DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

“FRONT END CARRIER FOR A VEHICLE”

APPLICANTS:

Name Nationality Address
Mahindra & Mahindra Limited Indian Mahindra Research Valley, Mahindra World City (MWC),
Plot No. 41/1, Anjur Post, Chengalpattu,
Kanchipuram District – 603204 (TN) INDIA

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

TECHNICAL FIELD
[001] The embodiments herein relate to front end modules in vehicles and more particularly but not exclusively to front end carrier in vehicles.

BACKGROUND
[002] Generally, front end of a vehicle is a critical area where most of the vehicle’s power train is placed, and thus the front end needs more structural stiffness to withstand the vibrations generated from the power train. Front end carriers are provided to withstand these vibrations generated from the power train, to provide a housing for the components such as headlamps, radiators, cooling fans, air conditioning condensers, grille-opening reinforcement panels, crumple zones, bumpers, hood latches, washer bottles, electronics and wiring etc, and to provide a good noise vibration harshness, herein after referred as NVH, performance.
[003] The conventional front end carrier is a modular front end carrier which is made up of plastic. The aforementioned front end carrier increases the body weight and does not provide structural stiffness in the front end of the car body. Another conventional front end carrier is devised to provide a robust body in white which takes care of front end structural stiffness and to provide housing to various components. The aforementioned carrier increases the body weight and provides a bad NVH performance.
[004] Therefore there exists a need for a front end carrier that can effectively reduce noise and vibration. Further, there also exists a need for a front end carrier that can eliminate the aforementioned drawbacks.

