Description:TECHNICAL FIELD
The embodiments of the present disclosure relate generally to a crash guard of a vehicle and more particularly to a crash guard system which safeguards a battery pack and a side panel of the vehicle in incidence of crash.
BACKGROUND
Motorcycles or motorbikes generally have a crash guard to protect various parts of the motorcycle in event of crash or hit. There are various types of crash guards existing in the form of a bar extending outwardly to the vehicle in order to protect the vehicle’s engine or saddlebag from getting damaged. Many motorcycle manufacturers use different types of crash bars which are structurally different from each other. Some crash bars are straight which are pointed out towards vehicle’s transverse direction, some are curved towards side of the vehicle along longitudinal direction of the vehicle. A significant problem of the existing crash bars is that it may damages the vehicle parts in case of extreme impact when the crash bar bends, and the load gets transferred to the vehicle parts.
Example of another conventional crash guard includes a hollow steel rod that is bent in a substantially C-shape and is fitted onto the rear side of the head pipe in motorcycles. When viewed from the front of a vehicle, this crash guard design appears as a C-shaped and inverted C-shape on either side of the motorcycle. But this construction has several disadvantages. Firstly, this type of crash guard occupies lot of space in motorcycles. This causes risk of hitting in traffic conditions wherein vehicles are closely spaced. It also makes it difficult to maneuver in narrow spaces such as removing or parking a bike in a mall. Secondly, this type of crash guard is bulky and heavier adding to the overall weight of the vehicle.
Moreover, IC engine vehicles have an engine as an important part which needs to be protected from direct impact likewise in electric vehicles, a battery pack and an electric motor are the crucial parts and need to be protected from direct impact. In case, if the electric vehicle without crash guard falls down on its side on the ground, the vehicle battery pack gets directly impacted and the load will directly come on the battery pack which results in damage of the battery pack and may deforms the battery or there is a chance of fire accident which may lead to explosion of the battery. In case of damage, the cost to repair the damage will be high as it is the costliest part of any electric vehicle. Hence, provision of crash guard is always advisable in all types of motorcycles. But in some instances, where we focus on aesthetics of the vehicle, the existing crash bars don’t look good. Especially in sporty motorcycles, as they belong to the premium range, one of the important aspects is its appearance.
Hence, there is need of a crash guard that protects the important parts of the vehicle from getting damaged in incidence of crash, without disturbing the appearance of the vehicle.
PROBLEM TO BE SOLVED BY INVENTION
It is main objective of the current invention to provide a failsafe crash guard that handles an impact load in stages.
It is another objective of the current invention to provide a crash guard that protect the vehicle battery and other parts of the vehicle in case of crash or accident.
It is yet another objective of the current invention to provide a crash guard which is accommodated in optimum space.
It is yet another objective of the current invention to provide a crash guard with optimum weight.
It is yet another objective of the current invention to provide an aesthetically pleasing appearance to the vehicle.
SUMMARY OF THE INVENTION
As per the current invention, a crash guard system to protect a motorcycle in an incidence of crash comprises of a crash tube, a reinforcement member and a cover. The crash tube comprises of a bracket configured with plurality of holes for fastening to the cradle, a first tube and a second tube configured to extend from front to side of the motorcycle which are fixedly mounted to said bracket at front side of the motorcycle and a third tube configured to join the first tube and the second tube towards the side of the motorcycle to form a substantially u-shape profile. The reinforcement member comprises of a first leg configured with a first rod portion and a first mounting portion, a second leg configured with a second rod portion and a second mounting portion, an intermediate leg joining the first leg and the second leg to form an integral single component, wherein the first leg, the second leg and the intermediate leg are configured to form a substantially u-shape profile. The cover is formed with an impact resistant material and configured to be mechanically fastened to a side panel of the motorcycle while assembly, the cover comprises of a first surface having predefined shape configured with a first mounting portion, a second surface having predefined shape configured with a second mounting portion, wherein the first surface and the second surface are configured to be an integral single part forming a hollow space to accommodate the reinforcement member.
Further, the cover is detachably mounted on the reinforcement member through the first and second mounting portion of the first and second surfaces respectively, wherein the cover is configured to be a first impact bearing member capable of bearing a first predetermined bearing capacity of the load.
Furthermore, the first mounting portion of the first leg and the second mounting portion of the second leg of the reinforcement member are fixedly mounted on the second tube of the crash tube which extends at predefined functional angle in transverse direction of the side of the motorcycle, wherein the reinforcement member is configured to be a second impact bearing member capable of bearing a second predetermined bearing capacity of the load.
Moreover, the crash tube is removably fastened to a cradle of the motorcycle frame on front side of the motorcycle through the bracket, wherein the crash tube is configured to be a third impact bearing member capable of bearing a third predetermined bearing capacity of the load.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
FIG. 1 illustrates a crash tube of a crash guard system, in accordance with the present invention.
FIG. 2 illustrates a reinforcement member of a crash guard system, in accordance with the present invention.
FIG. 3 illustrates a cover of a crash guard system, in accordance with the present invention.
FIG. 4 illustrates an assembly of a crash guard system including a crash tube, a reinforcement member and a cover, in accordance with the present invention.
FIG. 5 illustrates a motorcycle depicting an assembly of a crash guard system, in accordance with the present invention.
FIG. 6 illustrates a flowchart of a method to protect the motorcycle in an incidence of crash, in accordance with the present invention.

