DESC:CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the Indian provisional patent application No. 202541020371 filed on March 06, 2025, the complete disclosures of which, in their entirety, are herein incorporated by reference.

BACKGROUND
Technical Field
[0002] The embodiments herein generally relate to a vehicle, and more particularly, to a sub-frame assembly of a vehicle.

Description of related art
[0003] Background description includes information that may be useful in understanding the present disclosure, not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0004] Early automotive designs employed simpler frame structures with fewer mounted components, thus avoiding the complexities of integrating numerous components onto the main frame. However, modern automotive advancements necessitate numerous mounting points to accommodate an increasing number of components (like a primary battery pack, a secondary battery pack, and a controller unit). This has led to the development of complex frame designs, which, while providing the required mounting points, negatively impact accessibility and serviceability. Furthermore, these complex frames often exhibit suboptimal load distribution from key components such as the engine, transmission, and suspension, and demonstrate poor performance in isolating vibration and harshness from the vehicle body. Therefore, a need exists for a well-designed structural solution, such as a sub-frame, capable of providing improved stress distribution, superior vibration and harshness isolation, and enhanced accessibility and serviceability.
SUMMARY
[0005] In view of the foregoing, an embodiment herein provides a sub-frame of a vehicle. The sub-frame includes a seat holding member, one or more supporting members, and a base member. The seat holding member includes one or more seat holding member mounting points and extends upward and forward in an inclined orientation from a sub-frame mounting bracket located on a back frame member. The seat holding member is attached to the back frame member via the one or more seat holding member mounting points. The seat holding member further includes a seat holding member mounting bracket. The seat holding member mounting bracket includes a first set of battery mounting points and one or more utility box mounting points. The one or more supporting members extending downward from the seat holding member. The base member is horizontally disposed and connected to one or more lower ends of the one or more supporting members. The base member includes one or more base member mounting points and a second set of battery mounting points.
[0006] In some embodiments, the first set of battery mounting points is configured to secure a top portion of a secondary battery pack to the sub-frame.
[0007] In some embodiments, the second set of battery mounting points is configured to secure a bottom portion of the secondary battery pack.
[0008] In some embodiments, the sub-frame mounting bracket located on the back frame member is further configured to connect a controller unit.
[0009] In some embodiments, the sub-frame assembly further includes a controller unit mounting bracket configured to mount the controller unit. The controller unit mounting bracket is positioned between the controller unit and the sub-frame mounting bracket.
[0010] In some embodiments, the sub-frame assembly further includes a battery mounting bracket configured to connect the top portion of the secondary battery pack to the sub-frame assembly.
[0011] In another aspect, a sub-frame of a frame of a vehicle includes a seat holding member, one or more supporting members, and a base member. The seat holding member includes one or more seat holding member mounting points that extend upward and forward in an inclined orientation from a sub-frame mounting bracket located on a back frame member. The seat holding member is attached to the sub-frame mounting bracket via one or more seat holding member mounting points. The seat holding member further includes a seat holding member mounting bracket. The seat holding member mounting bracket includes one or more utility box mounting points. The one or more supporting members extending downward from the seat holding member, and include one or more supporting member brackets. The base member is horizontally disposed and connected to one or more lower ends of the one or more supporting members and includes one or more base member mounting points.
[0012] In some embodiments, the one or more supporting member brackets are configured to mount a controller unit between the one or more supporting members and beneath the seat holding member to optimize integration and structural efficiency.
[0013] In some embodiments, the sub-frame assembly further includes a controller unit mounting bracket configured to mount the controller unit. The controller unit mounting bracket is positioned between the one or more supporting member brackets and the controller unit.
[0014] In some embodiments, the one or more base member mounting points of the base member are configured to connect the base member to a floorboard frame member while simultaneously sandwiching an end of a primary battery pack, and an opposite end of the primary battery pack is connected to a front frame member.
[0015] In some embodiments, the sub-frame further includes one or more plastic part mounting brackets with one or more mounting points to receive one or more plastic parts of the vehicle.
[0016] In some embodiments, the one or more plastic part mounting brackets with the one or more mounting points located on the seat holding member mounting bracket and the base member.
[0017] 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
