Claims:[048] We claim:
1. A subframe (10) for a vehicle, comprising:
a frame (2) defining a predetermined profile; and
a plurality of hexagonal tubes (1) accommodated within the frame (2) and juxtaposed to each other defining a honeycomb structure, wherein each of the plurality of hexagonal tubes (1) is fixedly connected to an adjacent hexagonal tube of the plurality of hexagonal tubes (1) by a thermal joining process.

2. The subframe (10) as claimed in claim 1, wherein the frame is made of metallic strip and is contoured to define the predetermined profile.

3. The subframe (10) as claimed in claim 1, wherein the thermal joining process is at least one of spot-welding process and projection welding process.

4. The subframe (10) as claimed in claim 1, wherein the honeycomb structure is thermally joined to the frame (2) along an inner periphery of the frame (2).

5. The subframe (10) as claimed in claim 1 comprises one or more mounting brackets (3) fixedly mounted onto the plurality of hexagonal members (1).

6. The subframe (10) as claimed in claim 1, wherein the plurality of hexagonal member (1) is configured to accommodate one or more stiffeners (S)

7. The subframe (10) as claimed in claim 6, wherein the one or more stiffeners (S) includes at least one of plugs, tubes, and lugs.

8. The subframe (10) as claimed in claim 1, wherein the profile of the subframe (10) is scalable in one or more directions such that subframe (10) can be accommodated on various vehicles.

9. A method of manufacturing a subframe (10) for a vehicle, the method comprises:
providing, a frame (2) of a predetermined profile;
positioning, a plurality of hexagonal members (1) adjacent to each other within the frame (2) to define a honeycomb structure; and
joining, each of the plurality of hexagonal members (1) by thermal joining process.

10. The method as claimed in claim 9, wherein the frame (2) is defined by contouring a metallic strip in the predetermined profile.

11. The method as claimed in claim 9 comprises joining the honeycomb structure to the frame (2) along an inner periphery of the frame (2) by the thermal joining process.

12. A vehicle comprising;
a subframe (10) as claimed in claim 1, the subframe comprises:
a frame (2) defining a predetermined profile; and
a plurality of hexagonal tubes (1) accommodated within the frame (2) and juxtaposed to each other defining a honeycomb structure, wherein each of the plurality of hexagonal tubes (1) is fixedly connected to an adjacent hexagonal tube of the plurality of hexagonal tubes (1) by a thermal joining process.

, Description:[001] TECHNICAL FIELD

[002] The present disclosure generally relates to the field of automobiles. Particularly, but not exclusively, the present disclosure relates to frame of a vehicle. Further embodiments of the present disclosure describe a configuration of a subframe for a suspension system of a vehicle.

[003] BACKGROUND

[004] Automotive vehicles are often constructed at their front end to include various support structure for the engine, wheels, suspension, bumper, and other related components. These support structures may include members that are generally aligned with the longitudinal axis of the vehicle, that run in a generally transverse direction relative to the longitudinal members or at oblique angles to these axes. The support structures surrounding and supporting the engine compartment are ultimately connected to various structures that define the vehicle cabin. These cabin support structures may include a generally vertical door hinge pillar, A-pillar that extends from the door hinge pillar to the roof of the vehicle, a laterally extending cross beam, a floor pan running across the width of the vehicle, and a rocker member extending rearwardly from the bottom of the hinge pillar.

[005] These support structures provide support for various vehicle components, as well as exterior structures, that are mounted thereto. Examples of vehicle components include the engine, transmission, radiator, suspension, wheels, and the like. Examples of exterior structures include the doors, roof, windshield, floor panels, hood, and the like. In addition to providing support for the various vehicle parts, the support structure also operates to protect the vehicle occupants in the event of a collision, such as a frontal impact collision, reward collision, and collision from sides.

[006] Subframes are one such type of support structure used in passenger cars, in particular, but also for off-road vehicles and light trucks. In order to increase the structural stiffness of a vehicle frame assembly, one or more subframes are rigidly attached between the left and right frame rails of a vehicle. A vehicle frame will commonly include a front subframe located beneath the engine and supports suspension systems. The vehicle frame rails extend in a longitudinal direction to the vehicle body while the front subframe spans between the left and right frame rails in a transverse direction to the vehicle body. The front subframe is commonly used as a mounting structure for vehicle suspension components. Subframes may be suspension subframes which are coupled via flexible articulated links, or hinges to the frame or to the vehicle body. They are also so-called integral structural members, where the subframe is rigidly joined to the frame or to the vehicle body, in particular to the vehicle's side member elements, such as front-end members or the like. The subframes are, in part, assembly, or mounting, frames, on which the suspension elements, in some instances inclusive of the wheel suspension, are articulated or supported, and/or which are used as supports for the steering system and/or the stabilizer.

