicle, such as a motorcycle. In the present embodiment, the frame assembly 102 in the vehicle 100 is a trellis-type frame. The term “front portion” in the context of the present invention corresponds to a portion of the vehicle 100 that is in front of a seat (not shown) along a front-rear direction of the vehicle.
[021] The frame assembly 102 of the vehicle 100 comprises a headtube that is adapted to support a steering shaft (not shown) and a front suspension assembly (not shown) attached to the steering shaft through a bracket (not shown). A front wheel (not shown) is connected to the steering shaft and to the front suspension assembly. Further, a handlebar (not shown) is fixed to an upper bracket and can rotate about the steering shaft or a steering axis of the vehicle 100.
[022] Referring to Figures 2 and 3 in conjunction with Figure 1, the frame assembly 102 comprises a left main tube 106a extending rearwardly from the headtube 104. A right main tube 106b extends rearwardly from the headtube 104, and overlaps with the left main tube 106a in a side view of the vehicle 100. The left main tube 106a and the right main tube 106b extend rearwardly and downwardly upto a center tube (not shown) of the vehicle 100 from the headtube 104.
[023] In an embodiment, the left main tube 106a and the right main tube 106b diverge from the headtube 104 upto a predetermined length and thereafter, extend longitudinally and rearwardly from the headtube 104. As such, the left main tube 106a and the right main tube 106 form a narrow portion 126 (as shown in Figure 2) in the vicinity of the headtube 104 of the vehicle 100, when viewed from a top or a bottom view (as shown in Figures 2 and 3) of the vehicle 100.
[024] The frame assembly 102 further comprises a cross member 108 that connects the left main frame 106a and the right main frame 106b. As the left main frame 106a and the right main frame 106b are provided in the front portion of the vehicle 100, the cross member 108 is also provided in the front portion of the vehicle 100. The cross member 108 is adapted to enhance structural rigidity of the frame assembly 102. In the present embodiment, the cross member 108 is mounted in the narrow portion 126 between the left main frame 106a and the right main frame 106b. In an embodiment, the cross member 108 is a plate-like member coupled to the left main frame 106a and the right main frame 106b, through conventional coupling techniques known in the art.
[025] In an embodiment, the frame assembly 102 comprises a left lower main tube 132a positioned below the left main tube 106a in the side view of the vehicle 100. The frame assembly 102 also comprises a right lower main tube 132b positioned below the right main tube 106b in the side view of the vehicle 100. The left lower main tube 132a overlaps with the right lower main tube 132b in a left side view of the vehicle 100. The left lower main tube 132a and the right lower main tube 132b overlap with the left main tube 106a and the right main tube 106b, when viewed in a top view of the vehicle 100. The left lower main tube 132a and the right lower main tube 132b extend from a lower portion (not shown) of the headtube 104, while the left main tube 106a and the right main tube 106b extend from a top portion (not shown) of the headtube 104. In an embodiment, the left lower main tube 132a and the right lower main tube 132b maintain a distance between the left main tube 106a and the right main tube 106b.
[026] Further, an engine 118 such as an Internal Combustion (IC) engine is disposed on the frame assembly 102. In the present embodiment, the engine 118 is a gasoline engine or a spark-ignition type engine. The engine 118 is adapted to provide the motive force required for operation of the vehicle 100. Also, the engine 118 may be coupled to a rear wheel (not shown) or the front wheel, through an endless transmission drive such as a chain drive or a belt drive. Accordingly, the engine 118 can transmit motive force to the rear wheel or the front wheel for moving the vehicle 100. The engine 118 comprises a cylinder head 116 mounted on a cylinder block (not shown), which in turn is mounted on a crankcase (not shown) of the engine 118. In an embodiment, the cylinder head 116 is bolted or fastened to the cylinder block and the crankcase. The cylinder head 116 is adapted to enclose components such as a camshaft (not shown), one or more intake valves (not shown), one or more exhaust valves (not shown), a spark plug 128 (as shown in Figure 3) and the like. The spark plug 128 protrudes within a combustion chamber (not shown) in the cylinder block. The spark plug 128 is adapted to ignite air-fuel mixture entering the combustion chamber through the one or more intake valves, thereby generating the motive force. The motive force is transmitted to a crankshaft (not shown) disposed in the crankcase through a piston (not shown) and a connecting rod (not shown).
[027] In an embodiment, the engine 118 may be connected to a cooling assembly (not shown), such as a liquid cooling assembly or an air cooling assembly. The cooling assembly is mounted to the frame assembly 102 and may be positioned in front of the engine 118. The cooling assembly may be provided with a cooling duct. The cooling duct may be fluidically connected to the engine 118. The cooling duct may be adapted to circulate cooling fluid for maintaining an optimum temperature of the engine 118. In an embodiment, the cooling duct is positioned in front of the engine 118 and below the left main frame 106a and the right main frame 106b.
[028] Referring to Figure 4 in conjunction with Figures 1-3, the spark plug 128 is electrically connected to at least one ignition coil assembly 110. In the present embodiment, one ignition coil assembly 110 is provided. It is to be understood that, more than one ignition coil assembly 110 is provided, when the engine 118 is a multi-cylinder engine and/or more than one spark plug 128 is provided in the engine 118 for igniting the air-fuel mixture in the combustion chamber of the engine 118.
[029] The ignition coil assembly 110 is also adapted to be electrically connected to a battery pack (not shown). The ignition coil assembly 110 is adapted to receive current from the battery pack. The current received from the battery pack is modulated to an ignition current by the ignition coil assembly 100 and provided to the spark plug 128, which enables the spark plug 128 to ignite the air-fuel mixture within the combustion chamber. The term “ignition current” corresponds to a current modulated by the ignition coil assembly 110 and provided to the spark plug for enabling ignition of the air-fuel mixture. In an embodiment, the ignition coil assembly 110 is adapted to step up or amplify voltage received from the battery pack. In an embodiment, the ignition coil assembly 110 is a pencil type ignition coil assembly.
[030] The ignition coil assembly 110 comprises a coil unit 112 electrically coupled, through wired connection, to the battery pack. The coil unit 112 is mounted to the cross member 108. As such, the coil unit 112 is easily accessible for a user of the vehicle, during a maintenance event by eliminating the need for disassembling other components, such as the fuel tank. Moreover, placing the coil unit 112 on the cross member 108 ensures disposition of the coil unit 112 is in an easily reachable location within the frame assembly 102. The coil unit 112 comprises a plurality of windings on a core material, wherein the windings are adapted to modulate the current received from the battery pack to generate the ignition current required for igniting the air-fuel mixture in the combustion chamber of the engine.