OBJECTS
[005] The principal object of an embodiment of this invention is to provide a front end carrier that can effectively reduce noise and vibration.
[006] Another object of an embodiment of this invention is to provide a front end carrier that is light weight and has high structural stiffness.
[007] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[008] This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[009] FIG. 1 depicts a perspective view of the front end carrier according to an embodiment of the invention as disclosed herein;
[0010] FIG. 2 depicts a top view of the front end carrier according to an embodiment of the invention as disclosed herein;
[0011] FIG. 3 depicts a rear view of the front end carrier according to an embodiment of the invention as disclosed herein;
[0012] FIG. 4 depicts a cross sectional side view of the front end carrier according to an embodiment of the invention as disclosed herein; and
[0013] FIG. 5 depicts a graphical comparison of the cabin noise reduction achieved with the conventional front end carrier and the front end carrier according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0014] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0015] The embodiments herein achieve a front end carrier for a vehicle that can effectively reduce noise and vibration. Referring now to the drawings, and more particularly to FIGS. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0016] FIG. 1 depicts a perspective view of the front end carrier 100 according to an embodiment of the invention as disclosed herein. The front end carrier 100 includes a first longitudinal member 102, a plurality of side members 104, a second longitudinal member 106, a plurality of transverse members 108 and a plurality of mounting plates M.
[0017] In an embodiment the first longitudinal member 102 defines the top end of the front end carrier 100 and the second longitudinal member 106 defines the bottom end of the front end carrier 100. The first longitudinal member 102 and the second longitudinal member 106 are connected to each of the transverse members 108. Each of the side members 104 are connected to their corresponding transverse members 108.
[0018] In an embodiment the first longitudinal member 102 is provided with a plurality of first mounting points 110a at its ends. In an embodiment each of the side members 104 is provided with a second mounting point 110b. In an embodiment each of the mounting plate M includes a plurality of third mounting points 110c. In an embodiment the first mounting points 110a, second mounting points 110b and the third mounting points 110c are adapted to receive a mounting means (not shown) for assembling the front end carrier 100 with a vehicle (not shown). In an embodiment the mounting means is a bolt. However, it is also within the scope of the invention to provide screw or rivet as mounting means without otherwise deterring the intended function of the front end carrier 100 as can be deduced from this description. In an embodiment the mounting means is used for connecting the front end carrier 100 in the vehicle (not shown).
[0019] In an embodiment each of the first mounting points 110a of the first longitudinal member 102 are connected with each of the corresponding shot gun panel (not shown) of the vehicle (not shown) using the mounting means. In an embodiment the mounting point arrangement location can be changed according to the length of the shot gun panel based on the vehicle type. In an embodiment each of the second mounting points 110b of the side members 104 are connected with the each of the corresponding wheel arch gussets (not shown) of the vehicle using the mounting means.
[0020] In an embodiment the mounting locations of the vehicle for mounting the front end carrier 100 can be iterated to achieve the expected noise, vibration and harshness, herein after referred as NVH, performance. The location of the front end carrier 100 improves the body stiffness of the vehicle to give the best noise reduction.
[0021] FIG. 2 depicts a top view of the front end carrier 100 according to an embodiment of the invention as disclosed herein. In an embodiment the first longitudinal member 102 includes a first leg 102a and a plurality of second legs 102b. Each of the second legs 102b are transverse to the first leg 102a. In an embodiment the cross section of the second legs 102b is different from the cross section of the first leg 102. In an embodiment the cross section of the first leg 102a and the second legs 102b are adapted to match the engine bay outer most points (not shown) of the vehicle and to align with the bonnet (not shown) of the vehicle. In an embodiment the first portion 102a is flexible in XYZ directions to achieve the NVH performance.
[0022] FIG. 3 depicts a rear view of the front end carrier 100 according to an embodiment of the invention as disclosed herein. In an embodiment the thirds mounting points 110c of the mounting plate M are connected with underbody front rails (not shown) of the vehicle using the mounting means. Further, the circled portion shown in the figure illustrates the mounting point arrangement location connecting the front end carrier 100 to the front rails.
[0023] In an embodiment each of the mounting plate M includes a first leg L1, a top second leg L2 and a bottom second leg L3. The top second leg L2 and bottom second leg L3 of each of the mounting plate M is transverse to the corresponding first leg L1 of each the mounting plate M. The first leg L1 of each of the mounting plate M is connected to corresponding transverse members 108 and the top second leg L2 is connected to corresponding side members 104 and the bottom second leg L3 is connected to the second longitudinal member 106.
[0024] FIG. 4 depicts a cross sectional side view of the front end carrier 100 according to an embodiment of the invention as disclosed herein. In an embodiment each of the side members 104 includes a first leg 104a and a second leg 104b. The side members 104 are transverse to the transverse members 108. The first leg 104a of each of the side members 104 are connected to the corresponding transverse members 108. In an embodiment the location at which the side members 104 are connected to the transverse members 108 can be changed according to different vehicle types. The mounting of the side members 104 with the transverse members 108 optimizes the NVH performance of the vehicle. The side members 104 connected to the vehicle at the wheel arch gussets can be iterated along the Z-axis to arrive at the optimal location to provide target noise reduction at the defined frequency band.
[0025] In an embodiment each of the transverse members 108 include a first end 108a and a second end 108b. The first end 108a of each of the transverse members 108 are connected to the first longitudinal member 102 and the second end 108b of each of the transverse members 108 are connected to the second longitudinal member 106.
[0026] FIG. 5 depicts a graphical comparison of the cabin noise reduction achieved with the help of the front end carrier 100 according to an embodiment of the invention as disclosed herein. The graphical representation shows the noise reduction under power train load condition. The noise reduction is measured in hertz and the power train load is measured in Newton. The dotted line shown in the graph indicates the noise performance of a conventional plastic front end carrier (not shown). The continuous line shown in the graph indicates the noise performance achieved by the front end carrier 100. The straight line shown in the graph is the desired noise level. From the graph, it is clearly evident that the front end carrier 100 effectively reduces noise and vibration.
[0027] The advantages of the front end carrier 100 are as follows. The front end carrier 100 reduces boom noise and vibration, reduces weight and adds structural stiffness. The front end carrier 100 achieves noise reduction at all seat locations at low frequency. The front end carrier 100 can be tuned based on the engine configuration to reduce boom noise in vehicles. The front end carrier 100 eliminates a major body change to meet NVH targets. The front end carrier 100 eliminates welding complications while fabricating as it can be manufactured offline from the main body assembly line. The front end carrier 100 is a single module like any FRP\Steel reinforced plastic. The front end carrier 100 achieves good vibration reduction at critical customer interface points which is very challenging due to power train excitations. The front end carrier 100 is much superior compared to the latest trend steel reinforced plastic front end carriers in NVH refinement. The front end carrier 100 is made of steel sheet metal which is cheaper than the plastic front end carrier where plastic front end carrier cannot stiffen the body in white structure. The front end carrier 100 provides flexibility to manufacture according to the mounting requirements on the body in white structure. The front end carrier 100 can be optimized to give the best noise reduction at the desired frequency. The front end carrier 100 can be optimized to keep the weight within the limits of the plastic front end carrier.
[0028] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