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. 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 system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, members, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
Embodiments of the present invention will be described below in detail with reference to the accompanying figures.
Figure 1 illustrates a crash tube (100) of a crash guard system of the present invention. The crash tube (100) mainly comprises of a bracket (102), a first tube (106), a second tube (108) and a third tube (110) wherein all of the aforementioned elements constitute a single integral part. The bracket (102) comprises of a plurality of holes (104) for fastening the crash tube (100) to a cradle (502) of a motorcycle (500) wherein the crash tube (100) is removably fastened to the cradle (502) of the motorcycle frame on front side of the motorcycle (500) through the bracket (102). The first tube (106) and the second tube (108) are configured to extend towards rear (R) of the motorcycle (500) from the front (F) of the motorcycle (500) and are joined through the third tube (110) forming a U-shaped profile wherein only a small portion of said first tube (106) and the second tube (108) is visible on front of the motorcycle (500). Further, the first tube (106), the second tube (108) and the third tube (110) are hollow tubular metal structures wherein the first tube (106) and the second tube (108) are fixedly attached to the bracket (102). As mentioned, the first tube (106), the second tube (108) and the third tube (110) form the single integral part, hence, the diameter of each of the tube is same. Furthermore, on complete assembly of the motorcycle (500), the crash tube (100) is not visible as it is configured to hide behind a side panel of the motorcycle (500). Moreover, the crash tube (100) is configured to have variable length of the first tube (106), second tube (108) and the third tube (110), and are aligned at a predefined functional angle on the motorcycle (500) as shown in the figure.
Figure 2 illustrates a reinforcement member (200) of the crash guard system of the present invention. The reinforcement member (200) is a small part which is fixedly mounted on the crash tube (100). More specifically, the reinforcement member (200) is mounted on the second tube (108) of the crash tube (100) of the motorcycle (500). Further, the reinforcement member (200) is made up as rigid metal tubular part which is attached to the crash tube (100) through tac welding. However, the person skilled in the art may use any other technique for attachment of the reinforcement member (200) to the crash tube (100). Further, the reinforcement member (200) comprises of a first leg (202) having a first rod portion (208) and a first mounting portion (210), a second leg (204) having a second rod portion (212) and a second mounting portion (214), and an intermediate leg (206) joining the first leg (202) and the second leg (204). Said first leg (202), second leg (204) and the intermediate leg (206) form an integral single component i.e. the reinforcement member (200). Moreover, the first leg (202), the second leg (204) and the intermediate leg (206) are configured to form a substantially u-shape profile. The first mounting portion (210) and the second mounting portion (214) are formed by bending a rigid metal tube at a predefined angle to the first leg (202) and the second leg (204) respectively. Further, the first leg (202) and the second leg (204) are configured to be mounted at predefined angle with respect to the intermediate leg (206) as shown in the figure. The reinforcement member (200) is mounted perpendicular to the crash tube (100) i.e. the reinforcement member (200) is mounted along the motorcycle’s transverse direction (T).
Figure 3 illustrates a cover (300) of the crash guard system of the present invention. The cover (300) is configured to be detachably mounted on the reinforcement member (200); however, the cover (300) is fastened to the side panel of the motorcycle (500). The cover (300) is designed to accommodate the reinforcement member (200) in a hollow space (314) of the cover (300). Further, the cover (300) mainly comprises of a first surface (302) and a second surface (304) wherein the first surface (302) is provided with a first mounting portion (306) and the second surface (304) is provided with a second mounting portion (308). Both the first and second surfaces (302, 304) are configured to have a predefined shape and form a single integral part forming the hollow space (314) to accommodate the reinforcement member (200). Further, the cover (300) is mechanically fastened to the side panel of the motorcycle (504) through the first and second mounting portion (306, 308). The first and second mounting portions (306, 308) of the cover (300) are configured to be the weakest part of the cover (300) and hence, tend to deform first before deformation of any other component, on exceeding an impact load on occurrence of a crash. The cover (300) is formed with an impact resistant plastic material and designed to bear the impact load in case of crash of the motorcycle (500) or in case the motorcycle falls on its side, in order to protect a battery pack (504) and side panels of the motorcycle (500). As the cover (300) is the plastic part, there is very less chance that a rider’s legs get injured, in case of an accident or crash of the motorcycle unlike in case of a conventional metal crash guard. Along with that, it also ensures safety for pedestrians or passersby even upon impact. The cover (300) is the first part which gets damaged in case of crash as it is an exposed part of the crash guard system. The cover (300) is the only part of the crash guard system which is visible after assembly of the motorcycle (500) which is aesthetically appealing structure and makes the motorcycle appearance to be of the premium range.