[0018] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0019] FIG. 1 illustrates a frame of a vehicle with a sub-frame assembly according to an embodiment of the present disclosure;
[0020] FIG. 2 illustrates the sub-frame assembly of the frame according to an embodiment of the present disclosure;
[0021] FIG. 3A illustrates the frame and the sub-frame assembly with a primary battery pack, a secondary battery pack, and a controller unit according to an embodiment of the present disclosure;
[0022] FIG. 3B illustrates the frame and the sub-frame assembly with the primary battery pack and the secondary battery pack according to another embodiment of the present disclosure; and
[0023] FIG. 3C illustrates the frame and the sub-frame assembly with the primary battery pack and the controller unit according to yet another embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] 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.
[0025] Various embodiments provide a frame of a vehicle with a sub-frame assembly. More particularly, the frame with the sub-frame discloses a structural solution capable of providing improved stress distribution, superior vibration and harshness isolation, and enhanced accessibility and serviceability.
[0026] As mentioned, there remains a need for an improved frame structure incorporating a sub-frame to efficiently position various components. Referring now to the drawings, and more particularly to FIG. 1 to FIG. 3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0027] FIG. 1 illustrates a frame 100 of a vehicle with a sub-frame 108 according to an embodiment of the present disclosure. The frame 100 includes a headtube 101, a front frame member 102, a floorboard frame member 104, a back frame member 106, and a sub-frame assembly 108. In one embodiment, the vehicle may include, but not limited to, an electric vehicle. In another embodiment, the electric vehicle may include, but is not limited to, Battery Electric Vehicles (BEVs), Plug-in Hybrid Electric Vehicles (PHEVs), Hybrid Electric Vehicles (HEVs), and Fuel Cell Electric Vehicles (FCEVs). The front frame member 102 extends downward from the headtube 101 and connects to the floorboard frame member 104. Further, the floorboard frame member 104 extends backward and connects to the back frame member 106.
[0028] The back frame member 106 includes one or more inclined portions that extend inclinedly upward from the floorboard frame member 104. In one embodiment, the one or more inclined portions are inclined to one another, and the floorboard frame member 104. The back frame member 106 includes one or more cross members to provide support.
[0029] FIG. 2 illustrates the sub-frame assembly 108 according to an embodiment of the present disclosure. The sub-frame assembly 108 includes a seat holding member 110, one or more supporting members 112, and a base member 114.
[0030] The seat holding member 110 includes one or more seat-holding member mounting points 118, and extends upward and forward in an inclined orientation from a sub-frame mounting bracket 304, located on the back frame 106. The seat holding member 110 is attached to the back frame member 106 via the one or more seat holding member mounting points 118.
[0031] The seat holding member 110 includes a seat holding member mounting bracket 204. The seat holding member mounting bracket 204 includes a first set of battery mounting points 206 and one or more utility box mounting points 208. The first set of battery mounting points 206 is configured to secure a top portion 310A of a secondary battery pack 310 to the sub-frame assembly 108. The one or more utility box mounting points 208 are configured to receive at least one utility box.
[0032] The one or more supporting members 112 extend downward from the seat holding member 110 and connect to the base member 114. The one or more supporting members 112 include one or more supporting member brackets 224. The one or more supporting member brackets 224 are configured to mount a controller unit 308 between the one or more supporting members 112 and beneath the seat holding member 110 to optimize integration and structural efficiency.
[0033] The base member 114 is horizontally disposed and connected to one or more lower ends of the one or more supporting members 112. The base member 114 includes one or more base member mounting points 214, and a second set of battery mounting points 216. The one or more base member mounting points 214 are configured to connect the base member 114 to the floorboard frame member 104. The second set of battery mounting points 216 is configured to secure a bottom portion 310B of the secondary battery pack 310.
[0034] The sub-frame assembly 108 further includes one or more plastic part mounting brackets 210 with one or more mounting points to receive one or more plastic parts of the vehicle. In one embodiment, the one or more plastic part mounting brackets 210 with the one or more mounting points located on the seat holding member mounting bracket 204 or the base member 114 or both. In another embodiment, the one or more mounting points for receiving the plastic parts of the vehicle are positioned directly on the base member 114, the seat holding member mounting bracket 204, eliminating the need for the plastic part mounting brackets 210.
[0035] FIG. 3A illustrates the frame 100 and the sub-frame assembly 108 with the primary battery pack 116, the secondary battery pack 310, and the controller unit 308 according to an embodiment herein. The base member 114 of the sub-frame assembly 108 is connected to the floorboard frame member 104 using the one or more base member mounting points 214. The one or more base member mounting points 214 are configured to connect the base member 114 to the floorboard frame member 104 while simultaneously sandwiching an end of the primary battery pack 116. An opposite end of the primary battery pack 116 is connected to the front frame member 102.
