DESC:CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to the Indian provisional patent application No. 202541020370 filed on March 6, 2025, the complete disclosures of which, in their entirety, are herein incorporated by reference.
BACKGROUND
Technical Field
The embodiments herein generally relate to a vehicle, and more particularly, to a front frame assembly of a vehicle.
Description of related art
Vehicle frame design, especially for the front assembly, requires careful balancing of multiple factors. Manufacturers strive for frames that are strong, lightweight, and offer superior longitudinal stiffness. A critical area of concern is the front cradle region, particularly around the head tube and its connection to the downtube. Though offering certain benefits, traditional dual cradle front frames are characterized by significantly decreased longitudinal stiffness. Longitudinal stiffness reduction occurs because the frame's cross-sectional modulus changes, typically decreasing, after the head tube gusset and front cross member. Reduced longitudinal stiffness can negatively impact the vehicle's handling, potentially leading to flex, instability, and a less precise feel for the rider. Therefore, the traditional approach is inefficient in solving the problems mentioned earlier.
Therefore, there is a need for an improved front frame assembly of a vehicle that maintains longitudinal stiffness to enhance overall performance and rider experience.
SUMMARY
In view of the foregoing, an embodiment herein provides a front frame assembly of a vehicle. The front frame assembly includes a headtube, at least two down tubes, a left front frame member, a right front frame member, at least one headtube supporting member, and one or more horizontal cross members. The at least two downtubes include a left downtube and a right downtube. The left downtube and the right downtube project downward from the headtube. Each of the left downtube and the right downtube includes a variation in cross-sectional area at a corresponding distal end. The left front frame member and the right front frame member each project downward from a respective downtube and are connected to a left floorboard frame member and a right floorboard frame member. The left floorboard frame member and the right floorboard frame member are each connected to a respective front frame member. The left front frame member and the right front frame member each include a variation in cross-sectional area similar to the left downtube and the right downtube, form a predetermined shape. The left front frame member and the right front frame member with the predetermined shape include an inner flat surface, and an outer flat surface oriented laterally, along with a front curved surface and a rear curved surface oriented longitudinally. The outer flat surfaces of the left front frame member and the right front frame member are configured to form a predetermined profile with the left floorboard frame member and the right floorboard frame member to increase contact area and enhance load transfer. The front curved surfaces of the left front frame member and the right front frame member are mechanically configured to enable reduced air resistance. The at least one headtube supporting member projects downward from the headtube and is connected to the one or more horizontal cross members. The at least one headtube supporting member is configured to provide support to the headtube, the left downtube, and the right downtube. The one or more horizontal cross members extend between the left front frame member and the right front frame member to provide structural support to the front frame assembly.
In some embodiments, the one or more horizontal cross members include a first horizontal cross member positioned at a top portion and a second horizontal cross member positioned at a bottom portion of the left front frame member and the right front frame member. The first horizontal cross member and the second horizontal cross member are configured to connect the left front frame member and the right front frame member via the inner flat surface to improve coupling.
In some embodiments, the first horizontal cross member and the second horizontal cross member are in a predetermined shape to enable less air resistance.
In some embodiments, the left front frame member and the right front frame member each comprise equal cross-sectional area to the left downtube and the right downtube, respectively.
In some embodiments, the left floorboard frame member and the right floorboard frame member include a left floorboard sub-frame member and a right floorboard sub-frame member, respectively.
In some embodiments, the second horizontal cross member, along with the left floorboard frame member, the right floorboard frame members, the left floorboard sub-frame member, and the right floorboard sub-frame member, collectively form a cage structure configured to protect a floorboard battery pack.
In some embodiments, the front frame assembly further includes one or more load transfer paths. The one or more load transfer paths include a first load transfer path, a second load transfer path, and a third load transfer path.
In some embodiments, the first load transfer path originates at the headtube and extends to the left floorboard frame member and the right floorboard frame member via the at least one headtube supporting member, the first horizontal cross member, the left front frame member, and the right front frame member.
In some embodiments, the second load transfer path originates at the headtube and extends to the left floorboard frame member and the right floorboard frame member via the left downtube and the right downtube, the left front frame member, and the right front frame member.
In some embodiments, the third load transfer path travels from the left front frame member and the right front frame member, and extends to the left floorboard frame member, the right floorboard frame member, the left floorboard sub-frame member, and the right floorboard sub-frame member. The third load transfer path further extends to a back frame member of the vehicle.
These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
FIGS. 1A and 1B are isometric views illustrating a front frame assembly of a vehicle, according to an embodiment herein;
FIG. 1C is a cross-sectional top view illustrating the front frame assembly of the vehicle, according to an embodiment herein; and
