Claims:We claim:
1. A frame assembly for a vehicle (100) comprising:
a front frame structure (102); and
a rear frame structure (103);
wherein the rear frame structure (103) comprises of a first rear frame portion (104) and a second rear frame portion (107), the first rear frame portion (104) and the second rear frame portion (107) being detachably attached.
2. The frame assembly as claimed in claim 1, wherein said first rear frame portion (104) extends first inclinedly upwards and then extends horizontally rearwards from the front frame structure (102), said first rear frame portion (104) having a left member (105a) and a right member (105b) includes a flattened end (106a).
3. The frame assembly as claimed in claim 1, wherein said second rear frame portion (107) includes a first member (109), a second member (110), and a top member (112), said first member (109) includes a flattened end (106b) on both the end portions and being configured to be attached with the flattened end (106a) of said first rear frame portion (104).
4. The frame assembly as claimed in claim 1, said first rear frame portion (104) and said second rear frame portion (107) being configured to have a conjugately aligned complimentary mounting provisions (108a, 108b) to bolt said first rear frame (104) with the second rear frame portion (107).
5. The frame assembly as claimed in claim 1 or claim 4 or claim 7, wherein said bolted portion between the first rear frame portion (104) and the second rear frame portion (107) configured to be disposed at the rear side of a rear shock absorber (not shown) mounted on the vehicle (100).
6. The frame assembly as claimed in claim 1, said second rear frame portion (107) is a multi-material assembly.
7. A second rear frame portion (107) attached to a first rear frame portion (104) of a frame assembly for a vehicle (100), said second rear frame portion (107) comprising:
a first member (109);
a second member (110); and
a top member (112);
said first member (109) being attached to a top portion of said second member (110);
said top member (112) being attached to a top portion of said first member (109); and
said first member (109) being configured with one or more mounting provisions (108b), said one or more mounting provisions (108b) being configured to facilitate conjugate and complimentary mounting of the second rear frame portion (107) to the first rear frame portion (104).
8. The second rear frame portion (107) as claimed in claim 3 or claim 7, wherein said first member (109) being substantially a U-shaped member, when viewed from the top view of the frame assembly.
9. The second rear frame portion (107) as claimed in claim 7, wherein said first member (109) has a C-shaped cross section (111) at the end portion of the first member (109) configured to be bolted with a flattened end (106a) portion of said first rear frame portion (104).
10. The second rear frame portion (107) as claimed in claim 7, wherein said first member (109) being configured to be made of metal reinforcement, and the second member (110) being configured to be made of resin material.
11. The second rear frame portion (107) as claimed in claim 10, wherein said first member (109) being configured to be a sheet metal.
12. The second rear frame portion (107) as claimed in claim 7, wherein said first member (109) being configured to have a tubular cross section.
13. The second rear frame portion (107) as claimed in claim 7, wherein said second member (110) being configured to be a fibre reinforced plastic or resin.
14. The second rear frame portion (107) as claimed in claim 7, wherein said C shaped cross-section (111) configured to have an opening of the C shaped cross-section (111) towards said first frame member portion (104) of the frame assembly.
15. The second rear frame portion (107) as claimed in claim 7, wherein said C shaped cross-section (111) being of substantially same height as that of the flattened end (106a) portion of the first rear frame portion (104) to increase the contact surface.
16. The second rear frame portion (107) as claimed in claim 7, wherein said second rear frame portion (107), when viewed from the side of the vehicle, forms a substantial L-shaped profile, said L-shaped profile includes the first member (109) and the second member (110), said first member (109) extends towards the vehicle end, and said second member (110) extends downwards from the end portion of said first member (109).
17. The second rear frame portion (107) as claimed in claim 16, said second member (110) being configured to be disposed at the rear of a rear wheel axle (not shown). , Description:TECHNICAL FIELD
[0001] The present subject matter relates generally to a vehicle. More particularly but not exclusively the present subject matter relates to a frame assembly of said vehicle.