Figure 4 illustrates an assembly (400) of the crash guard system and figure 5 illustrates a motorcycle (500) having the assembly (400) of the crash guard system. Hereinafter, the crash guard system is discussed in detail. The crash guard system of the present invention is made to bear the impact load in stages wherein the impact load is transferred from one element to another, after handling its maximum impact load bearing capacity. As the cover (300) is the outer most part of said crash guard system, it directly comes in contact with the impacting surface and the impact load gets transferred to the cover (300). Herein, the cover (300) is configured to be a first impact bearing member capable of bearing a first predetermined load. The amount of load which the cover (300) is not able to handle is known as a first additional impact load. In case, if the impact load exceeds the first predetermined load or the first predetermined bearing capacity of the load, the cover (300) transfers the first additional impact load to the reinforcement member (200) and the cover (300) tends to deform or break down. More specifically, as the first and second mounting portions (306, 308) of the cover (300) are the weakest part, the cover (300) tends to break down from its first and second mounting portions (306, 308). Thereinafter, the transferred impact load is handled by the reinforcement member (200) wherein the reinforcement member (200) is configured to be a second impact load bearing member capable of bearing a second predetermined load. As the reinforcement member (200) is the metal part, it is mostly able to deal with maximum amount of impact load, thereby safeguards the battery pack (504) and the side panels from being hit to the external surface or getting impacted. In extreme impact conditions, if the impact load exceeds the second predetermined load, the reinforcement member (200) transfers a second additional impact load to the crash tube (100) and the reinforcement member (200) tends to deform. The second additional impact load is the amount of load that the reinforcement member (200) is unable to handle. Mostly, the reinforcement member (200) tends to deform from the first and second mounting portion (210, 214) of the first and second leg (202, 204), as it is the weakest part where welding joint is present. Moreover, the crash tube (100) is configured to be a third impact bearing member capable of bearing a third predetermined capacity of load. The crash tube (100) is present surrounding the battery pack (504) as shown in figure, hence, in extreme condition when the reinforcement member (200) deforms, the crash tube (100) safeguards the battery pack (504) which is the critical component of the electric motorcycle (500). Safety of the battery pack (504) is of paramount importance in EV’s as if it gets crashed or hit or impacted, it may get ruptured or punctured which will result in thermal runaway event and may potentially lead to a fire. Here, the crash guard system of the present invention mainly protects the battery pack (504) in stages.
Figure 6 is a flowchart of a method to protect the motorcycle in an incidence of crash. Step (601) is, encountering of the motorcycle (500) with a crash wherein a side part of the motorcycle (500) coupled with a cover (300) hit an external surface. At step (602), the cover (300) being a first impact bearing member bears a first predetermined bearing capacity of the impact load upon encountering with the crash. Step (603) represents transferring a first additional impact load to a reinforcement member (200) by the cover (300) upon bearing of the impact load by the cover (300). Thereafter, at step (604), handling of the transferred first additional impact load by the reinforcement member (200) wherein the reinforcement member (200) is a second impact bearing member capable of bearing a second predetermined bearing capacity of the load. At step (605), transferring a second additional impact load to a crash tube (100) by the reinforcement member (200) upon handling of the first additional load by the reinforcement member (200) and at step (606), handling of the transferred second additional impact load by the crash tube (100) wherein the crash tube (100) is a third impact member capable of bearing a third predetermined bearing capacity of the load. Further, the impact load bearing of the cover (300) of the motorcycle (500) comprises breaking of the cover (300) on exceeding the bearing of the impact load beyond the first predetermined bearing capacity of the load. The handling of the transferred first additional impact load by the reinforcement member (200) comprises deformation of the reinforcement member (200) while handling the impact load transferred by the cover (300) or on exceeding the bearing of the impact load beyond the second predetermined bearing capacity of the load. The handling of the transferred second additional impact load by the crash tube (100) comprises deformation of the crash tube (100) on exceeding the bearing of the impact load beyond the third predetermined bearing capacity of the load.
While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
FURTHER ADVANTAGES OF THE INVENTION
The system and method as disclosed in the present invention is able to protect the motorcycle (500) in incidence of crash or in a situation where the motorcycle (500) falls on its side. The crash guard system of the present invention bears the impact load in stages thereby failure of one component does not harm the motorcycle (500) or the battery pack (504) of the motorcycle. The crash guard system of the present invention gives aesthetic appeal to the motorcycle (500). The cover (300) of said crash guard system is mounted on the reinforcement member (200) and the combination of the cover (300) and the reinforcement member (200) provides optimum impact load bearing capacity to the crash guard system ensuring optimum safety of the motorcycle (500). The mounting of the crash guard system at predefined functional angle prevents easy deformation of the crash guard thereby preventing the motorcycle damage. Also, the presence of a plastic part i.e. cover (300), ensures safety for the motorcycle rider and also for pedestrians or passersby even upon impact.
Moreover, the crash guard system mounting is configured to provide comfort to a motorcycle rider. The angular mounting of the crash guard system helps in protecting a leg injury to the motorcycle rider.

