Claims:WE CLAIM:
1. A composite mounting bracket (100) for motor vehicles, the mounting bracket (100) comprising: a metal substrate (110) configured to be fixed on a first component of the motor vehicle; and an overmolded plastic (120) formed on the metal substrate (110), the overmolded plastic (120) configured to receive a second component of the motor vehicle thereby coupling the first component and the second component.

2. The composite mounting bracket (100) as claimed in claim 1, wherein the metal substrate (110) configured to rigidly grip the overmolded plastic (120).

3. The composite mounting bracket (100) as claimed in claim 1, wherein the metal substrate (110) includes a portion (110a) protruding inside the overmolded plastic (120).

4. The composite mounting bracket (100) as claimed in claim 1, wherein the overmolded plastic (120) comprises a housing (128) having a plurality of stiffening ribs (128b) disposed inside the housing (128) and fixed between walls (128a) of the housing (128).

5. The composite mounting bracket (100) as claimed in claim 1, wherein the overmolded plastic (120) of the mounting bracket (100) comprises at least one of a C-section, an I-section and a D-section.

6. A method (700) of manufacturing a composite mounting bracket for motor vehicles, the method comprising the steps of:
forming (710) a metal substrate (110) to conform with geometry of a space defined by a first component of the motor vehicle;
positioning (720) the metal substrate (110) in a mold; and
overmolding (730) a plastic on the metal substrate (110), the overmolded plastic (120) configured to receive a second component of the motor vehicle.

7. The method (700) as claimed in claim 6, the method (700) comprising step of: applying adhesive to edges of the composite mounting bracket thereby chemically bonding the metal substrate (110) and the overmolded plastic (120).

8. A composite mounting bracket (100) for mounting a fuel tank (20) to a main tube (24) of a motor vehicle (10), comprising:
a metal substrate (110) configured to be secured on a portion of the fuel tank (20); and an overmolded plastic (120) formed on the metal substrate (110), the overmolded plastic (120) configured to receive a bush (24b) coupled with a mounting rod (24a) secured to the main tube (24) for mounting the fuel tank (20) on the main tube (24).

9. The composite mounting bracket (100) as claimed in claim 8, wherein the mounting bracket (100) comprises a C-section overmolded plastic (120) having a web (122), and a pair of flanges (124, 126) extending from ends of the web (122).

10. The composite mounting bracket (100) as claimed in claim 9, wherein the metal substrate (120) extends between the pair of flanges (124, 126) of the overmolded plastic (120) thereby rigidly gripping the overmolded plastic (120).

11. The composite mounting bracket (100) as claimed in claim 9, wherein width of the C-section overmolded plastic (120) is equal to width of the bush (24b).

12. The composite mounting bracket (100) as claimed in claim 8, wherein the metal substrate (110) comprises a flat flange (110b) configured to be welded on the fuel tank (20).
, Description:FIELD OF THE INVENTION
[001] The present invention relates to a composite mounting bracket for motor vehicles and a method of manufacturing the same.