BACKGROUND
[0002] Generally, a frame, also known as a chassis, is the main supporting structure of the vehicle to which all the parts are attached. In a two-wheeled vehicle, generally the frame structure of the vehicle is made up of metal structure, where many sheet-metal brackets, tubes and rods are joined to form the frame structure. The frame structure supports a number of vehicle parts like a fuel tank, a seat, a tail lamp mounting, a pillion handle, and the like. So, the construction of the frame structure has to be such that it facilitates the mounting of various vehicle parts without interfering with other neighbouring parts. This requirement makes the design of the frame structure complex, as the frame structure is to be juxtaposed cum disposed around the vehicle parts.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The details are described with reference to an embodiment of a saddle type two wheeled vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components.
[0004] Figure 1(a) exemplarily illustrates a side view of a two-wheeled vehicle.
[0005] Figure 1(b) exemplarily illustrates a chain adjuster with a spacer.
[0006] Figure 1(c) exemplarily illustrates a fuel tank assembly with a charging port.
[0007] Figure 2 exemplarily illustrates a frame assembly for a saddle type two-wheeled vehicle with other parts and panels removed.
[0008] Figure 3 exemplarily illustrates a side view of a partial frame assembly of the two-wheeled vehicle as per the present invention.
[0009] Figure 4 exemplarily illustrates exploded perspective view of the first rear frame portion and the second rear frame portion.
[00010] Figure 5 (a) exemplarily illustrates the perspective top view of the first rear frame portion with flattened ends as part of frame assembly.
[00011] Figure 5 (b) exemplarily illustrates a perspective view of the second rear frame.
[00012] Figure 6 exemplarily illustrates an exploded view of the first rear frame portion and the second rear frame portion.

DETAILED DESCRIPTION

[0001] In a two wheeled vehicle, the rear frame structure having a left hand and right-hand rear frames are joined to facilitate the mounting of various vehicle parts. In order to achieve the mountings, a number of sheet metal brackets, tubes, and rods are welded together to the rear frame. The sheet metal brackets tubes, and rods add weight and part count to the vehicle, which is not desirable. As the number of metallic parts increases, the complexity associated with manufacturing of the vehicle also increases. The various mounting points makes the overall shape of the rear frame structure more complex, as the mountings are located in various position having different butting planes. Since, the mounting points are in different planes, the welding of such parts made of sheet metal is complex, which leads to difficulty in manufacturing.
[0002] A large number of welding points results in welding distortion in the frame, which further results in dimensional inaccuracy at one or more location in the frame. Said dimensional inaccuracy leads to mismatch of style panels and misalignment of parts in the final vehicle assembly. Also, due to increase in number of part count in the vehicle, the assembly time to produce the rear frame structure increases, adding to the final vehicle delivery time at the end of the assembly line. This also adds to the cost of the vehicle, due to the increase in the number of operations.
[0003] Therefore, there exists a need for a rear frame structure of a two-wheeler, which helps to reduce the weight of the frame, while reducing the part count & number of assembly processes for the rear frame. In addition, there exists a need for a frame for a vehicle which is adaptable to cater to the various requirements of platform of products while overcoming all above problems as well as other problems of known art.
[0004] An objective of the present subject matter is to provide a rear frame structure of a two-wheeler, which can enable the mountings for the vehicle parts, while reducing the part count, number of assembly processes, assembly weight and weld distortions, which in turn helps in overcoming misalignment of assembled parts and in turn helps in improving the dimensional stability and aesthetics of the vehicle. The present subject matter is described using an exemplary saddle type two-wheeled vehicle, whereas the claimed subject matter is applicable to any type of two-wheeled vehicles, with required changes and without deviating from the scope of invention.
[0005] Another objective of the present subject matter is to determine mounting zones that require higher sectional properties and those which requires lesser sectional properties of the frame, in order to ensure that the overall weight of the frame structure is reduced without compromising the required strength and stiffness of the rear frame. As per an aspect of the present invention, the rear frame structure is configured with multi material design.
[0006] As per an aspect of the present subject matter, a frame assembly for a saddle-type two-wheeled vehicle comprises of a front frame structure and a rear frame structure. The rear frame structure comprises of a first rear frame portion and a second rear frame portion, said first rear frame portion and the second rear frame portion being detachably attached.
