CLIAMS:1. An integrated front cover (100) for an engine of an automobile, comprising:
at least one housing configured to house an oil pump assembly (1) and a water pump assembly (2);
at least one provisions configured to mount a crank shaft (3), a belt tensioner (4) and an integral shaft bearing (5) of the engine,
characterized in that;
an oil top up channel (6) is provided at the top portion (7) of the integrated front cover (100) for pouring of lubrication oil;
a thermostat housing (8) provided proximal to the water pump assembly (2) which houses a thermocouple (9).

2. The integrated front cover as claimed in claim 1, wherein the oil top-up channel (5) is connected to plurality of oil channels of the engine.

3. The integrated front cover (100) as claimed in claim 1, wherein the provision provided for the crank shaft (3) and integral shaft bearing (4) is provided substantially at bottom portion (11) of the integrated front cover (100).

4. The integral front cover (100) as claimed in claim 1, wherein the oil pump assembly (1) is driven by the crank shaft (3) of the engine.

5. The integral front cover (100) as claimed in claim 1, wherein the water pump assembly (2) is driven by belt drives connected to the belt tensioner (4) and crank shaft assembly (1).

6. A method of assembling an integrated front cover (100) onto an engine of an automobile, the method comprising acts of:
connecting an oil pump assembly (1) to an oil pump housing (11) provided on the integrated front cover (100);
connecting a water pump assembly (2) to water pump housing (12) provided on the integrated front cover (100);
coupling a crank shaft (3) and integral shaft bearing (4) of the engine to the oil pump assembly (1) to drive the oil pump;
connecting at least one belt to a belt tensioner (4) which is connected to the water pump assembly (2) and in turn connected to the crank shaft (3) of the engine;
connecting an oil top up (5) at the top portion (7) to the integrated front cover (100);and
connecting a thermostat housing (8) to the integrated front cover (100).
,TagSPECI:FORM 2

THE PATENTS ACT, 1970
[39 of 1970]
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
[See section 10 and rule 13]

TITLE: “INTEGRATED FRONT COVER OF AN ENGINE OF AN AUTOMOBILE”
Name of the Applicant: SUNDRAM FASTENERS LIMITED
Address: 98-A, VII Floor, Dr. Radhakrishnan Salai, Mylapore, Chennai – 600 004, India
Nationality: Indian

The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

TECHNICAL FIELD
The present disclosure relates to front cover of an automobile engine. More particularly relates to an integrated front cover of an automobile engine which integrates the oil pump assembly, water pump assembly, thermostat assembly and the oil inlet channel to a single engine cover fixed to the front of the engine.
BACKGROUND OF THE DISCLOSURE
The engine bay of an automobile can be located at the front of the vehicle, rear of the vehicle or mid-way of the vehicle body. The engine bay of an automobile takes up 25 to 30% of the body of the vehicle. The engine bay consists of an engine block, gear box components, headers, in-take components, cooling mechanisms, battery and other critical parts. In conventional automobiles the oil pump assembly, water pump assembly etc, are mounted separately in the engine bay. These assemblies were driven by belt drives or chain drives to operate the oil pump assembly and water pump assembly. Mounting of these critical parts had to be done within the engine bay, which consumes additional space and additional materials for mounting the same. This led to lesser space in the cockpit of the vehicle and more space in the engine bay.
In recent past, importance is drawn to manage the space within an automobile to provide more space in the vehicle cockpit rather than wasting the place in the engine bays. The main idea is to make compact engines, wherein all the components necessary for proper working of the engine are made compactly into a small engine bay space so that the additional space can be utilized in the interior of the vehicle. Compact engines have oil pump and water pump assemblies integrated to one single front cover of the engine. By doing this a lot of space can be saved within the engine bay of the vehicle. Less space in the engine bay leads to more compact engine bays and more spacious interiors of the vehicle. Large engine bays like in conventional automobiles can be avoided and more compact cars with better performance can be achieved. In light of foregoing discussion, it is necessary to integrate most of the components into the single casing to overcome the problems stated above.
SUMMARY OF THE DISCLOSURE
The shortcomings of the prior art are overcome and additional advantages are provided through the provision 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.
In an embodiment of the disclosure an integrated front cover for an engine of an automobile, comprising: at least one housing configured to house an oil pump assembly and a water pump assembly; at least one provisions configured to mount a crank shaft, a belt tensioner and an integral shaft bearing of the engine, characterized in that; an oil top up channel is provided at the top portion of the integrated front cover for pouring of lubrication oil; a thermostat housing provided proximal to the water pump assembly which houses a thermocouple.
In an embodiment of the disclosure, the oil top-up channel is connected to plurality of oil channels of the engine.

In an embodiment of the disclosure, the provision provided for the crank shaft and integral shaft bearing is provided substantially at bottom portion of the integrated front cover.

In an embodiment of the disclosure, the oil pump assembly is driven by the crank shaft of the engine.

In an embodiment of the disclosure, the water pump assembly is driven by belt drives connected to the belt tensioner and crank shaft assembly.

In an embodiment of the disclosure, a method of assembling an integrated front cover onto an engine of an automobile, the method comprising acts of: connecting an oil pump assembly to an oil pump housing provided on the integrated front cover; connecting a water pump assembly to water pump housing provided on the integrated front cover; coupling a crank shaft and integral shaft bearing of the engine to the oil pump assembly to drive the oil pump; connecting at least one belt to a belt tensioner which is connected to the water pump assembly and in turn connected to the crank shaft of the engine; connecting an oil top up at the top portion to the integrated front cover; and connecting a thermostat housing to the integrated front cover.