[007] Conventionally, the subframes are usually constructed from two side parts, which are detachably joined across front and rear to structural members or frame side members. The subframes are braced against each other across the cross elements, and the subframe usually forms a single, integrated unit. In practical applications, subframes of this kind are used both in conjunction with front axles as well as with rear axles of passenger vehicles, with conflicting demands being placed on the subframe and on the front-end vehicle design, particularly as far as the front axles are concerned. Other process of producing the subframes include stamping subframes from sheet metal blanks and reinforcing suitably.

[008] However, the conventional subframes have one or more disadvantages associated with it from manufacturing to usability. Manufacturing the subframe requires butting blank into determined shape. During cutting, the percentage of utilization of sheet metal is around 65% to 70%, which means approximately 30% of the sheet material goes waste. Further the conventional subframes have major limitations with regards to scalability and cannot be easily used across different variants of vehicles. Further, the conventional subframes are provided with one or more structural components which adds additional weight to the subframe.

[009] The present disclosure is directed to overcome one or more limitations stated above or other such limitations associated with the prior arts.

[010] The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the disclosure and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

[011] SUMMARY OF THE DISCLOSURE

[012] One or more shortcomings of conventional systems are overcome, and additional advantages are provided through the assembly and the system as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

[013] In one non-limiting embodiment of the disclosure, a subframe for a vehicle is disclosed. The subframe includes a frame defining a pre-determined profile. The frame is configured to accommodate a plurality of hexagonal tubes. The hexagonal tubes are juxtaposed to each other defining a honeycomb structure. Each of the plurality of hexagonal tubes in fixedly connected to an adjacent hexagonal tube of the plurality of hexagonal tubes by a thermal joining process.

[014] In an embodiment of the disclosure, the frame is made of metallic strip and is contoured to define the pre-determined profile.

[015] In an embodiment of the disclosure, the thermal joining process is at least one of spot-welding process and projection welding process.

[016] In an embodiment of the disclosure, the honeycomb structure is thermally joined to the frame along an inner periphery of the frame.

[017] In an embodiment of the disclosure, the subframe includes one or more mounting brackets fixedly mounted onto the plurality of hexagonal members.

[018] In an embodiment of the disclosure, the profile of the subframe is scalable in one or more directions such that subframe can be accommodated on various vehicles.

[019] In an embodiment of the disclosure, the plurality of hexagonal member is configured to accommodate one or more stiffeners. The one or more stiffeners includes at least one of plugs, tubes, and lugs.

[020] In a yet another non-limiting embodiment of the disclosure, a method of manufacturing a subframe for a vehicle is disclosed. The method includes providing a frame of a predetermined profile and positioning a plurality of hexagonal members within the frame and adjacent to each other to define a honeycomb structure. Each of the plurality of hexagonal members is joined to each other by thermal joining process.

[021] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[022] BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

[023] The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

[024] FIG.1 illustrates a schematic view of a subframe for a vehicle, in accordance with an embodiment of the present disclosure.

[025] FIG.2 illustrates an exemplary top-view of the subframe of FIG.1, in accordance with an embodiment of the present disclosure.

[026] FIG.3 illustrates a schematic view of the subframe of FIG.1 with a plurality of stiffener plugs positioned in lengthwise and widthwise direction, in accordance with some embodiments of the present disclosure.

[027] FIGS. 4a and 4b illustrates a schematic view of the subframe of FIG.1 with a plurality of stiffener tubes positioned in lengthwise and widthwise direction, in accordance with some embodiments of the present disclosure.

[028] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the mechanism and the assembly illustrated herein may be employed without departing from the principles of the disclosure described herein.