BACKGROUND OF THE INVENTION
[002] Various large components like fuel tank, seat, headlamp, tires, engine, handlebar etc. along with various small components like mirrors, indicators, fenders, guards, footrests etc. are all mounted on and around the chassis of a motor vehicle. This mounting of the various components of the motor vehicle is done either by welding; or by using fixating means such as nuts, bolts, screws, zip ties, etc., or using harnessers; or by using mounting brackets.
[003] Mounting brackets are essentially made and configured according to their desired use. Mounting brackets generally have two regions, whereby one region is generally affixed to a respective component, by welding or by using fixating means such as screws, nuts, bolts etc.; whereas the other region is made to receive and hold another respective component. By this means, one mounting bracket is used to couple two or more components of the motor vehicle. As an illustration, mounting brackets are used to mount a fuel tank to a chassis; or to mount a headlamp or a tail lamp assembly to the chassis; or to mount a set of panniers to the chassis; or to mount turn indicators to either the headlamp assembly or the tail lamp assembly, etc.
[004] Thus, mounting brackets are an integral part of any motor vehicle and have been used amply. However, there are several disadvantages to the mounting brackets known in the art. Foremost disadvantage is that the known mounting brackets are made entirely of metal. Thus, as explained above, one region of the mounting bracket is welded to a portion of one component, while the other region of the mounting bracket receives another component and is affixed to the received component by fixating means such as nuts, bolts etc. or welding. When multiple such metal mounting brackets are used on a motor vehicle, it considerably increases the overall weight of the motor vehicle, which is undesired.
[005] Another disadvantage of the known metal mounting bracket is that although the entire mounting bracket is sturdy, it offers no flexibility. Thus, due to negligible flexibility, the metal brackets become deformed and eventually cause damage to the associated parts when subjected to high stress/ strain conditions. In further stress/ strain conditions, the metal hybrid brackets often succumb and crack. Thus, breakage or deformation of the mounting bracket not only requires replacement of the mounting bracket, but also replacement of the respective components.
[006] Thus, there is a need in the art for a mounting bracket which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[007] In one aspect, the present invention is directed to a composite mounting bracket for motor vehicles. The composite mounting bracket of the present invention has a metal substrate configured to be fixed on a first component of the motor vehicle, and an overmolded plastic formed on the metal substrate. The overmolded plastic is configured to receive a second component of the motor vehicle thereby coupling the first component and the second component.
[008] In an embodiment of the invention, the metal substrate is configured to rigidly grip the overmolded plastic.
[009] In another embodiment of the invention, the metal substrate includes a portion protruding inside the overmolded plastic.
[010] In a further embodiment of the invention, the overmolded plastic has a housing having a plurality of stiffening ribs disposed inside the housing and fixed between walls of the housing.
[011] In yet another embodiment of the invention, the overmolded plastic of the mounting bracket comprises at least one of a C-section, an I-section and a D-section.
[012] In another aspect, the present invention is directed to a method of manufacturing a composite mounting bracket for motor vehicles. The method includes the steps of: forming a metal substrate to conform to geometry of a space defined by a first component of the motor vehicle; positioning the metal substrate in a mold; and overmolding a plastic on the metal substrate, the overmolded plastic configured to receive a second component of the motor vehicle.
[013] In another embodiment of the invention, the method includes a step of: applying adhesive to edges of the composite mounting bracket thereby chemically bonding the metal substrate and the overmolded plastic.
[014] In another aspect, the present invention is directed to a composite mounting bracket for mounting a fuel tank to a main tube of a motor vehicle. The mounting bracket has a metal substrate configured to be secured on a portion of the fuel tank; and an overmolded plastic formed on the metal substrate. The overmolded plastic is configured to receive a bush coupled with a mounting rod secured to the main tube for mounting the fuel tank on the main tube.
[015] In an embodiment of the invention, the mounting bracket has a C-section overmolded plastic having a web and a pair of flanges extending from ends of the web.
[016] In another embodiment of the invention, the metal substrate extends between the pair of flanges of the overmolded plastic thereby rigidly gripping the overmolded plastic.
[017] In a further embodiment of the invention, width of the C-section overmolded plastic is equal to width of the bush.
[018] In yet another embodiment of the invention, the metal substrate has a flat flange configured to be welded on the fuel tank.

BRIEF DESCRIPTION OF THE DRAWINGS
[019] 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 an exemplary motor vehicle, in accordance with an embodiment of the invention.
Figure 2 shows a composite mounting bracket according to an embodiment of the present invention.
Figure 3 is a section view (Section A-A) of the composite mounting bracket as shown in Figure 2 of the present invention.
Figure 4 shows a method for manufacturing the composite mounting bracket according to an embodiment of the present invention.
Figure 5 shows a composite mounting bracket according to an embodiment of the present invention.
Figure 6 is a side view of a motor vehicle showing a fuel tank mounted on frame of the vehicle.
Figure 7 shows a composite mounting bracket fixed on the fuel tank according to an embodiment of the present invention.
Figure 8 is a section view showing mounting of the fuel tank on main tube.

