DESC:FIELD OF THE INVENTION
[001] The invention relates to a front-end module for a vehicle.

BACKGROUND OF THE INVENTION
[002] Front-end module or front-end carrier is adapted to a front-side of a vehicle chassis, and is configured to support components such as lights, bumpers, hood latches, grill, etc and their sub-components. The front-end module also acts as a body frame, and thus is important from a functional, aesthetic and safety perspective.
[003] Typically, the front-end module is provided with an upper bar, a lower bar arranged parallel to the upper bar and two side bars for connecting the upper and lower bars respectively so as to form a generally rectangular frame. The bars are metal, and the front-end module is made by stamping and welding together several individual metal bars.
[004] While, such front-end modules provide necessary structure, they are heavy, and are expensive to manufacture. The front-end modules thus make vehicle unnecessary heavy and reduces fuel efficiency of the vehicle. Further, metals suffer from poor corrosion resistance, and also have poor crash behavior.
[005] In view of stringent fuel economy, emissions and safety standards, automobile industry is focused on designing light-weight vehicles without sacrificing on safety standards. Accordingly, a front-end module for a vehicle addressing at-least the aforementioned problems is desired.

SUMMARY OF THE INVENTION
[006] In one aspect, the present invention provides a front-end module for a vehicle, the front-end module comprising a non-metallic frame having an upper member, a lower member arranged parallel to the upper member and opposing side members connecting the upper member and the lower member; and plurality of metallic support members, each member of the non-metallic frame configured to be coupled with at-least one metallic support member to reinforce the non-metallic frame with metallic support members.

BRIEF DESCRIPTION OF THE DRAWINGS
[007] 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 shows an exploded view of a front-end module in accordance with an embodiment of the invention.
Figure 2 shows a ribbed support structure of the front-end module in accordance with an embodiment of the invention.
Figure 3 shows the front-end module adapted to a front-side of a vehicle body in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[008] The present invention is directed towards a front-end module for a vehicle. The front-end module is designed to be light-weight without sacrificing on rigidity and strength of the front-end module.
[009] Figure 1 shows an exploded view of a front-end module 100 in accordance with an embodiment of the invention. The front-end module 100 comprises a frame 110 and plurality of support members 120A to 120D.
[010] The frame 110, as shown in the figure, comprises of an upper member 110A, a lower member 110B arranged parallel to the upper member 110A, and two opposing side members 110C, 110D connecting the upper member 110A and the lower member 110B forming a generally rectangular frame 110. In an embodiment, the frame 110 is a unitary structure formed of plastic. The members of the frame 110 have an open-channeled structure or has one or more slots so as to accommodate one or more support members.
[011] The support members include at-least a first horizontal member 120A, a second horizontal member 120B, a first vertical member 120C and a second vertical member 120D. As shown in figure 1, the first horizontal member 120A is configured to be accommodated by the upper member 110A, the second horizontal member 120B is configured to be accommodated by the lower member 110B, the first vertical member 120C and the second vertical member 120D are configured to be accommodated by the opposing side member 110C, 110D. Accordingly, the support members 120A to 120D also forms a generally rectangular structure within the frame 110 whereby the support members 120A to D are interconnected and coupled with the frame 110.
[012] In an embodiment of the invention, the frame 110 is a non-metallic frame 110 and the support members 120A to 120D are metallic support members. The frame 110 is preferably a plastic frame and the support members 120A to 120D are steel support members. The support members can be coupled to the frame via fasteners. In an embodiment, a ribbed support structure 130 is provided to couple the plastic with the metal. In this regard, the frame 110 and the support members 120A to 120D are pre-formed and a thermo-plastic material is injected or made to flows through and around sheet metal access holes to secure the support members 120A to 120D with the frame 110 at pre-determined locations to form ribbed support structure as shown in figure 2 during an insert molding process whereby the ribbed support structure couples the metallic support member within the non-metallic frame. The support members 120A to 120D are thus embedded/ retained by the frame 110 whereby metal support members 120A to 120D reinforce the mechanical properties of the frame 110 which is plastic. The front-end module 100 thus has improved structural integrity and stiffness.
[013] The front-end module 100 is thus a hybrid structure comprising of metal and plastic which imparts high stiffness, good corrosion resistance to the vehicle and, also exhibits good impact absorbing characteristics. Further, the front-end module 100 is light-weight, resulting in improved fuel-efficiency of the vehicle.
[014] Figure 3 shows the front-end module 100 adapted to a front-side of a vehicle body X in accordance with an embodiment of the invention. The front-end module 100 is mechanically fastened to the vehicle body X via bolts at plurality of locations. Further, torque limiters are provided to avoid damage to the plastic. Various components of the vehicle are mounted on the front-end module 100. Such components include condenser radiator fan module (crfm), intercooler assembly, air guide, bumper assembly, front cover assembly, engine under cover, forward headlamps, hood latch, cable assembly, hood stopper, hood switches, airbag sensors, wiring harness, impact beam assembly, air intake snorkel and water protector, front frame assembly, etc
[015] Advantageously, the present invention provides a light-weight front-end module with good structural rigidity and strength.
[016] 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.
,CLAIMS:WE CLAIM:

1. A front-end module (100) for a vehicle, the front-end module comprising:
a non-metallic frame (110) having an upper member (110A), a lower member (110B) arranged parallel to the upper member and opposing side members (110C, 110D) connecting the upper member and the lower member; and
plurality of metallic support members (120A to 120D), each member of the non-metallic frame configured to be coupled with at-least one support member to reinforce the non-metallic frame with metallic support members.

2. The front-end module as claimed in claim 1, wherein the non-metallic frame is a plastic frame.

3. The front-end module as claimed in claim 1, wherein the frame has an open-channel structure to receive the support members.

4. The front-end module as claimed in claim 1, wherein each member has one or more slots to receive one or more support members.

5. The front-end module as claimed in claim 1, wherein each metallic support member is coupled with the non-metallic frame via a ribbed support structure 130 whereby the ribbed support structure extends from the frame and couples the metallic support member within the non-metallic frame.