[029] DETAILED DESCRIPTION

[030] The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent processes do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

[031] Embodiments of the present disclosure discloses a subframe for a vehicle. The subframe according to the present disclosure among other advantages ensures scalability in lateral and longitudinal directions. Thus, catering to various vehicle requirements and making the subframe modular. The subframe of the present disclosure includes a frame defining a predetermined profile. The frame may be made of metallic strip and may be contoured to define the predetermined profile. A plurality of hexagonal tubes may be accommodated within the frame. The plurality of hexagonal tubes may be juxtaposed to each other within the frame and joined by a thermal joining process. The plurality of hexagonal tubes may define a honeycomb structure. The honeycomb structure may be thermally joined to the frame along an inner periphery of the frame. Further, the subframe may be structured to accommodate one or more mounting brackets. The one or more mounting brackets may be fixedly mounted onto the plurality of hexagonal members. To increase the stiffness of the subframe, a plurality of stiffeners may be provided at desired locations within the subframe. The plurality of hexagonal tubes may be configured to accommodate the one or more stiffeners. Hereinafter, the configuration of the subframe may be elucidated with reference to figures.

[032] The terms “comprises…. a”, “comprising”, or any other variations thereof used in the specification, are intended to cover a non-exclusive inclusion, such that an assembly that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or method. In other words, one or more elements in an assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly.

[033] Henceforth, the present disclosure is explained with the help of one or more figures of exemplary embodiments. However, such exemplary embodiments should not be construed as limitation of the present disclosure.

[034] The following paragraphs describe the present disclosure with reference to FIG(s) 1 to 4b. In the figures, the same element or elements which have similar functions are indicated by the same reference signs. For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated methods, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention pertains.

[035] The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description. It is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices or components illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions or other physical characteristics relating to the embodiments that may be disclosed are not to be considered as limiting, unless the claims expressly state otherwise. Hereinafter, preferred embodiments of the present disclosure will be described referring to the accompanying drawings. While some specific terms directed to a specific direction will be used, the purpose of usage of these terms or words is merely to facilitate understanding of the present invention referring to the drawings. Accordingly, it should be noted that the meanings of these terms or words should not improperly limit the technical scope of the present invention.

[036] Referring in general to all the figures, there is disclosed an exemplary embodiment of a portion of the vehicle [not shown]. The vehicle may include a plurality of wheels for providing mobility to the vehicle. Further, the vehicle may include a vehicle frame and a body [not shown]. The body may be secured to the vehicle frame. Accordingly, the vehicle may have the body on frame construction such as may be known for use as a passenger vehicle or the like. However, such constructions should not be construed as a limitation of the present disclosure as the vehicle may have several other configurations such as monocoque chassis etc. The vehicle further includes a bumper coupled or connectable to a bumper beam located at the vehicle forward end of the vehicle. The vehicle frame may also be referred to as a chassis and may hereinafter be used interchangeably. The chassis may include a pair of right and left main frames (also called side frames), as may be generally known as right-side beam and left-side side beam. The pair of right and left main frames may extend in a vehicle lengthwise direction (longitudinal direction) of the vehicle. A frontal portion of the pair of right and left frames may be connected by at least one subframe (10) [as shown in FIG.1]. Henceforth, the configuration and design of the subframe (10) may be elucidated with reference to FIG.1.

[037] Referring now to FIG.1, which illustrates a schematic view of the subframe (10) for the vehicle. The subframe (10), for the vehicle may include a frame (2). The frame (2) may be made of metallic strips of pre-determined dimensions. In an embodiment, the dimensions of the frame (2) may be based on various parameters including wheel track, length between the right-side beam and the left-side beam of the chassis and the like. The frame (2) may be produced by contouring or bending metallic strip in a pre-determined profile. The pre-defined profile may resemble a skeletal structure of the subframe (10). Within the skeletal structure i.e., the frame (2), a plurality of hexagonal tubes (1) may be arranged in a predetermined order. In other words, the plurality of hexagonal tubes (1) may be accommodated within the frame (2) and is juxtaposed to each other. In an embodiment, the plurality of hexagonal tubes (1) may be obtained by fragmenting an elongated hexagonal tube or a larger hexagonal tube. The larger hexagonal tube may be fragmented to the plurality of hexagonal tubes (1) based on the desired length and the number of hexagonal tubes necessary for manufacturing the subframe (10). Each of the plurality of hexagonal tubes (1) may be thermally joined to an adjacent hexagonal tube of the plurality of hexagonal tubes (1). The thermal joining process used for joining each of the plurality of hexagonal tubes (1) may be at least one of spot welding or projection welding process but not limiting to the same. In some embodiment, one or more of the plurality of hexagonal tubes (1) may have a portion of the complete shell/shape of hexagon to match boundary requirements of the frame (2).
[038] In an embodiment, the each of the plurality of hexagonal tubes (1) may be joined to adjacent hexagonal tubes of the plurality of hexagonal tubes (1) to form a honeycomb structure. The honeycomb structure may be joined to the frame (2) along an inner periphery of the frame (2) by thermal joining process such as but not limiting to spot-welding and projection welding. In an embodiment, one or more mounting brackets (3) may be defined in the frame (2) of the subframe (10). That is, the one or more mounting brackets (3) may be provided on or within the honeycomb structure defined by the plurality of hexagonal tubes (1). In an embodiment, some of the mounting brackets (3) may be fixedly connected on the honeycomb structure.