REFERENCES
Sr. No. Reference No. Part Name
1 100 Crash Tube
2 102 Bracket
3 104 plurality of holes
4 106 first tube
5 108 second tube
6 110 third tube
7 200 reinforcement member
8 202 first leg
9 204 second leg
10 206 intermediate leg
11 208 first rod portion
12 210 first mounting portion
13 212 second rod portion
14 214 second mounting portion
15 300 cover
16 302 first surface
17 304 second surface
18 306 first mounting portion
19 308 second mounting portion
20 310 hole of first mounting portion of first surface
21 312 hole of second mounting portion of second surface
22 314 hollow space
23 400 assembly of crash guard system
24 500 motorcycle
25 502 cradle

, Claims:We Claim:
1. A crash guard system to protect a motorcycle (500) in an incidence of crash comprising:
a crash tube (100), the crash tube comprising of
a bracket (102) configured with plurality of holes (104) for fastening to the cradle;
a first tube (106) and a second tube (108) configured to extend from front to side of the motorcycle (500) which are fixedly mounted to said bracket (102) at front of the motorcycle; and
a third tube (110) configured to join the first tube (106) and the second tube (108) towards the side of the motorcycle (500) to form a substantially u-shape profile;

a reinforcement member (200), the reinforcement member comprising of
a first leg (202) configured with a first rod portion (208) and a first mounting portion (210);
a second leg (204) configured with a second rod portion (212) and a second mounting portion (214);
an intermediate leg (206) joining the first leg (202) and the second leg (204) to form an integral single component, wherein the first leg (202), the second leg (204) and the intermediate leg (206) are configured to form a substantially u-shape profile; and