[0036] The secondary battery pack 310 is connected to the sub-frame assembly 108 using the first set of battery mounting points 206 and the second set of battery mounting points 216. The first set of battery mounting points 206 is located on the seat holding member mounting bracket 204 of the seat holding member 110. The second set of battery mounting points 216 is located on the base member 114.
[0037] The first set of battery mounting points 206 is configured to secure the top portion 310A of the secondary battery pack 310 to the sub-frame assembly 108. The second set of battery mounting points 216 is configured to secure the bottom portion 310B of the secondary battery pack 310. In one embodiment, the first set of battery mounting points 206 is configured to secure the bottom portion 310B of the secondary battery pack 310 to the sub-frame assembly 108. The second set of battery mounting points 216 is configured to secure the top portion 310A of the secondary battery pack 310.
[0038] In one embodiment, the sub-frame assembly 108 further includes a battery mounting bracket 302 configured to connect the top portion 310A of the secondary battery pack 310 to the sub-frame assembly 108. In one embodiment, the battery mounting bracket 302 is positioned between the secondary battery pack 310 and the seat holding member mounting bracket 204. In another embodiment, the battery mounting bracket 302 is positioned between the secondary battery pack 310 and the seat holding member 110.
[0039] The controller unit 308 is connected to the back frame member 106 of the frame 100 using the sub-frame mounting bracket 304. The sub-frame mounting bracket 304 is located on the back frame member 106. In one embodiment, the sub-frame assembly 108 further includes a controller unit mounting bracket 306 configured to mount the controller unit 308. The controller unit mounting bracket 306 is positioned between the controller unit 308 and the sub-frame mounting bracket 304. In another embodiment, the controller unit 308 is positioned on a controller mounting bracket (not shown in the figure), which extends downward from the seat holding member 110.
[0040] FIG. 3B illustrates the frame 100 and the sub-frame assembly 108 with the primary battery pack 116 and the secondary battery pack 310 according to another embodiment herein. The base member 114 of the sub-frame assembly 108 is connected to the floorboard frame member 104 using the one or more base member mounting points 214. The one or more base member mounting points 214 are configured to connect the base member 114 to the floorboard frame member 104 while simultaneously sandwiching an end of the primary battery pack 116. An opposite end of the primary battery pack 116 is connected to the front frame member 102.
[0041] The secondary battery pack 310 is connected to the sub-frame assembly 108 using the first set of battery mounting points 206 and the second set of battery mounting points 216. The first set of battery mounting points 206 is located on the seat holding member mounting bracket 204 of the seat holding member 110. The second set of battery mounting points 216 is located on the base member 114.
[0042] The first set of battery mounting points 206 is configured to secure the top portion 310A of the secondary battery pack 310 to the sub-frame assembly 108. The second set of battery mounting points 216 is configured to secure the bottom portion 310B of the secondary battery pack 310. In one embodiment, the first set of battery mounting points 206 is configured to secure the bottom portion 310B of the secondary battery pack 310 to the sub-frame assembly 108. The second set of battery mounting points 216 is configured to secure the top portion 310A of the secondary battery pack 310.
[0043] FIG. 3C illustrates the frame 100 and the sub-frame assembly 108 with the primary battery pack 116 and the controller unit 308 according to yet another embodiment herein. The present embodiment illustrates the positioning of the controller unit 308 in a location of the secondary battery pack 310. The one or more supporting member brackets 224 are configured to mount the controller unit 308 between the one or more supporting members 112 and beneath the seat holding member 110 to optimize integration and structural efficiency.
[0044] In one embodiment, the sub-frame assembly 108 further includes the controller unit mounting bracket 306 configured to mount the controller unit 308. The controller unit mounting bracket 306 is positioned between the one or more supporting member brackets 224 and the controller unit 308.
[0045] The base member 114 of the sub-frame assembly 108 is connected to the floorboard frame member 104 using the one or more base member mounting points 214. The one or more base member mounting points 214 are configured to connect the base member 114 to the floorboard frame member 104 while simultaneously sandwiching an end of the primary battery pack 116. An opposite end of the primary battery pack 116 is connected to the front frame member 102. The one or more base member mounting points 214 are located on the base member 114.
[0046] The present disclosure describes the sub-frame assembly 108 of the frame 100, which provides a structural solution capable of providing improved stress distribution, superior vibration and harshness isolation, and enhanced accessibility and serviceability.
[0047] 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