FIGS. 2A and 2B illustrate one or more load transfer paths of the front frame assembly of the vehicle, according to an embodiment herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
Various embodiments provide a structurally improved design that is both strong and lightweight. More particularly the front frame assembly prevents longitudinal stiffness reduction through the use of the left downtube and right downtube, the left front frame member 108 and right front frame member, as well as the strategic positioning of one or more horizontal cross members and at least one headtube supporting member. Additionally front frame assembly 100 enhances the longitudinal stiffness of the structure while minimizing additional mass, thereby contributing to improved vehicle stability.
As mentioned, there remains a need for an improved front frame assembly of a vehicle that maintains longitudinal stiffness to enhance overall performance and rider experience. Referring now to the drawings, and more particularly to FIG. 1 to FIG. 2, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
FIGS. 1A and 1B are isometric views illustrating a front frame assembly 100 of a vehicle, according to an embodiment herein. The front frame assembly 100 of the vehicle includes a headtube 102, at least two downtubes, a left front frame member 108, a right front frame member 110, at least one headtube supporting member 112, and one or more horizontal cross members 114. The at least two downtubes include a left downtube 104, a right downtube 106.
In one embodiment, the vehicle may include, but is not limited to, an internal combustion engine and an electric vehicle. In another embodiment, the electric vehicle may include, but is not limited to, a Battery Electric Vehicle (BEV), Plug-in Hybrid Electric Vehicle (PHEV), Hybrid Electric Vehicle (HEV), or Fuel Cell Electric Vehicle (FCEV). The headtube 102 includes an ignition locking mounting bracket, a charger bracket, and one or more front fairing brackets (not shown in the figure).
The left downtube 104 and the right downtube 106 project downward from the headtube 102. Each of the left downtube 104 and the right downtube 106 includes a variation in cross-sectional area at a corresponding distal end. In one embodiment, the variation in the cross-sectional area gradually increases or decreases from a proximal end to the distal end of the left downtube 104 and the right downtube 106. In one embodiment, the left downtube 104 is a single member or may be made of one or more sub-members. In another embodiment, the right downtube 106 is a single member or may be made of one or more sub-members. The one or more sub-members of the left downtube 104 and the right downtube 106 each have a different cross-sectional area than preceding sub-members. In one embodiment, the one or more sub-members of the left downtube 104 and the right downtube 106 each have a smaller cross-sectional area than the preceding sub-members. In another embodiment, the one or more sub-members of the left downtube 104 and the right downtube 106 each have a bigger cross-sectional area than the preceding sub-members. The one or more sub-members of the left downtube 104 and the right downtube 106 are joined to the preceding sub-members using a joining mechanism. In one embodiment, the joining mechanism may include, but not limited to, welding.
The left front frame member 108 and the right front frame member 110 each project downward from a respective downtube 104, 106 and are connected to a left floorboard frame member 116 and the right floorboard frame member 118. The left front frame member 108 and the right front frame member 110 each include equal cross-sectional area to the left downtube 104 and the right downtube 106, respectively.
The left front frame member 108 and the right front frame member 110 each include a variation in cross-sectional area similar to the left downtube 104 and the right downtube 106, forming a predetermined shape 121. The left front frame member 108, the right front frame member 110, the left downtube 104, and the right downtube 106, with the variation in cross-sectional area, avoid a drop in longitudinal stiffness after the at least one headtube supporting member 112.
The left front frame member 108 and the right front frame member 110, with the predetermined shape 121, include an inner flat surface 122 and an outer flat surface 124 oriented laterally, along with a front curved surface 126 and a rear curved surface 128 oriented longitudinally. The left floorboard frame member 116 and the right floorboard frame member 118 include a left floorboard sub-frame member 116A and a right floorboard sub-frame member 118A, respectively. The predetermined shape of the left front frame member 108 and the right front frame member 110 facilitates increased airflow directed toward the floorboard-mounted battery pack, thereby enhancing battery cooling efficiency.
The left front frame member 108, and the right front frame member 110 each have a different cross-sectional area than the left downtube 104, and the right downtube 106, respectively. In one embodiment, the left front frame member 108, and the right front frame member 110 each have a bigger the cross-sectional area than the left downtube 104, and the right downtube 106, respectively. In another embodiment, the left front frame member 108, and the right front frame member 110 each have a smaller than the cross-sectional area of the left downtube 104, and the right downtube 106 respectively.
The outer flat surfaces 124 of the left front frame member 108 and the right front frame member 110 are configured to form a predetermined profile 130 with the left floorboard frame member 116 and the right floorboard frame member 118 to increase contact area and enhance load transfer.
The front curved surfaces 126 of the left front frame member 108 and the right front frame member 110 are mechanically configured to enable reduced air resistance.
In one embodiment, the left front frame member 108 is a single member or may be made of one or more sub-members. In another embodiment, the right front frame member 110 is a single member or may be made of one or more sub-members. The one or more sub-members of the left front frame member 108 and the right front frame member 110 each have a different cross-sectional area than preceding sub-members. In one embodiment, the one or more sub-members of the left front frame member 108 and the right front frame member 110 each have a smaller cross-sectional area than the preceding sub-members. In another embodiment, the one or more sub-members of the left front frame member 108 and the right front frame member 110 each have a bigger cross-sectional area than the preceding sub-members