CLAIMS
We claim,
1. A front end carrier for a vehicle, the front end carrier comprising:
a first longitudinal member having a first leg, a plurality of second legs and a plurality of first mounting points;
a second longitudinal member;
a plurality of transverse members, each having a first end and a second end, the first end of each of the transverse members connected to the first longitudinal member and the second end of each of the transverse members are connected to the second longitudinal member;
a plurality of side members, each having a first leg, a second leg and at least one second mounting point, the first leg of each of the side members are connected to the corresponding transverse members,
wherein
the first mounting points and the second mounting points are adapted to connect the front end carrier with the vehicle.
2. The front end carrier as claimed in claim 1, wherein each of the plurality of second legs of the first longitudinal member is transverse to the first leg of the first longitudinal member.
3. The front end carrier as claimed in claim 1, wherein the second leg of each of the side members is transverse to the corresponding first leg of the side members.
4. The front end carrier as claimed in claim 1, further comprising a plurality of mounting plates having a plurality of third mounting points adapted to connected the front end carrier with the vehicle.
5. A vehicle comprising:
a plurality of shot gun panel;
a plurality of wheel arch gussets;
a plurality of underbody front rails; and
a front end carrier comprising, a first longitudinal member having a first leg, a plurality of second legs and a plurality of first mounting points; a second longitudinal member; a plurality of transverse members, each having a first end and a second end, the first end of each of the transverse members connected to the first longitudinal member and the second end of each of the transverse members are connected to the second longitudinal member; a plurality of side members, each having a first leg, a second leg and at least one second mounting point, the first leg of each of the side members are connected to the corresponding transverse members; a plurality of mounting plates, each having a plurality of third mounting points,
wherein
the first mounting points are connected to the corresponding shot gun panels and the second mounting points are connected to the corresponding wheel arch gussets and the third mounting points are connected to the corresponding underbody front rails.

Date: February 25th, 2016 Signature:
Dr..Kalyan Chakravarthy

ABSTRACT
Front end carrier for a vehicle includes a first longitudinal member, a second longitudinal member, a plurality of transverse members, a plurality of side members and a plurality of mounting plates. The side members are connected to corresponding transverse members and the first longitudinal member and the second longitudinal member are connected to each of the transverse members. The first longitudinal member has a plurality of first mounting points. Each of the side member includes a second mounting point. Each of the mounting plates include a plurality of third mounting points. The first mounting points, the second mounting points and the third mounting points are used for connecting the front end carrier with the vehicle.

,CLAIMS:CLAIMS
We claim,
1. A front end carrier for a vehicle, the front end carrier comprising:
a first longitudinal member having a first leg, a plurality of second legs and a plurality of first mounting points;
a second longitudinal member;
a plurality of transverse members, each having a first end and a second end, the first end of each of the transverse members connected to the first longitudinal member and the second end of each of the transverse members are connected to the second longitudinal member;
a plurality of side members, each having a first leg, a second leg and at least one second mounting point, the first leg of each of the side members are connected to the corresponding transverse members,
wherein
the first mounting points and the second mounting points are adapted to connect the front end carrier with the vehicle.
2. The front end carrier as claimed in claim 1, wherein each of the plurality of second legs of the first longitudinal member is transverse to the first leg of the first longitudinal member.
3. The front end carrier as claimed in claim 1, wherein the second leg of each of the side members is transverse to the corresponding first leg of the side members.
4. The front end carrier as claimed in claim 1, further comprising a plurality of mounting plates having a plurality of third mounting points adapted to connected the front end carrier with the vehicle.
5. A vehicle comprising:
a plurality of shot gun panel;
a plurality of wheel arch gussets;
a plurality of underbody front rails; and
a front end carrier comprising, a first longitudinal member having a first leg, a plurality of second legs and a plurality of first mounting points; a second longitudinal member; a plurality of transverse members, each having a first end and a second end, the first end of each of the transverse members connected to the first longitudinal member and the second end of each of the transverse members are connected to the second longitudinal member; a plurality of side members, each having a first leg, a second leg and at least one second mounting point, the first leg of each of the side members are connected to the corresponding transverse members; a plurality of mounting plates, each having a plurality of third mounting points,
wherein
the first mounting points are connected to the corresponding shot gun panels and the second mounting points are connected to the corresponding wheel arch gussets and the third mounting points are connected to the corresponding underbody front rails.