[031] In an embodiment, the coil unit 112 is mounted to the cross member 108 through a detachable bracket 120. The detachable bracket 120 is mounted below the cross member 108, through conventional mounting techniques known in the art such as fastening, and the like. As such, the coil unit 112 is positioned below the cross member 108 and, the left main frame 106a and the right main frame 106b in the side view of the vehicle 100 (as shown in Figure 1). Further, as a fuel tank (not shown) is mounted on top of the left main frame 106a and the right main frame 106b, the coil unit 112 is also positioned below the fuel tank of the vehicle.
[032] In an embodiment, the detachable bracket 120 has a first end 120a mounted to a bottom surface of the cross member 108, and a second end 120b mounted to a housing 112a of the coil unit 112. The housing 112a may be provided with openings 130 for aligning with corresponding slots on the detachable bracket 120 at the second end 120b for fastening. In an embodiment, the detachable bracket 120 may be a plate-like member capable of mounting the coil unit 112 and the cross member 108.
[033] In an embodiment, the detachable bracket 120 is provided at a central portion of the cross member 108. As such, the coil unit 112 is positioned at a mid-portion between the left main frame 106a and the right main frame 106b. Such a disposition may mitigate interference of the coil unit 112 with the metal parts (i.e. the frame assembly 102), thereby ensuring optimum operation of the coil unit 112.
[034] Further, the coil unit 112 is mounted to the cross member 108 such that, the coil unit 112 is located above the cylinder head 116 and located behind the cooling duct in the front-rear direction of the vehicle 100. Also, the coil unit 112 is located above the cooling duct in a top-down direction of the vehicle. Such a disposition further mitigates interference with other components in the vehicle.
[035] In an embodiment, the vehicle 100 comprises an engine control unit mounting bracket 122, that is adapted to support an Engine Control Unit (ECU) (not shown). The engine control unit mounting bracket 122 is positioned below the left main frame 106a and the right main frame 106b (as shown in Figure 1). Accordingly, the ECU of the vehicle 100 is positioned below the left main frame 106a and the right main frame 106b. Additionally, the coil unit 112 is mounted to the cross member 108 such that, the coil unit 112 overlaps with the engine control unit mounting bracket 122 and the ECU in the side view of the vehicle 100 (as shown in Figure 1). Such a disposition of the coil unit 112 enhances packaging in the vehicle 100, while preventing interference with other components.
[036] In an embodiment, the coil unit 112 is mounted to the cross member 108 such that, the coil unit 112 is disposed in an area surrounded by the left main tube 106a, the right main tube 106b, the left lower main tube 132a and the right lower main tube 132b. In other words, the coil unit 112 is disposed between the left main tube 106a, the right main tube 106b, the left lower main tube 132a and the right lower main tube 132b (as shown in Figure 1).
[037] Further, the ignition coil assembly 110 comprises a suppressor cap 114 electrically coupled to the coil unit 112 and the spark plug 128. The suppressor cap 114 is adapted to receive the ignition current generated in the coil unit 112 and transfer the ignition current to the spark plug 128. The suppressor cap 114 is also adapted to prevent magnetic and electro-magnetic interference with the spark plug 128 while supplying the ignition current to the spark plug 128. As the suppressor cap 114 is mounted to the spark plug 128 which is provided in the cylinder head 116, the suppressor cap 114 is spaced apart from the coil unit 112. Also, the suppressor cap 114 is located or disposed below the coil unit 112 in the top-down direction of the vehicle. Such a disposition further mitigates magnetic and/or electromagnetic interference between the coil unit 112 and the suppressor cap 114.
[038] The suppressor cap 114 is electrically coupled to the coil unit 112 through a High Tension (HT) cable 124. The HT cable 124 is provided with a bending radius R (as shown in Figure 4). The HT cable 124 may be oriented towards the left main tube 106a or the right main tube 106b. In an embodiment, due to the space between the coil unit 112 and the suppressor cap 114, the requisite bending radius R is provided to the HT cable 124. As such, possibility of kinking of the HT cable 124 is mitigated. In an embodiment, the bending radius R is in the range of 50 mm to 100mm. Such a range ensures adequate flexibility for routing the cable within an engine compartment of the vehicle 100, while minimizing risk of kinking or damage to the HT cable 124. Further, such a range of bending radius to the HT cable 124 allows for smooth and efficient transmission of ignition current between the coil unit 112 and the suppressor cap 114, thereby enhancing overall performance and reliability of the ignition coil assembly 110.
[039] 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 disposing the coil unit of the ignition coil assembly on the cross member, ensures easy serviceability and accessibility to the coil unit and thus the spark plug of the engine. As such, the suppressor cap can also be easily accessed in the vehicle. Further, by mounting the coil unit on the cross member, it becomes easily accessible to a user or technician during maintenance events. This positioning eliminates the need for disassembling other components or removing the fuel tank, which might be necessary if the coil unit were in a more enclosed or hard-to-reach area. Also, placing the coil unit on the cross member ensures that it is positioned in a central and easily reachable location within the frame assembly of the vehicle. This centralized position minimizes effort required to access the coil unit, as it is not tucked away in hard-to-reach corners or obscured by other components. Additionally, mounting the coil unit on the cross member, eliminates need for additional brackets or mounting points on the frame assembly. This reduces complexity of the assembly process and simplifies maintenance procedures, as there are fewer parts to disassemble or remove when accessing the coil unit. Also, placement of the coil unit on the cross member ensures that it is easily visible and identifiable within the vehicle's engine compartment. This visibility facilitates inspection and troubleshooting tasks, allowing technicians to quickly locate and assess the coil unit without extensive searching or disassembly. Mounting the coil unit on the cross member provides a level of protection from potential damage caused by external impacts or vibrations to the vehicle. The cross member typically offers structural rigidity and stability, shielding the coil unit from accidental bumps or knocks that could occur during vehicle operation or maintenance activities. By specifying the disposition of the coil unit on the cross member, the present disclsosure emphasizes the practical benefits of enhanced accessibility, ease of maintenance, and protection provided by this arrangement within the vehicle's frame assembly. Also, such a disposition of the coil unit provides protection from damage in the event of a sideward fall of the vehicle. Moreover, disposition of the ignition coil assembly makes the packaging compact in the vehicle, while also ensuring easy access to the coil unit during a service requirement. Additionally, by maintaining the distance between the coil unit and the suppressor cap, the interference therebetween is eliminated. Accordingly, magnetic and/or electromagnetic related interference related losses are mitigated. Also, due to the space between the coil unit and the suppressor cap, the requisite bending radius is provided to the HT cable. As such, the possibility of kinking of the HT cable is mitigated.
[040] 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.