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.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Figure 1 illustrates front view of the integrated front cover showing the provision for the crank shaft, oil pump assembly and belt tensioner as shown.
Figure 2 illustrates front view of the integrated front cover along with water pump assembly and oil pump assembly as shown.
Figure 3 illustrates front view of the integrated front cover with ribs for reinforcements along with water pump assembly, oil pump assembly and belt tensioner..
Figure 4 illustrates back view of the integrated front cover showing provisions for mounting oil pump assembly.
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 structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF DISCLOSURE

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 embodiment 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 constructions 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.

Referring now to the drawings wherein the drawings are for the purpose of illustrating an exemplary embodiment of the disclosure only, and not for the purpose of limiting the same.
Figure 1 illustrates front view of the integrated front cover (100) with the crank shaft (3) of the engine protruding into the integrated front cover (100). The crank shaft (3) protrudes into the integrated front cover (100) at the bottom portion (10) of the integrated front cover (100). The crank shaft (3) is surrounded by an integral shaft bearing (5) which helps in reducing the friction and heat generated by the crank shaft (3) and also to keep the shaft (3) in place. The oil pump assembly (1) is mounted onto the crank shaft (5). The oil pump assembly (1) is provided with a oil pump housing (11) mounted all around the oil pump assembly (1). The oil pump housing (11) is mounted onto the integrated front cover (100) by means of suitable fasteners. From the figure 1, a provision for mounting a belt tensioner (4) is provided wherein a belt is connected to the oil pump housing (11) which is in turn connected to the water pump assembly (2) to run the water pump. The main power to run the belt drives is generated from the crank shaft (3) of the engine. The integrated front cover (100) is made of casted materials like aluminium, which is light and very durable in nature. The integrated front cover (100) is casted using pressure die casting method, where the production of castings is for thicker sections and higher melting point alloys. A suitable template of the integrated front cover (100) is sketched onto the casting mould. The molten metal is poured into the mould and suitable desired shape of the integrated front cover is achieved. The sharp edges are smoothened and the burrs are deburred. The integrated front cover (100) is provided with fastening holes (13) at the entire length of the front cover (100).
Figure 2 illustrates front view of the integrated front cover (100) wherein, a water pump assembly (2) is mounted into a water pump housing (12) which is then fixed onto the integrated front cover (100) by the aid of suitable fasteners. The water pump assembly (2) is driven by belt drives wherein, a belt connected to the crank shaft (3) of the engine which is connected to the belt tensioner (4). A belt tensioner (4) has a belt which winds its way around the oil pump assembly (1), water pump assembly (2) and belt tensioner (4). When the crank shaft (3) of the engine rotates the water pump assembly (2) is also rotated and the impeller in the water pump is rotated which pumps out the water.
Figure 3 illustrates front view of the integrated front cover (100) showing the provision for the crank shaft (3) and the water pump housing (12). The design of the integrated front cover (100) varies with varying engine capacities, engine dimensions and design of the engine. The integrated front cover (100) of the automobile engine has crank shaft (3) housing at the bottom portion (10) of the integrated front cover (100) of the automobile engine. The water pump assembly (2) is fixed in the water pump housing (12) provided at the center portion of the integrated front cover (100) of the engine of an automobile. The water pump assembly (2) as shown in figure is securely fastened using suitable fasteners chosen from a group comprising of collar bolts, hollow dowels etc. The water pump assembly (2) is fitted onto the integrated front cover (100) of the engine of the automobile and made sure that the fixed water pump assembly is having a leak proof joint. The joint leak test is carried out using air as an agent under a pressure of 1 BAR and tested for 3 seconds. An allowable leakage of 8cc/ min is tolerable for this kind of joint. Also from the figure 2 we can see that the fastening holes (13) are provided at the outline of the integrated front cover (100) so as to join to the front of an engine. An oil top up channel (6) is provided at the top portion (7) of the integrated front cover (100) wherein the top up channel (7) is used to pour the lubrication oil into the engine.
Figure 4 illustrates back view of the integrated front cover (100) with ribs for reinforcements. The gravity die casted integrated front cover (100) of the engine for an automobile has several fastener holes (13) provided at the outline of the integrated front cover (100) of the engine of an automobile. The integrated front cover (100) of the engine of the automobile is fixed to the front of the engine. The front cover also acts as a cover plate for the engine block. The integrated front cover (100) of the engine also aids as a sealant for the engine block and the other parts like water pump assembly (2), oil pump assembly (1) and thermostat housing (8). A provision for mounting the belt tensioner (4) is also provided on the integrated front cover (100) as discussed in figure 1.
The integration of the water pump assembly (2), oil pump assembly (1), thermostat housing (8), belt tensioner (4) and the oil top up channel (6) leads to compactness of the engine and other critical parts of the engine. This leads to lesser space within the engine bay of the automobile. This leads to less space for the engine bay and more space for the vehicle cabin. The parts are integrated to the front cover of the engine of an automobile and the drive mechanisms are also shared and no additional drives like belt drive, chain drive are required for the instant invention.
EQUIVALENTS

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.

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 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 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.”

In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

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.

REFERENCE NUMERALS

100 Integrated front cover
1 Oil Pump Assembly
2 Water pump assembly
3 Crank shaft
4 Belt Tensioner
5 Integral Shaft Bearing
6 Top Up Channel
7 Top Portion
8 Thermostat Housing
9 Thermocouple
10 Bottom Portion
11 Oil Pump Housing
12 Water pump Housing
13 Fastener holes