The one or more sub-members of the left front frame member 108 and the right front frame member 110 are joined to the preceding sub-members using a joining mechanism. In one embodiment, the joining mechanism may include, but not limited to, welding.
The at least one headtube supporting member 112 projects downward from the headtube 102 and is connected to one or more horizontal cross members 114. The at least one headtube supporting member 112 is configured to provide support to the headtube 102, the left downtube 104, and the right downtube 106. The one or more horizontal cross members 114 extend between the left front frame member 108 and the right front frame member 110 to provide structural support to the front frame assembly 100. In one embodiment, the at least one headtube supporting member 112 may be a gusset.
The one or more horizontal cross members 114 include a first horizontal cross member 114A positioned at a top portion and a second horizontal cross member 114B positioned at a bottom portion, of the left front frame member 108 and the right front frame member 110, wherein the first horizontal cross member 114A and the second horizontal cross member 114B are configured to connect the left front frame member 108 and the right front frame member 110 via the inner flat surface 122 to improve coupling. The first horizontal cross member 114A and the second horizontal cross member 114B are in a predetermined shape to enable less air resistance. In one embodiment, the predetermined shape may be any shape that enables less air resistance. Furthermore, the second horizontal cross member 114B, along with the left floorboard frame member 116, the right floorboard frame members 118, the left floorboard sub-frame member 116A, and the right floorboard sub-frame member 118A, collectively form a cage structure configured to protect the floorboard battery pack.
The left and right downtubes (104 and 106) connect to the left and right front frame members 108 and 110, respectively, at a predetermined height above the first horizontal cross member 114A. In one embodiment, the predetermined height may vary based on the total height of the front frame assembly 100. In addition to that, the left and right front frame members 108 and 110 may each be configured in a variety of shapes. In one embodiment, the left and right front frame members 108 and 110 are polygonal. In another embodiment, the left and right front frame members 108 and 110 are oblong. In yet another embodiment, the left and right front frame members 108 and 110 are rectangular. Other shapes are also contemplated and within the scope of the present disclosure.
In addition to that, the left and right downtubes (104 and 106) may each be configured in a variety of shapes. In one embodiment, the left and right downtubes (104 and 106) are polygonal. In another embodiment, the left and right downtubes (104 and 106) are oblong. In yet another embodiment, the left and right downtubes (104 and 106) are rectangular. Other shapes are also contemplated and within the scope of the present disclosure. The left & right downtubes (104 and 106), and the left and right front frame members (108 and 110) may differ in shape.
In addition, the front frame assembly 100 further includes a set of cross-member brackets 120 located on the second horizontal cross member 114B, which are joined to the left front frame member 108 and the right front frame member 110, respectively, to improve load transfer. The front frame assembly 100 may be subjected to loads transmitted from the ground upward.
FIG. 1C is a cross-sectional top view illustrating the front frame assembly 100 of the vehicle, according to an embodiment herein. The cross-sectional top view discloses the predetermined shape 121 formed by the variation in cross-sectional area, similar to the left downtube 104 and the right downtube 106. The variation in cross-sectional area allows more air flow towards the floorboard battery pack to improve cooling. The predetermined shape 121 includes an inner flat surface 122, and an outer flat surface 124 oriented laterally, along with a front curved surface 126 and a rear curved surface 128 oriented longitudinally.
FIGS. 2A and 2B illustrate one or more load transfer paths of the front frame assembly 100 of the vehicle, according to an embodiment herein. The one or more load transfer paths include a first load transfer path 202, a second load transfer path 204, and a third load transfer path 206.
The first load transfer path 202 originates at the headtube 102 and extends to the left floorboard frame member 116 and the right floorboard frame member 118 via the at least one headtube supporting member 112, the first horizontal cross member 114A, the left front frame member 108, and the right front frame member 110.
The second load transfer path 204 originates at the headtube 102 and extends to the left floorboard frame member 116 and the right floorboard frame member 118 via the left downtube 104 and the right downtube 106, the left front frame member 108, and the right front frame member 110.
The third load transfer path 206 travels from the left front frame member 108 and the right front frame member 110, and extends to the left floorboard frame member 116, the right floorboard frame member 118, the left floorboard sub-frame member 116A, and the right floorboard sub-frame member 118A. The third load transfer path 206 further extends to a back frame member 208 of the vehicle.
The front frame assembly 100 provides a structurally improved design that is both strong and lightweight. Furthermore, the front frame assembly 100 prevents longitudinal stiffness reduction through the use of the left downtube 104 and right downtube 106 with varying cross-sectional areas at their respective distal ends, the left front frame member 108 and right front frame member 110 with similar variation, as well as the strategic positioning of one or more horizontal cross members 114 and at least one headtube supporting member 112. The front frame assembly 100 enhances the longitudinal stiffness of the structure while minimizing additional mass, thereby contributing to improved vehicle stability.
Improvements and modifications may be incorporated herein without deviating from the scope of the invention. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