Reference Numerals and Characters
100 - Vehicle
102 – Frame assembly
104 – Headtube
106a – Left main tube
106b – Right main tube
108 – Cross member
110 – Ignition coil assembly
112 – Coil unit
114 – Suppressor cap
116 – Cylinder head
118 – Engine
120 – Detachable bracket
122 – Engine control unit mounting bracket
124 – High Tension cable
126 – Narrow portion
128 – Spark plug
130 – Openings
132a – Left lower frame tube
132b – Right lower frame tube , Claims:WE CLAIM:
1. A vehicle (100) having at least one ignition coil assembly (110), the vehicle (100) comprising:
a frame assembly (102), comprising:
a headtube (104),
a left main tube (106a) extending rearwardly from the headtube (104),
a right main tube (106b) extending rearwardly from the headtube (104), and
a cross member (108) connecting the left main frame (106a) and the right main frame (106b) in a front portion of the vehicle (100); and
each of the at least one ignition coil assembly (110) comprising:
a coil unit (112) mounted to the cross member (108); and
a suppressor cap (114) disposed in a cylinder head (116) of an engine (118) of the vehicle (100), the suppressor cap (114) being electrically coupled to the coil unit (112).

2. The vehicle (100) as claimed in claim 1, wherein coil unit (112) being mounted to the cross member (108) through a detachable bracket (120).