Frame 100.
Headtube 101.
Front frame member 102.
Floorboard frame member 104.
Back frame member 106.
Sub-frame assembly 108.
Seat holding member 110.
One or more supporting members 112.
Base member 114.
Primary battery pack 116.
Seat holding member mounting bracket 204.
First set of battery mounting points 206.
One or more utility box mounting points 208.
One or more plastic part mounting brackets 210.
One or more base member mounting points 214.
Second set of battery mounting points 216.
One or more supporting member brackets 224.
Battery mounting point 302
Sub-frame mounting bracket 304.
Controller unit mounting bracket 306.
Controller unit 308.
Secondary battery pack 310.
Top portion of the secondary battery pack 310A.
Bottom portion of the secondary battery pack 310B.
,CLAIMS:CLAIMS

I/We claim:

1. A sub-frame assembly (108) of a frame (100) of a vehicle, comprising:
a seat holding member (110) comprises one or more seat holding member mounting points (118), and extends upward and forward in an inclined orientation from a sub-frame mounting bracket (304), located on a back frame member (106), wherein the seat holding member (110) is attached to the back frame member (106) via the one or more seat holding member mounting points (118), wherein the seat holding member (110) further comprises:
a seat holding member mounting bracket (204), wherein the seat holding member mounting bracket (204) comprises:
a first set of battery mounting points (206); and
one or more utility box mounting points (208);
one or more supporting members (112) extending downward from the seat holding member (110); and
a base member (114) is horizontally disposed and connected to one or more lower ends of the one or more supporting members (112), wherein the base member (114) comprises:
one or more base member mounting points (214); and
a second set of battery mounting points (216).

2. The sub-frame assembly (108) as claimed in claim 1, wherein the first set of battery mounting points (206) is configured to secure a top portion (310A) of a secondary battery pack (310) to the sub-frame assembly (108).

3. The sub-frame assembly (108) as claimed in claim 1, wherein the second set of battery mounting points (216) is configured to secure a bottom portion (310B) of the secondary battery pack (310).
4. The sub-frame assembly (108) as claimed in claim 1, wherein the sub-frame mounting bracket (304) located on the back frame member (106) is further configured to connect a controller unit (308).

5. The sub-frame assembly (108) as claimed in claim 1, wherein the sub-frame assembly (108) further comprises a controller unit mounting bracket (306) configured to mount the controller unit (308), wherein the controller unit mounting bracket (306) positioned between the controller unit (308) and the sub-frame mounting bracket (304).

6. The sub-frame assembly (108) as claimed in claim 1, wherein the sub-frame assembly (108) further comprises a battery mounting bracket (302) configured to connect the top portion (310A) of the secondary battery pack (310) to the sub-frame assembly (108).

7. A sub-frame assembly (108) of a frame (100) of a vehicle, comprising:
a seat holding member (110) comprises one or more seat holding member mounting points (118) and extending upward and forward in an inclined orientation from a sub-frame mounting bracket (304) located on a back frame member (106), wherein the seat holding member (110) is attached to the sub-frame mounting bracket (304) via one or more seat holding member mounting points (118), wherein the seat holding member (110) further comprises:
a seat holding member mounting bracket (204), wherein the seat holding member mounting bracket (204) comprises:
one or more utility box mounting points (208);
one or more supporting members (112) extending downward from the seat holding member (110) and comprising one or more supporting member brackets (224); and
a base member (114) is horizontally disposed and connected to one or more lower ends of the one or more supporting members (112) and comprises one or more base member mounting points (214).
8. The sub-frame assembly (108) as claimed in claim 7, wherein the one or more supporting member brackets (224) are configured to mount a controller unit (308) between the one or more supporting members (112) and beneath the seat holding member (110) to optimize integration and structural efficiency.

9. The sub-frame assembly (108) as claimed in claim 7, wherein the sub-frame assembly (108) further comprises a controller unit mounting bracket (306) configured to mount the controller unit (308), wherein the controller unit mounting bracket (306) is positioned between the one or more supporting member brackets (224) and the controller unit (308).

10. The sub-frame assembly (108) as claimed in any one of the preceding claims, wherein the one or more base member mounting points (214) of the base member (114) are configured to connect the base member (114) to a floorboard frame member (104) while simultaneously sandwiching an end of a primary battery pack (116), wherein an opposite end of the primary battery pack (116) is connected to a front frame member (102).

11. The sub-frame assembly (108) as claimed in any one of the preceding claims, wherein the sub-frame assembly (108) further includes one or more plastic part mounting brackets 210 with one or more mounting points to receive one or more plastic parts of the vehicle.

12. The sub-frame assembly (108) as claimed in claim 11, wherein the one or more plastic part mounting brackets 210 with the one or more mounting points located on the seat holding member mounting bracket (204) and the base member (114).