LIST OF REFERENCE NUMERALS
Front Frame Assembly 100.
Headtube 102.
Left downtube 104.
Right downtube 106.
Left front frame member 108.
Right front frame member 110.
At least one headtube supporting member 112.
One or more horizontal cross members 114.
First horizontal cross member 114A.
Second horizontal cross member 114B.
Left floorboard frame member 116.
Left floorboard sub-frame member 116A.
Right floorboard frame member 118.
Right floorboard sub-frame member 118A.
Set of cross-member brackets 120.
First load transfer path 202.
Second load transfer path 204.
Third load transfer path 206.
Back frame member 208.
,CLAIMS:CLAIMS
I/We claim:
1. A front frame assembly (100) of a vehicle, comprising:
a headtube (102);
at least two down tubes:
a left downtube (104) and a right downtube (106) project downward from the headtube (102), wherein each of the left downtube (104) and the right downtube (106) comprises a variation in cross-sectional area at a corresponding distal end;
a left front frame member (108) and a right front frame member (110) each project downward from a respective downtube (104, 106) and are connected to a left floorboard frame member (116) and a right floorboard frame member (118),
wherein the left front frame member (108) and the right front frame member (110) each comprise a variation in cross-sectional area similar to the left downtube (104) and the right downtube (106), form a predetermined shape (121), wherein the left front frame member (108) and the right front frame member (110) with the predeermined shape (121), comprise an inner flat surface (122), and an outer flat surface (124) oriented laterally, along with a front curved surface (126) and a rear curved surface (128) oriented longitudinally,
wherein the outer flat surfaces (124) of the left front frame member (108) and the right front frame member (110) are configured to form a predetermined profile (130) with the left floorboard frame member (116) and the right floorboard frame member (118) to increase contact area and enhance load transfer;
wherein the front curved surfaces (126) of the left front frame member (108) and the right front frame member (110) are mechanically configured to enable reduced air resistance;
at least one headtube supporting member (112) projects downward from the headtube (102) and is connected to one or more horizontal cross members (114), wherein the at least one headtube supporting member (112) is configured to provide support to the headtube (102), the left downtube (104), and the right downtube (106); and
the one or more horizontal cross members (114) extend between the left front frame member (108) and the right front frame member (110) to provide structural support to the front frame assembly (100).
2. The front frame assembly (100) as claimed in claim 1, wherein the one or more horizontal cross members (114) comprise a first horizontal cross member (114A) positioned at a top portion and a second horizontal cross member (114B) positioned at a bottom portion, of the left front frame member (108) and the right front frame member (110), wherein the first horizontal cross member (114A) and the second horizontal cross member (114B) are configured to connect the left front frame member (108) and the right front frame member (110) via the inner flat surface (122) to improve coupling.