[039] As seen from FIG.2, the one or more mounting brackets (3) may be provided on either sides of the frame (2) along the periphery. The one or mounting brackets (3) may also be provided at desired location on the honeycomb structure at which any component of the vehicle may be mounted or joined. During assembly of the vehicle, engine and transmission, suspension system among other components may be mounted on the subframe (10). In addition, the suspensions for the left and right front wheels may be mounted on the subframe (10). The said components may be mounted on the subframe (10) using the said mounting brackets (3). Also, the subframe (10) may be coupled onto an underbody of the frame by installing bolts through the mounting brackets (3).

[040] To increase the stiffness of the subframe (10) a plurality of stiffeners (S) may be included in the honeycomb structure. For example, a plurality of plugs (S4) [as shown in FIG.3] may be included at desired places to increases the stiffness of the subframe (10). In an exemplary embodiment, the plugs (S4) may be provided in a group of plurality of hexagonal tubes to improve stiffness of along a desired orientation including lengthwise and width wise orientation. Further referring to FIG(s) 4a and 4b, a plurality of elongated tubes (S5) may be provided within the honeycomb structure in a lateral or longitudinal direction or both to increase the stiffness of the subframe. In an embodiment, a provision may be made in the honeycomb structure by drilling to accommodate the elongated tubes (S5). The above disclosed stiffeners (S) should not be construed as a limitation of the present disclosure as other suitable stiffeners (S) such as lugs and the like may be used. The stiffeners (S) aid in achieving desired stiffness values of the subframe (10).

[041] The configuration of the subframe (10) of the present disclosure has an inherent advantage of scalability in lateral and longitudinal directions. As shown in FIG.2, the lateral and the longitudinal length of the subframe (10) may be increase based on the vehicle requirements. That is the subframe (10) of the present disclosure may be used a modular platform for vehicles of various dimensions. For example, in the passenger vehicle segment, the vehicles are divided under various platforms including hatchbacks, sedans, multi-utility vehicles (MUV) or sports utility vehicles (SUV). The subframe (10) being modular in nature may be used across various such platforms in the passenger vehicle segment. Also, such modular subframes (10) may also be used across various vehicles in the commercial segment. This may be achieved by adding a greater number of hexagonal tubes at the desired position within the subframe (10). The conventional subframes have limitations to update the design and would eventually add to the weight of the subframe to increase the dimensions for various vehicles.

[042] The configuration of the subframe (10) of the present disclosure provides a double thickness effect and significantly improves the rigidity of the subframe (10). The said advantage may be achieved due to the vertical adjacent walls of the each of the plurality of hexagonal tubes (1) in the honeycomb structure. Since, the subframe (10) uses local stiffeners (S) at desired location the overall weight of the subframe (10) is less when compared to conventional subframes. The stiffness of the subframe (10) may be tuned as per requirement to cater to different vehicles requirements. Manufacturing of the subframe (10) of the present disclosure may eliminate the use of CO2 welding. Also, manufacturing the subframe (10) of the present disclosure optimizes material utilisation, thereby reducing material wastage to a greater extent.

[043] It is to be understood that a person of ordinary skill in the art may develop a system of similar configuration without deviating from the scope of the present disclosure. Such modifications and variations may be made without departing from the scope of the present invention. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents.

[044] Equivalents:

[045] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

[046] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system (108) having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system (108) having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.” While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[047] Referral Numerals:
Description Reference Number
Subframe 10
Hexagonal tubes 1
Frame 2
Mounting brackets 3
Stiffeners S
Plug and elongated tubes S (4, 5)