[0007] As per an aspect of the present subject matter, the first rear frame portion extends first inclinedly upwards and then extends horizontally rearwards from the front frame structure. The first rear frame portion having a left member and a right member includes a flattened end.
[0008] As per an aspect of the present subject matter, the said second rear frame portion includes a first member, a second member, and a top member. The first member includes a flattened end on both the end portions being configured to be attached with the flattened end of said first rear frame portion.
[0009] As per an aspect of the present subject matter, the first rear frame portion and said second rear frame portion being configured to have an conjugately aligned complimentary mounting provisions to bolt said first rear frame portion with the second rear frame portion.
[00010] As per an aspect of the present subject matter, the bolted portion between the first rear frame portion and the second rear frame portion is configured to be disposed at the rear side of a rear shock absorber mounted on the vehicle.
[00011] As per another aspect of the present subject matter, the second rear frame portion is a multi-material assembly.
[00012] As per another aspect of the present subject matter, the second rear frame portion is attached to the first rear frame portion of a frame assembly for a vehicle, said second rear frame portion comprises a first member, a second member, and a top member. The first member being attached to a top portion of said second member. The top member being attached to a top portion of said first member. The first member being configured with one or more mounting provisions. The one or more mounting provisions being configured to facilitate mounting of the second rear frame portion to the first rear frame portion.
[00013] As per another aspect of the present subject matter, the first member being substantially a U-shaped member, when viewed from the top view of the frame assembly.
[00014] As per another aspect of the present subject matter, the first member has a C-shaped cross section at the end portion of the first member configured to be bolted with a flattened end portion of said first rear frame portion.
[00015] As per another aspect of the present subject matter, the first member being configured to be made of metal reinforcement, and the second member being configured to be made of resin material.
[00016] As per another aspect of the present subject matter, the first member being configured to be a sheet metal.
[00017] As per yet another aspect of the present subject matter, the first member being configured to have a tubular cross section and the second member being configured to be a fibre reinforced plastic.
[00018] As per yet another aspect of the present subject matter, the C shaped cross-section is configured to have an opening of the C shaped cross-section towards the first rear frame portion of the frame assembly. The C shaped cross-section is of substantially same height as that of the flattened end portion of first rear frame portion to increase the contact surface of the conjugate coupling or joint.
[00019] As per yet another aspect of the present subject matter, the second rear frame, when viewed from the side of the vehicle, forms a substantial L-shaped profile. The L-shaped profile includes the first member and the second member. The first member extends towards the vehicle end, and the second member extends downwards from the end portion of said first member. The second member is configured to be disposed at the rear of a rear wheel axle. The embodiments of the present invention will now be described in detail with reference to an embodiment in a saddle type two wheeled vehicle along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00020] Fig.1(a) exemplarily illustrates a side view of a two-wheeled vehicle 100. The two-wheeled vehicle 100 have a front portion F and a rear portion R. The front portion F of the vehicle 100 includes a head pipe 101 (shown schematically with dotted lines), a front frame structure 102 extending from the head pipe 101, a front shock absorber 100(a), a steering assembly 100(b) and a front wheel 100(c). The rear portion R of the vehicle 100 includes a rear frame structure 103, a seat assembly 100 (d), a rear wheel 100(e), a pair of rear shock absorbers 100(f) (one shown), a swingarm 100(g), and a pillion handle 100(h). The front frame structure 102 of the vehicle 100 along with the front shock absorber 100(a) is connected to the front wheel 100(c). The seat assembly 100(d) is mounted on the rear frame structure 103. The rear portion R having the pair of rear shock absorber 100(f) is connected to the rear frame structure 103 of the vehicle 100 at one end and the other end of the shock absorber 100(f) is connected to an axle of the rear wheel 100(e). The swingarm 100(g) is connected to the frame of the vehicle 100 at one end in longitudinal direction of the vehicle 100 and the other end is connected to the axle of the rear wheel 100(e). In an embodiment, Fig.1(b) exemplarily illustrates a chain adjuster 114 having a front end provided with a spacer 116 part with an opening to guide a motor wire (not shown). An arrester plate 115 is fixed to the swingarm 100(g) by mounting screws 117 and is used to hold the axle as well as act as stopper to prevent the axle from falling off from the swingarm 100(g). This is done to reduce the axle misalignment and for ease of assembly in the vehicle 100. The pillion handle 100(h) is provided at the rear portion R of the seat assembly 100(d) for the support of the pillion rider of the vehicle 100.