3. The front frame assembly (100) as claimed in claim 2, wherein the first horizontal cross member (114A) and the second horizontal cross member (114B) are in a predetermined shape to enable less air resistance.

4. The front frame assembly (100) as claimed in claim 1, wherein the left front frame member (108) and the right front frame member (110) each comprise equal cross-sectional area to the left downtube (104) and the right downtube (106), respectively.

5. The front frame assembly (100) as claimed in claim 1, wherein the left floorboard frame member (116) and the right floorboard frame member (118) comprise a left floorboard sub-frame member (116A) and a right floorboard sub-frame member (118A), respectively.

6. The front frame assembly (100) as claimed in claim 2 and 5, wherein the second horizontal cross member (114B), along with the left floorboard frame member (116), the right floorboard frame members (118), the left floorboard sub-frame member (116A), and the right floorboard sub-frame member (118A), collectively form a cage structure configured to protect a floorboard battery pack.

7. The front frame assembly (100) as claimed in claims 1, wherein the front frame assembly (100) further comprises one or more load transfer paths, wherein the one or more load transfer paths comprise a first load transfer path (202), a second load transfer path (204), and a third load transfer path (206).

8. The front frame assembly (100) as claimed in claim 7, wherein the first load transfer path (202) originates at the headtube (102) and extends to the left floorboard frame member (116) and the right floorboard frame member (118) via the at least one headtube supporting member (112), the first horizontal cross member (114A), the left front frame member (108), and the right front frame member (110).

9. The front frame assembly (100) as claimed in claim 7, wherein the second load transfer path (204) originates at the headtube (102) and extends to the left floorboard frame member (116) and the right floorboard frame member (118) via the left down tube (104) and the right down tube (106), the left front frame member (108), and the right front frame member (110).

10. The front frame assembly (100) as claimed in claim 7, wherein the third load transfer path (206) travels from the left front frame member (108) and the right front frame member (110), and extends to the left floorboard frame member (116) the right floorboard frame member (118), the left floorboard sub-frame member (116A) and the right floorboard sub-frame member (118A), wherein the third load transfer path (206) further extends to a back frame member (208) of the vehicle.