FORM 2
THE PATENTS ACT 1970 (as amended)
[39 OF 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See Section 10 and Rule 13]
TITLE “INTEGRATED SUB-FRAME SYSTEM FOR A VEHICLE”
APPLICANT
TATA MOTORS LIMITED, an Indian company having its
registered office at Bombay house, 24 Homi Mody Street,
Hutatma Chowk, Mumbai 400 001,
Maharashtra, INDIA.
INVENTORS
Nilesh Ojha, Akshay Pratap Zagade, Sagar Ramchandra Deshmukh, Nitin Babaso Bodhale, Shamsher Singh Ghatoude and Jayeshkumar K Raghuvanshi 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.
All Indian Nationals
PREAMBLE TO DESCRIPTION
The following specification particularly describes the invention and the manner in which it
is to be performed.

TECHNICAL FIELD
The present disclosure generally relates to mounting systems. More particularly, the present disclosure relates to a mounting system for supporting, locating and assembling various vehicle elements on a vehicle chassis.
Definition:
Sub-frame: A sub-frame is a structural component of a vehicle that uses a discrete, separate structure within a larger body-on-frame or unit body to carry certain components, such as an engine, a drivetrain, or a suspension.
BACKGROUND OF DISCLOSURE
Conventionally, various mounting arrangements/ mounts such as an A and B Engine mount, a Lower Control Arm (LCA) mount, an Anti-Roll Bar (ARB) mount and a steering gear mount for supporting, locating and assembling various vehicle elements are either mounted on a sub-frame or mounted on separate cross members. More specifically, in case of a hatchback or compact sedan with transverse engine arrangement, the various mounting arrangements/ mounts are secured on separate brackets welded to a “Body In White” (BIW) at front end of the sub-frame.
In case of Utility vehicles with longitudinal engine arrangement, the LCA mount, the steering gear mount, the ARB mount and the A and B engine mount are mounted on separate cross members. Typically, a front cross member supports the A and B engine mount, a middle cross-member supports the LCA mount, the ARB mount and the steering gear mount, whereas a third cross member supports the engine C mount. With such a configuration of three cross members bolted to the BIW separately, considerable amount of time is required for assembly. Further, such configuration of separate cross members for supporting the different mounts have certain drawbacks associated there-with. Specifically, with such configuration there is width constraints, as the cross member are bolted to BIW within given width. As a result difficult in maintaining dimensional consistency of mounting

pitch is faced and such configuration results in difficulty in mounting the different components on the cross members considering limited width available for mounting. Further, allowable spacing between the cross-members is also limited. Still further, such configuration, wherein the heavy engine is mounted / supported on the cross-members of the frame acts like cantilever type structure and adversely effects the structural stability of the frame and may cause deflection of the vehicle frame. With such configuration of various mounts supported on different cross-members, Noise Vibration harshness (NVH) and durability requirement are difficult to meet and the vehicle frame exhibits low stiffness to weight ratio.
Accordingly, there is a need for a mounting system for supporting, locating and assembling various vehicle elements such as the LCA mount, the steering gear mount, the ARB mount and the engine mount without compromising with the structural stability of the vehicle frame. Further, there is a need for a mounting system that provides desirable mounting pitch and enough space for mounting the different vehicle components. Also, there is a need for a mounting system that reduces noise and vibration transmitted to passengers and enhances riding comfort and product reliability. Also, there is need for a mounting system that reduces chances of misalignment of suspension hard points at which the various vehicle elements are mounted on vehicle frame. Further, there is a need for a mounting system that exhibits good NVH performance and improves durability.
OBJECTS OF THE DISCLOSURE
One object of the present disclosure is to provide an integrated sub-frame system for supporting, locating and assembling various vehicle elements without compromising with the structural stability of the vehicle frame.
Another object of the present disclosure is to provide an integrated sub-frame system that provides desirable mounting pitch and enough space for mounting the different vehicle components.

Yet another object of the present disclosure is to provide an integrated sub-frame system that reduces noise and vibration transmitted to passengers and enhances riding comfort and product reliability.
Another object of the present disclosure is to provide an integrated sub-frame system that reduces chances of misalignment of suspension hard points at which the various vehicle elements are mounted on vehicle frame.
Yet another object of the present disclosure is to provide an integrated sub-frame system that exhibits good NVH performance and improves durability.
Still another object of the present disclosure is to provide an integrated sub-frame system that enhances stiffness to weight ratio of vehicle frame and reduces overall weight of the vehicle frame and vehicle.
Another object of the present disclosure is to provide an integrated sub-frame system that reduces assembly time.
Still another object of the present disclosure is to provide an integrated sub-frame system that involves fewer number of child parts, thereby easing manufacturing thereof and improving production rate.
SUMMARY OF THE DISCLOSURE
The shortcomings of the prior art are overcome and additional advantages are provided through 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 present disclosure an integrated sub-frame system (10) for a vehicle is disclosed. The integrated sub-frame system (10) has an operative top portion (10a) and an operative bottom portion (10b), with at least one Lower Control Arm (LCA) mount (20), a steering gear mount (30), an Anti-Roll Bar (ARB) mount (40) and at least two engine mounts (50) integrally configured thereon, wherein each of the mounts stably supports at least one Lower Control Arm (LCA) (22), a steering gear (32), an Anti-Roll Bar (ARB) (42) and an engine respectively.
In accordance with an embodiment, the at least two engine mounts (50) are load bearing engine mounts.
In accordance with another embodiment, the at least two engine mounts (50) are A and B engine mounts.
In accordance with still another embodiment, the integrated sub-frame system (10) further includes an anti-roll engine mount integrally configured thereon.
In accordance with yet another embodiment, the integrated sub-frame system (10) further includes a C engine mount.
Typically, the integrated sub-frame system (10) further includes at least two first vibration isolator (60a) disposed between the engine mounts (50) and the engine and at least one second vibration isolator (60b) disposed between the integrated sub-frame system (10) and an under body structure of the vehicle.
In accordance with an embodiment, the integrated sub-frame system (10) further includes at least one first vibration isolator (60a) disposed between the at least one mount and the vehicle component mounted on the mount and at least one second vibration isolator (60b) disposed between the integrated sub-frame system (10) and the under body structure.