[00021] Fig.1(c) exemplarily illustrates a fuel tank assembly 100(i) with a charging port 113. The fuel tank assembly 100(i) is provided at the rear portion R, below the seat 100(d) of the vehicle 100. In an embodiment, a Fuel Sensor Unit (not shown) is mounted on the fuel tank assembly 100(i) by means of a plurality of brackets (not shown). One bracket (not shown) is disposed on the outer side of a fuel tank inner (not shown), and one bracket is disposed on the inner side of a fuel tank inner (not shown). A plurality of fasteners (not shown) is used to mount the fuel sensor unit (not shown) on the bracket. In another embodiment, the Fuel Sensor Unit (not shown) is mounted on a fuel tank assembly 100(i) by means of two brackets on the outer side of fuel tank inner (not shown). This mounting mechanism eliminates the use of TIG (Tungsten Inert Gas) welding process which is costly. In an embodiment, the mobile charging port 113 is disposed on top of the fuel tank assembly 100(i). A mobile charger adapter (not shown) is disposed between the fuel tank assembly 100(i) and a fuel tank cover (not shown) with the charging port 113 located on the fuel tank cover (not shown). The mobile charging port 113 and the mobile charging adapter (not shown) is separated from each other. In another embodiment, the mobile charger adapter (not shown) is disposed between the fuel tank assembly 100(i) and the fuel tank cover (not shown) with the charging port 113 located on the fuel tank cover (not shown). In an embodiment, a relay and flasher (not shown) are disposed below the fuel tank assembly 100(i) such that when seen from side view and top view, the relay and flasher (not shown) are not overlapping even partially with the seat tubes (not shown). This provides ease of packaging of the relay and flasher (not shown). The steering assembly 100(b) includes an instrument cluster (not shown). In an embodiment, an instrument cluster (not shown) in the vehicle consists of in-built GPS, GSM, an accelerometer, Bluetooth, Wi Fi and a processor which runs on an operating system. The accelerometer in the instrument cluster (not shown) detects the movement and transmits the unauthorized movement status to a vehicle control unit (not shown). The vehicle control unit (not shown) enables the lighting loads and horn so as to indicate the user about the unauthorized vehicle movement.
[00022] Fig.2 exemplarily illustrates a frame assembly for a saddle type two-wheeled vehicle with other parts and panels removed. The frame assembly of the two-wheeled vehicle 100 comprises of a head tube 101, a front frame structure 102, and a rear frame structure 103. The front frame structure 102 extends downward from the head tube 101 and then extends rearward forming a floorboard portion 102(b) from a lower portion of the front frame portion 102(a). The rear frame structure 103 extends rearwards from the rear end of the front frame floorboard portion 102(b). The rear frame structure 103 includes a first rear frame portion 104 and a second rear frame portion 107. The first rear frame portion 104 further includes an inclined portion 104(a) which extends inclinedly upward, and a horizontal portion 104(b) which extends horizontally rearward from the inclined portion 104(a). The first rear frame portion 104 extending horizontally in rearwards direction through horizontal portion 104(b) includes a flattened end (shown in fig.4) 106(a). The second rear frame portion 107 is configured to have a flattened end 106(b) (shown in fig.4) which is attached to the flattened end 106(a) (shown in fig.4) of the first rear frame portion 104. The second rear frame portion 107 is a multi-material hybrid frame, which facilitates reduction in weight, part count, and number of assembly process.
