FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)


TITLE OF THE INVENTION An Improved Front Underrun Protection Device For A Vehicle
APPLICANTS
TATA MOTORS LIMITED, An Indian Company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVNETORS
Mr. Ganeshkumar R. and Mr. Adwait K Kulkarni
Both are Indian Nationals
of TATA MOTORS LIMITED,
an Indian company having its registered office
at Bombay House, 24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed


FIELD OF INVENTION
The present invention is related to Underrun protection system and more particularly it relates to Front underrun protection device assembly for vehicles.
BACKGROUND OF INVENTION
Commercial vehicle chassis frame is located at higher distance from the road surface. The distance between the chassis frame and the road is so high that a smaller vehicle can go beneath the chassis frame. Such an interaction is called as "Underrun" of a vehicle. Such underrun impacts at high speeds are quite fatal since there is no structure on the smaller vehicle to stop it till the chassis frame long members of a commercial vehicle hit the upper part of the smaller vehicle structure, such as "A" pillar, roof headers, which does not have any energy absorbing capability. Occasionally the chassis frame long members can pierce through the windshield glass and hit the front seat occupants of the smaller vehicle directly. Therefore such underride crashes are severe and lead to human fatalities. Commercial vehicles are therefore provided with underrun protection device (UPD) which comprise of an auxiliary barrier fitted to the chassis frame to interact with the front structure of the smaller vehicles and stop it to avoid from being underrun. The said UPDs consist of an underrun protection member with a suitable bracket to connect it to the chassis frame. The UPD is positioned in such a way as to engage with the frontal structure of the smaller car and avoid its underrun. Such underrun devices are recognized as Front underrun protection device(FUPD) , Rear Underrun Protection Device(RUPD) and Side underrun protection device(SUPD) as per their location on the vehicle.
This invention is associated with the Frontal underrun protection device (FUPD).
Generally in an FUPD, the mounting brackets are connected to top, bottom & side faces of the chassis frame. The mounting fasteners are exposed to higher amount of shear forces reducing the robustness of attachment scheme. Therefore the attachment fasteners

used are of higher strengths and superior quality. Because of this the FUPDs are costlier and time consuming for assembly / disassembly sequences.
OBJECTS OF INVENTION
The main object of the present invention is to provide an improved front underrun protection device assembly.
Another object of the present invention is to provide an improved front underrun protection device assembly which prevents shearing of mounting fasteners and increases the robustness of assembly with less number of mounting fasteners.
Yet another object of the present invention is to provide an improved front underrun protection device assembly which is simple in construction and cost effective.
STATEMENT OF INVENTION
Accordingly the present invention discloses a front underrun protection device for vehicles comprising; a front member configured to be reinforced by back plate constituting a front beam; plurality of reinforcement patch plates for improving the strength of the said front beam locally; at least one primary mounting bracket and intermediate mounting bracket on each side of front cross member for connecting the said front beam to chassis member; said intermediate mounting bracket comprising a holder configured for holding front beam and a support bracket with plurality of reinforcements; plurality of rubber beading for fitting at the end of said front beam; at least one reinforcement bracket provided at the front end of both long members to withstand the forces generated on said front underrun protection device during impact.

BRIEF DESCRIPTION OF DRAWINGS
According to the present invention,
Figure-01 shows an isometric view of front end of a commercial vehicle showing the
vehicle cabin (1), FlJPD, chassis frame (3). Figure-02 shows enhanced view of the front end of a commercial vehicle. It shows
the front beam (2), chassis frame (3), primary mounting brackets (4) and
intermediate mounting brackets (5). Figure-03 shows the exploded view of the mounting arrangement of positioning of
front beam, primary mounting bracket & intermediate mounting bracket. Figure-04 shows the front & rear isometric views of front beam. Figure-05 shows the front & rear isometric views of the right handed primary
mounting bracket. Figure-06 shows the front & rear isometric views of the left handed intermediate
mounting bracket. Figure-07 shows the isometric view of the said chassis frame (3).
BRIEF DESCRIPTION OF INVENTION
In accordance with the present invention, and improved front underrun protection device comprises; a front beam (2), chassis frame (3), primary mounting bracket (4) and intermediate mounting bracket (5). The said front beam is connected to the said chassis frame through the said primary mounting bracket & intermediate mounting bracket. The said primary mounting bracket is connected to the front end of the said chassis frame such that it is mounted at the front, side & top side of the said chassis member. This arrangement facilitates side mounting fasteners to experience lower shear forces which enable FUPD to achieve the required strength with minimal numbers of fasteners. This FUPD is cost effective, weight effective & reliable.