a cover (300) formed with an impact resistant material is configured to be mechanically fastened to a side panel of the motorcycle (500) while assembly, the cover comprising of
a first surface (302) having predefined shape configured with a first mounting portion (306);
a second surface (304) having predefined shape configured with a second mounting portion (308);
wherein the first surface (302) and the second surface (304) are configured to be an integral single part forming a hollow space (314) to accommodate the reinforcement member (200); and
characterized in that:
the cover (300) is detachably mounted on the reinforcement member (200) through the first and second mounting portion (306, 308) of the first and second surfaces (302, 304) respectively, wherein the cover (300) is configured to be a first impact bearing member capable of bearing a first predetermined bearing capacity of the load;
the first mounting portion (210) of the first leg (202) and the second mounting portion (214) of the second leg (204) of the reinforcement member (200) are fixedly mounted on the second tube (108) of the crash tube (100) which extends at predefined functional angle in transverse direction (T) of the side of the motorcycle (500), wherein the reinforcement member (200) is configured to be a second impact bearing member capable of bearing a second predetermined bearing capacity of the load; and
the crash tube (100) is removably fastened to a cradle (502) of the motorcycle frame on front of the motorcycle (500) through the bracket (102), wherein the crash tube (100) is configured to be a third impact bearing member capable of bearing a third predetermined bearing capacity of the load.

2. The crash guard system as claimed in claim 1, wherein the first and second mounting portions (306, 308) of the cover (300) tend to break down if the impact load exceeds beyond the first predetermined bearing capacity of the load.

3. The crash guard system as claimed in claim 1, wherein the reinforcement member (200) is configured to bear the impact load transferred from the cover (300) or on break down of the cover (300), the reinforcement member (200) is capable to deform if the impact load exceeds beyond the second predetermined bearing capacity of the load.

4. The crash guard system as claimed in claim 1, wherein the crash tube (100) is configured to bear the impact load on load transfer from the reinforcement member (200) or on deformation of the reinforcement member (200), the crash tube (100) is configured to deform if the impact load exceeds beyond the third predetermined bearing capacity of the load.

5. The crash guard system as claimed in claim 1, wherein the system is configured to safeguard a battery pack (504) and a pair of side panels of the motorcycle (500).

6. The crash guard system as claimed in claim 1, wherein the assembly (400) of the cover (300), the reinforcement member (200), the crash tube (100) and the cradle (502) is configured to act as a single integral part to handle any amount of impact load.

7. The crash guard system as claimed in claim 1, wherein the reinforcement member (200) is configured to be tack welded to the crash tube (100).

8. The crash guard system as claimed in claim 1, wherein the crash tube (100) and the reinforcement member (200) are configured to be made of metal wherein the crash tube (100) is hollow, and the reinforcement member (200) is solid rigid tube to handle maximum amount of impact load.

9. The crash guard system as claimed in claim 1, wherein the cover (300) is configured to be made of an impact resistant plastic material.

10. A method to protect a motorcycle (500) in an incidence of crash, the method comprises:
encountering of the motorcycle with a crash wherein a side part of the motorcycle (500) coupled with a cover (300) hit an external surface;
bearing an impact load of the motorcycle upon encountering with the crash by the cover (300), wherein the cover (300) is configured to be a first impact bearing member capable of bearing a first predetermined bearing capacity of the load;
transferring a first additional impact load to a reinforcement member (200) by the cover (300) upon bearing of the impact load by the cover (300);
handling the transferred first additional impact load by the reinforcement member (200) wherein the reinforcement member (200) is a second impact bearing member capable of bearing a second predetermined bearing capacity of the load;
transferring a second additional impact load to a crash tube (100) by the reinforcement member (200) upon handling of the first additional load by the reinforcement member (200); and
handling the transferred second additional impact load by the crash tube (100) wherein the crash tube (100) is a third impact member capable of bearing a third predetermined bearing capacity of the load.

11. The method as claimed in claim 1, wherein the impact load bearing by the cover (300) of the motorcycle (500) comprises:
breaking of the cover (300) on exceeding the bearing of the impact load beyond the first predetermined bearing capacity of the load.

12. The method as claimed in claim 1, wherein the handling of the transferred first additional impact load by the reinforcement member (200) comprises:
deformation of the reinforcement member (200) while handling the impact load transferred by the cover (300) or on exceeding the bearing of the impact load beyond the second predetermined bearing capacity of the load.

13. The method as claimed in claim 1, wherein the handling of the transferred second additional impact load by the crash tube (100) comprises:
deformation of the crash tube (100) on exceeding the bearing of the impact load beyond the third predetermined bearing capacity of the load.