[00023] Fig.3 exemplarily illustrates a side view of a partial frame assembly of the two-wheeled vehicle 100 as per the present invention. In an embodiment, the second rear frame portion 107 is a metal-plastic hybrid structure. The second rear frame hybrid structure portion 107 forms substantially a L-shaped profile, when viewed from the side view of the frame. The L-shaped profile includes a first member 109, a second member 110, and a top member 112 (shown in fig.4). The first member 109 extends from the first rear frame portion 104 towards the vehicle end, and the second member 110 extends downwards from the end portion of the first member 109. The second member 110 is disposed at the rear of the rear wheel axle (not shown).
[00024] Fig.4 exemplarily illustrates exploded perspective view of the first rear frame portion 104 and the second rear frame portion 107. In the present embodiment, the first rear frame portion 104 includes a pair of rear tubes, one left member 105(a) and one right member 105(b). The pair of tubes (105(a), 105(b)) run rearward and upwardly, maintaining a space between them, said space is used as a packaging space for various parts of the two-wheeled vehicle 100. However, the first rear frame portion 104 can have more than one tube per left-side and right-side. Said pair of tubes (105a, 105b) act as a supporting structure for the parts mounted or attached to it. So, the strength and stiffness of the first rear frame portion 104 is such that it can carry the load of the parts, while in operation. As not all parts mounted on the first rear frame portion 104, said second rear frame portion 107 necessitates high strength requirements so as to support vehicle parts. The mounting zones of the hybrid second rear frame portion 107 require considerably lower cross-sectional properties to mount and withstand parts such as, the mounting of body panels, rear fender, tail lamp assembly etc. and hence the second rear frame portion 107 is configured out of resin or plastic material. On the other hand, the mounting zones of the hybrid second rear frame portion 107 that requires considerably higher geometric cross-sectional properties so as to securely mount parts such as, the mounting of main frame, pillion handle etc. As a result, the first front frame portion 104 is configured to be made out of metal or metal reinforced resin material. So, the second rear frame portion 107 can be customized depending upon the mounting zones that requires higher sectional properties and those that requires lesser sectional properties. This customization ensures that the overall weight of the structure is reduced without compromising the required strength and stiffness for a given configuration and requirements of the vehicle 100. In an embodiment, a plurality of wiring harness couplers (not shown) is located at a junction connecting the pair of tubes (105(a), 105(b)) and the first rear frame portion 104 extending rearward from said head pipe 101. The plurality of couplers (not shown) are covered with a fuel tank (not shown), when viewed from the top of the frame assembly so as to protect the coupling from any damage.
[00025] In an embodiment, the first member 109 of the second rear frame portion 107 is substantially a U-shaped sheet metal reinforcement frame when seen from a top view and the rear end of the first member 109 has flattened end. The rear end i.e. the conjugately coupling end of the first rear frame portion 104 is correspondingly flattened 106(a) to form vertical flat surface so as to abut and overlap with the flattened rear end 106(b) of the first member 109 of the frame. The first member 109 of the second rear frame portion 107 and the first rear frame portion 104 are configured to have conjugately aligned complimentary mounting provisions (108(a), 108(b)) to bolt the first rear frame portion 104 with the second rear frame portion 107. A top member 112 is attached to a top portion of the first member 109, connecting a plurality of sides of the first member 109. The bolted joint between the first rear frame portion 104 and the second rear frame portion 107 is positioned at the rear side of a rear shock absorber (not shown) along the length of the first rear frame portion 104. The bolting is disposed behind the shock absorber (not shown), because the first rear frame portion 104 after the shock absorber (not shown) does not bear major structural loads. This facilitates weight reduction by the use of multi material in the frame and thus providing a lightweight plastic-metal hybrid structure in a two-wheeled vehicle. In another embodiment, the rear end structure having the first member 109 is a tubular cross-section.