DETAILED DESCRIPTION OF THE INVENTION
[020] The present invention relates to a composite mounting bracket for motor vehicles and a method of manufacturing the same.
[001] Figure 1 illustrates an exemplary motor vehicle, in accordance with an embodiment of the invention. The motor vehicle 10 comprises an IC engine 12 that is vertically disposed. Preferably, the IC engine 12 is a single-cylinder type IC engine. The two-wheeled vehicle 10 comprises a front wheel 14, a rear wheel 16, a frame member, a seat 18 and a fuel tank 20. The frame member includes a head pipe 22, a main tube 24, a down tube (not shown), and seat rails (not shown). The head pipe 22 supports a steering shaft (not shown) and two telescopic front suspensions 26 (only one shown) attached to the steering shaft through a lower bracket (not shown). The two telescopic front suspensions 26 support the front wheel 14. The upper portion of the front wheel 14 is covered by a front fender 28 mounted to the lower portion of the telescopic front suspension 26 at the end of the steering shaft. A handlebar 30 is fixed to upper bracket not shown and can rotate to both sides. A head light 32, a visor guard (not shown) and instrument cluster (not shown) is arranged on an upper portion of the head pipe 22. The frame member comprises a down tube that may be located in front of the IC engine 12 and extends slantingly downward from head pipe 22. The main tube 24 of the frame member is located above the IC engine 12 and extends rearward from head pipe 22. The IC engine 12 is mounted at the front to the down tube and a rear of the IC engine 12 is mounted at the rear portion of the main tube 24. In an embodiment, the IC engine 12 is mounted vertically, with a cylinder block extending vertically above a crankcase. In an alternative embodiment, the IC engine 12 is mounted horizontally (not shown) with the cylinder block extending horizontally forwardly from the crankcase. In an embodiment, the cylinder block is disposed rearwardly of the downtube.
[002] The fuel tank 20 is mounted on the horizontal portion of the main tube 24. Seat rails are joined to main tube 24 and extend rearward to support a seat assembly 18. A rear swing arm 34 is connected to the frame member to swing vertically, and a rear wheel 16 is connected to rear end of the rear swing arm 34. Generally, the rear swing arm 34 is supported by a mono rear suspension 36 (as illustrated in the present embodiment) or through two suspensions on either side of the motor vehicle 10. A taillight unit (not shown) is disposed at the end of the motor vehicle 10 and at the rear of the seat assembly 18. A grab rail (not shown) is also provided on the rear of the seat rails. The rear wheel 16 arranged below seat 18 rotates by the driving force of the IC engine 12 transmitted through a chain drive (not shown) from the IC engine 12. A rear fender 38 is disposed above the rear wheel 16.
[003] Further, an exhaust pipe 40 of the vehicle extends vertically downward from the IC engine 12 up to a point and then extends below the IC engine 12, longitudinally along the vehicle length before terminating in a muffler 42. The muffler 42 is typically disposed adjoining the rear wheel 16.
[004] Figure 2 illustrates a composite mounting bracket 100 according to an embodiment of the present invention. The composite mounting bracket 100 has a metal substrate 110 and an overmolded plastic 120 formed on the metal substrate 110. The metal substrate 110 is configured to be fixed on a first component of the motor vehicle. In this regard, in an embodiment of the invention, the metal substrate 110 is a sheet metal formed to conform to geometry of a space defined by the first component of the motor vehicle. The space defined by the first component receives the metal substrate 110. In an embodiment of the invention, the metal substrate 110 is welded in the space defined by the first component.
[005] Further, the overmolded plastic 120 is configured to receive a second component of the motor vehicle. As such, shape and dimensions of the ovemolded plastic 120 will depend upon geometry and dimensions of the second component to be received by the overmolded plastic 120. In an embodiment of the invention, the overmolded plastic 120 of the mounting bracket 100 has a C-section, while in other embodiment the overmolded plastic 120 of the mounting bracket 100 has an I-section or a D-section. In another embodiment of the invention, the overmolded plastic 120 is further configured to rigidly grip the second component whereby, when the metal substrate 110 is fixed to the first component, the mounting bracket 100 couples the first component and the second component.
[006] In an embodiment of the invention, the overmolded plastic 120 is defined by a housing 128. The housing has walls 128a defining an interior region in which stiffening ribs 128b are disposed and fixed between the walls 128a. Such ribs provide structural rigidity and strength to the overmolded plastic 120.
[007] Thus, the overmolded plastic 120 can be of any shape and size, and same depends upon the geometry of the component to be received by the overmolded plastic 120. Similarly, the shape and size of metal substrate 110 will depend on the geometry of the component on which it is desired to be fixed as well as on the shape and size of the overmolded plastic 120. In this regard, the metal substrate 110 is formed in a shape which can grip the overmolded plastic 120 in entirety thereby providing rigidity and strength to the overmolded plastic 120.
[008] Figure 3 is a section view (Section A-A) of the composite mounting bracket as shown in Figure 2 of the present invention. In an embodiment of the invention, as shown in Figure 3, a portion 110a of the metal substrate 110 protrudes inside the overmolded plastic 120 thereby increasing the contact area between the metal substrate 110 and the overmolded plastic 120. Such a configuration provides additional rigidity and strength to the overmolded plastic 120.
[009] Further, as shown in Figure 3, a portion of the metal substrate 110 also protrudes outwardly from the mounting bracket 100 forming a flat flange 110b. The flat flange 110b is configured to be fixed on the first component of the vehicle thereby fixing the mounting bracket 100 on the vehicle.