3. The vehicle (100) as claimed in claim 1, wherein the coil unit (112) is positioned below the cross member (108) and a fuel tank of the vehicle (100).

4. The vehicle (100) as claimed in claim 1, wherein the coil unit (112) overlaps with an engine control unit mounting bracket (122) and an engine control unit in a side view of the vehicle (100).

5. The vehicle (100) as claimed in claim 1, wherein the coil unit (112) is located above the cylinder head (116) of the engine (118).

6. The vehicle (100) as claimed in claim 1, wherein the coil unit (112) is located behind a cooling duct in a front-rear direction of the vehicle (100), and above the cooling duct in a top-down direction of the vehicle (100).

7. The vehicle (100) as claimed in claim 1, wherein the suppressor cap (114) being spaced apart from the cross member (108) by a distance about a top-down direction of the vehicle (100).

8. The vehicle (100) as claimed in claim 1, wherein the suppressor cap (114) is electrically coupled to the coil unit (112) through a high tension cable (124).

9. The vehicle (100) as claimed in claim 8, wherein the high tension cable (124) connecting the suppressor cap (114) and the coil unit (112) being provided with a bending radius (R).

10. The vehicle (100) as claimed in claim 9, wherein the high tension cable (124) with the bending radius (R) being oriented towards one of the left main tube (106a) and the right main tube (106b).

Dated this 07th day of March 2024
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

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