DETAILED DESCRIPTION OF INVENTION
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same, Now referring to figure 04, in accordance with the present invention, front beam comprises a front member (2.1) supported with a back plate (2.2) constituting a front beam (2), plurality of reinforcement patch plates (2.3), plurality of weld nuts for connecting the intermediate mounting brackets, plurality of rubber headings (2.4) fitted at the end of the said front member, The said front member and the said back plate are integrated, preferably by welding.
The said front beam (2.1) is provided with plurality of reinforcement patch plates to improve its strength locally. The said front beam has also been provided with plurality of weld nuts for connecting the intermediate mounting brackets. The said front beam(2) is connected to said chassis frame through the primary mounting bracket (4) and said intermediate mounting bracket (5).
Now referring to figure-05 which shows the front & rear isometric views of the right handed primary mounting bracket (4). The said front beam (2) is connected to said chassis frame through the primary mounting bracket (4) and intermediate mounting bracket (5). The top end of said primary bracket (4) is connected to the said chassis frame and the bottom end is connected to the said intermediate bracket (5). The said primary mounting bracket (4) having front face (4.1), side face (4.2) & top faces (4.3) to match the corresponding faces of the said chassis frame through the set of mounting holes(4.5.1, 4.5.2 & 4.5.3) respectively. The lower portion of the said primary mounting bracket (4) has also been provided with mounting hole (4.5.4) for mounting the said bracket to the bottom face of the chassis frame. Said primary mounting bracket (4) has been provided with a connector bracket (4.4) and plurality of second set of holes (4.6.1, 4.6.2 & 4.6.3) to suit bolting of the said intermediate mounting bracket (5). The said primary mounting bracket (4) is made by forming a single piece sheet metal. The connector bracket (4.4) is

attached to said primary mounting bracket (4) by welding. The left handed mounting bracket will be mirror opposite of said right handed bracket.
Now referring to figure-06 which shows the front & rear isometric views of the left handed intermediate mounting bracket (5). The lower end of said bracket is connected to the said front beam and the top end is connected to the said primary mounting bracket (4). The said intermediate mounting bracket (5) comprising a holder (5.1) configured to hold said front beam, support bracket (5.2) and plurality of reinforcements (5.3). The said front beam holder (5.1) is a C- shaped member configured to hold the said front beam. Said front beam holder (5.1) is also bolted to the front beam through plurality of the first set of holes (5.4.1). The said support bracket (5.2) is connected to the said mounting brackets (4) through plurality of second set of holes (5.4.2). The said front beam holder, the support bracket & plurality of reinforcements are joined together preferably by welding, to form a complete intermediate mounting bracket. The right handed mounting bracket will be mirror opposite of left handed bracket.
It is also possible to integrate the said primary mounting bracket (4) with the said intermediate bracket (5) to form one bracket depending on the suitability of its manufacturing and assembly.
Now referring to figure-07 which shows the isometric view of the said chassis frame (3). The said chassis frame comprises; long members (3.1) connected to a cross member (3.2) at the front end and pair of gusset plates (3.3) connected at the corners. The said primary mounting bracket (4) is mounted to the said chassis member (3) through set of mounting holes (3.4.1, 3.4.2, 3.4.3) on front, side and top face respectively. A reinforcement bracket (3.5) has also been provided in the front end of the said chassis long member (3.1) to provide adequate strength to react to the forces generated on the said FUPD. The said primary mounting bracket (4) is also connected at the bottom face of the said chassis member (3) through suitable holes (not shown).

The proposed arrangement of FUPD is provided with mounting with the front face of the chassis frame. With this arrangement the side mounting fasteners are exposed to very low shear forces improving the robustness of the mounting system. It is therefore possible to use mounting fasteners with lower strength and quantity. This has made the FUPD cost effective and simple for assembly/disassembly sequences.
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

WE CLAIM
1. A front underrun protection device for vehicles comprising;
a front member configured to be reinforced by back plate constituting a front beam; plurality of reinforcement patch plates for improving the strength of the said front beam locally; at least one primary mounting bracket and intermediate mounting bracket on each side of front cross member for connecting the said front beam to chassis member; said intermediate mounting bracket comprising a holder configured for holding front beam and a support bracket with plurality of reinforcements; plurality of rubber beading for fitting at the end of said front beam; at least one reinforcement bracket provided at the front end of both long members to withstand the forces generated on said front underrun protection device during impact.
2. The device as claimed in claim 1, wherein said primary mounting bracket and intermediate mounting bracket are connected to each other such that said primary mounting bracket being at top to be connected to chassis frame and said intermediate mounting bracket being at bottom to be connected to said front beam.
3. The device as claimed in claim 1, wherein said at least one primary mounting bracket and intermediate mounting bracket are provided on each side of front cross member.
4. The device as claimed in claim 1, wherein said primary mounting bracket comprises connector bracket and plurality of holes configured for connecting said intermediate mounting bracket.
5. The device as claimed in claim 1 wherein said primary mounting bracket is made from a single piece sheet metal by forming.

6. The device as claimed in claim 1 wherein said primary mounting bracket and said intermediate mounting bracket can be integrally connected to form one bracket for connecting said front beam to chassis member.
7. The device as claimed in claim 1 wherein front face, side face and top face of said primary mounting bracket are connected to corresponding faces of said chassis frame.
8. The device as claimed in claim 1, wherein gusset plates configured to be connected at each front corner constituted by long member and cross member of the chassis frame.
9. The device as claimed in claim 1 to 8 wherein said left handed primary mounting bracket, intermediate mounting bracket, support bracket, gusset plate and reinforcement bracket are the mirror images of right handed brackets.
10. A front underrun protection device for a vehicle substantially as herein described in the description as illustrated with reference to the accompanying drawings.