[010] Further, in an embodiment, referring to the section A-A shown in Figure 2, it can be understood that the metal substrate 110 is inserted into the overmolded plastic 120 and is bent so as to increase the contact area between the metal substrate 110 and the overmolded plastic 120, which is in turn intended to increase the pull-off strength or the tensile strength of the mounting bracket 100 enabling the mounting bracket 100 to increase its strength to weight ratio and possess enhanced dimensional stability, thus overcoming dimensional variations and increased weight.
[011] Figure 4 shows a method 700 of manufacturing the composite mounting bracket 100. At step 710 of the method 700, a metal substrate is formed to conform to geometry of a space defined by a first component of the motor vehicle. In an embodiment of the invention, the metal substrate is a stamped sheet metal substrate. At step 720, the metal substrate is positioned in a mold and method proceeds to step 730. At step 730, a plastic is overmolded on the metal substrate. In this regard, the mold generally conforms to a shape in which the overmolded plastic is desired. Further, the overmolded plastic at step 730 is configured to receive a second component of the motor vehicle. In an embodiment of the invention, the method 700 also includes a step of applying adhesive to edges of the composite mounting bracket thereby chemically bonding the metal substrate and the overmolded plastic.
[012] In another embodiment of the invention, the plastic is overmolded on the metal substrate by injection molding. In this regard, as shown in Figure 5, the overmolded plastic has plurality of mounting holes 150 for mechanical interlocking.
[013] Figure 6 is a side view of the motor vehicle 10 showing a fuel tank 20 mounted on frame of the vehicle 10. As described hereinbefore, the frame includes a head pipe 22, a main tube 24 (shown in Figure 8), a down tube 46, and seat rails 44. The fuel tank 20 has an upper face area 20a, a side face area 20b, and a lower face area 20c (shown in Figures 7 and 8). The fuel tank 20 is prolonged in a front-rear direction and extends between a front end 20d and a rear end 20e. At rear end 20e of the fuel tank 20, a flange (not shown) projecting from the lower face area 20c is provided. The flange is provided with slots to receive a mounting bracket (not shown) connected to the main tube 24 whereby the rear end of the fuel tank 20 can be mounted on the main tube 24.
[014] As shown in Figures 7 and 8, the lower face area 20c is formed with a concave portion 20f so as to pass the main tube 24 oriented in the vehicle front-rear direction. A mounting rod 24a is fixed on the main tube 24 in the vehicle width direction. In an embodiment, the mounting rod 24a is welded on the main tube 24 and extends approximately equally on each side of the concave portion 20f. Each end of the mounting rod 24a couples with a bush 24b of a plurality of bushes 24b. In an embodiment, the bush 24b is mounted and fixed on each end of the mounting rod 24a. The mounting rod 24a is positioned on the main tube 24 such that each of the bushes 24b can be coupled with the concave portion 20f of the fuel tank 20 on each side of the concave portion 20f.
[015] Figure 7 shows a composite mounting bracket 100 fixed on the fuel tank 20. As described hereinbefore, the composite mounting bracket 100 has a metal substrate 110 and an overmolded plastic 120 formed on the metal substrate 110. In an embodiment of the invention, as shown in Figures 7 and 8, the mounting bracket 100 is fixed on the concave portion 20f, on each side of the concave portion 20f, of the fuel tank 20. Accordingly, shape and size of the metal substrate 110 of each of the mounting bracket 100 is configured to be secured on the concave portion 20f of the fuel tank 20. In an embodiment of the invention, as described hereinbefore, the metal substrate is provided with a flat flange 110b configured to be welded on the fuel tank 20.
[016] Further, the overmolded plastic 120 on each of the mounting bracket 100 is configured to receive the bush 24b. The overmoluded plastic 120 is further configured to rigidly grip the bush 24b whereby the fuel tank 20 is mounted on the main tube 24. In this regard, in an embodiment of the invention, the mounting bracket 100 has a C-section overmolded plastic 120.
[017] As shown in Figure 2, the C-section overmolded plastic 120 is defined by a web 122, and a pair of flanges 124, 126 extending from ends of the web 122. In a mounted configuration, the bush 24b is received between the pair of flanges 124, 126. In this regard, in an embodiment of the invention, width of the C-section overmolded plastic 120 is equal to width of the bush 24b so that the bush 24b snugly fits between the flanges 124, 126. Corresponding to the shape of the overmolded plastic 120, the metal substrate 110 extends between the pair of flanges 124, 126 thereby gripping the overmolded plastic 120.
[018] Advantageously, due to the overmolded plastic, the composite mounting bracket of the present invention is significantly less in weight. Thus, considerable reduction in weight of the motor vehicle can be achieved when multiple of such composite mounting brackets are mounted in place of conventional brackets. Also, the composite of bracket of the present invention provides high strength thereby increasing the strength to weight ratio. Further, the overmolded plastic provides flexibility to the mounting bracket whereby stress/ strain caused due to shaking of the vehicle is minimized and a better dimensional stability is achieved. Accordingly, chances of breakage or deformation of the mounting bracket is considerably reduced. Additionally, since the second component rigidly fits into the overmolded plastic, need of fastening means for fixing a component on the mounting bracket has been eliminated. As such, mounting and replacement of a component on the composite mounting bracket is easier thereby reducing the assembly and service time.
[019] 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.