[00026] Fig. 5(a) exemplarily illustrates the perspective top view of the first rear frame portion 104 with flattened ends 106(a) as part of frame assembly. Fig.5(b) exemplarily illustrates a perspective view of the second rear frame portion 107 of the frame assembly. The first rear frame portion 104 includes the pair of tubes (105a, 105b) disposed on both at left side and at right side of the vehicle to support the various parts of the vehicle. The first rear frame portion 104 has flattened ends 106(a) so that it is bolted with the second rear frame portion 107. The second rear frame portion 107 includes the first member 109 and the second member 110. The first member 109 is metal member and the second member 110 is made up of plastic. The use of multi material i.e. metal and plastic in frame assembly reduces the weight and ensures the strength requirement of the vehicle. This configuration enables achieving a flexible design of a frame assembly which can be adjusted or customised to have different rear frame portion design to cater to variety of requirements of the manufacturer as well as the user. Plastic as a material facilitates freedom of design in the frame structure thereby further reducing welding, its related distortion effects as well as eliminates number of parts which effectively enhances the finish of the vehicle and reduces undesirable gaps. The thickness of plastic can be varied and reinforcement elements like ribs and stringers and the like can be added in the structure to increase the strength. Plastic reduces the corrosion process and increase the life of the vehicle frame assembly. Also, plastic provides flexibility in integrating the parts and is economical. But plastic alone is not capable of fulfilling the requirement of structural integrity in higher sectional mounting zones. So, metal reinforcements are disposed at structurally demanding regions of the rear end structure and plastic material is disposed at lesser sectional mounting zones. By combining the metal reinforcement to plastic, it prevents the plastic structure to grow in size, distort or crack at the load bearing points, where the loading requirements of the structure is high. Metal-to-plastic assemblies combine the strength and ductility of metal with the ability of plastic structure to attain complex shape while retaining the advantage of low weight of plastic. As per an embodiment, the metal-to-plastic assembly is achieved by en-moulding the metal reinforcement to the plastic structure during the plastic moulding in a single process. However, said reinforcement can be joined to the plastic structure by other joining methods like, Adhesive Bonding, Welding, Ultrasonic Welding, Laser Welding, Friction Stir Welding, Friction Spot Joining, self-piercing-rivets and the like. In another embodiment, the second member of the rear end structure is made up of fibre reinforced plastic with the first member made up of metal reinforcements.
[00027] Fig.6 exemplarily illustrates an exploded perspective view of the first rear frame portion 104 and the second rear frame portion 107. The first member 109 has a C shaped cross-section 111 at the end portion of the first member 109 which is attached with the flattened end 106(a) portion of the first rear frame portion 104 with attachment means e.g. bolts. The C shaped cross-section 111 is oriented to have an opening of the C shaped cross-section 111 towards the first rear frame portion 104 of the frame assembly. The C shaped cross-section 111 is configured to be of the same height as that of the flattened end 106(a) portion of the first rear frame portion 104 to increase the contact surface at the joint. This provides additional stiffness in addition to the bolting done between the second rear frame portion 107 and the first rear frame portion 104 of the vehicle. This way of joining the first rear frame portion 104 with C-section 111 hugging the second rear frame portion 107 from three sides gives a mechanical advantage of positive locking to the bolted joint between first rear frame portion 104 and the second rear frame portion 107. Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of Reference numerals
100: Two-wheeled vehicle
100(a): Front shock absorber of 100
100(b): Steering assembly of 100
100(c): Front wheel of 100
100(d): Seat assembly of 100
100(e): Rear wheel of 100
100(f): Pair of rear shock absorbers of 100
100(g): Swingarm of 100
100(h): Pillion handle of 100
100(i): Fuel tank assembly of 100
101: Head tube 100
102: Front frame structure of 100
102(a): Lower portion of 102
102(b): Rearward extension of 102
103: Rear frame structure of 100
104: First rear frame portion of 100
104(a): Inclined portion
104(b): Horizontal portion
105(a): Left member of 104
105(b): Right member of 104
106(a): Flattened end of 104
106(b): Flattened end of 107
107: Second rear frame portion of 100
108(a): Mounting provisions on 106(a)
108(b): Mounting provisions on 106(b)
109: First member of 106
110: Second member of 106
111: C shaped cross-section of 106
112: Top member of 107
113: Charging port
114: Chain adjuster
115: Arrester plate
116: spacer
117: Mounting screw