In accordance with an embodiment, the mounts are strategically configured on the integrated sub-frame system (10) for enhancing dimensional consistency of mounting pitch.
Typically, the integrated sub-frame system (10) further includes internal reinforcement structures welded thereto.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
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 an exploded view of an integrated sub-frame system in accordance with an embodiment depicting various portions thereof along with at least one first vibration isolator disposed between an engine mount and an engine and at least one second vibration isolator disposed between the integrated sub-frame system and an under body structure of the vehicle;
FIG. 2a illustrates a schematic representation of the integrated sub-frame system for a vehicle, wherein the integrated sub-frame system is shown mounted on the chassis or the under body structure;
FIG. 2b illustrates a schematic representation of the integrated sub-frame system of FIG. 2a, wherein the integrated sub-frame system is shown dis-assembled from the chassis or the under body structure;

Figure 3a and Figure 3b illustrate an operative top portion and an operative bottom portion respectively of the integrated sub-frame system.
DETAILED DESCRIPTION
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.
The present disclosure provides an integrated sub-frame system for a vehicle in accordance with an embodiment of the present disclosure. The integrated sub-frame system supports, locates and facilitates assembly of vehicle elements on the vehicle chassis. The integrated sub-frame system has an operative top portion and an operative bottom portion with at least one mount integrally configured thereon, wherein each of the mounts stably supports at least one vehicle element. Such a configuration of the integrated sub-frame system configured of top and bottom pressed parts, ensures suspension hard points dimensional consistency which are critical for maintaining the wheel geometry of vehicle in service for prolonged duration.

Figure 1 illustrates an exploded view of the integrated sub-frame system 10. More specifically, the integrated sub-frame system 10 has an operative lower/bottom portion 10b (illustrated in Figure 3b) and an operative top/upper portion 10a (illustrated in Figure 3a). The integrated sub-frame system 10 further include various mounts integrally configured thereon, particularly, a Lower Control Arm (LCA) mount 20 for mounting a Lower Control Arm 22, a steering rack/gear mount 30 (illustrated in FIG. 1 and FIG. 3a) for mounting a steering rack/ gear 32, an Anti-Roll Bar (ARB) mount 40 (illustrated in FIG. 1 and FIG. 3a) for mounting an Anti-Roll Bar (ARB) 42 and at least two engine mounts 50 integrally formed with the integrated sub frame system 10 for supporting the engine (not shown in Figure). In accordance with an embodiment, the at least two engine mounts 50 are load bearing engine mounts. In accordance with another embodiment, the at least two engine mounts 50 are A and B engine mounts.
FIG. 2a illustrates a schematic representation of the integrated sub-frame system 10 for a vehicle in, wherein the integrated sub-frame system 10 is shown mounted on the chassis “C”, particularly on the under body structure of the vehicle. FIG. 2b illustrates a schematic representation of the integrated sub-frame system 10, wherein the integrated sub-frame system 10 is shown dis-assembled from the chassis “C”.
In accordance with still another embodiment, the integrated sub-frame system (10) further includes an anti-roll engine mount integrally configured thereon. In accordance with yet another embodiment, the integrated sub-frame system 10 further includes a C engine mount.
The LCA mount 20, the steering gear mount 30, the ARB mount 40 and the engine mounts 50 are integrally configured on the integrated sub frame system 10 and are strategically placed such that there is sufficient spacing between the different mounts and the vehicle elements mounted on the mounts can operate without interfering with operation of other vehicle elements. With such configuration, the mounting pitch is enhanced. The placement of the Anti-Roll Bar (ARB) mount 40 and the engine mounts 50 can be interchanged and the

present integrated sub-frame system 10 is not limited to any particular configuration or placement of the different mounts.
Figure 3a and Figure 3b illustrates an operative top portion 10a and an operative bottom portion 10b configuring the integrated sub-frame system 10. The integrated sub-frame system 10 includes provision for mounting the integrated sub-frame system 10 on the chassis “C”. Particularly, the integrated sub-frame system 10 is configured with mounting apertures “A” that get aligned with apertures configured on the chassis. Once, the apertures are aligned, nut and bolt arrangement is used for mounting the integrated sub-frame system 10 on the chassis “C”. However, the present disclosure is not limited to any particular arrangement for mounting the integrated sub-frame system 10 on the chassis “C” and the integrated sub-frame system 10 can be mounted on the chassis in any other way. In accordance with an embodiment of the present disclosure, the integrated sub-frame system 10 includes integrally formed front mounting brackets at left hand and right hand side (LH/RH), rear mounting brackets at LH/RH and internal reinforcements welded together to configure an integrated structure.
The integrated sub-frame system (10) is provided with provision for isolating vibration and noise. More particularly, the integrated sub-frame system 10 further includes at least one first vibration isolator/primary isolator 60a disposed between at least one of the mounts and the corresponding vehicle component mounted on the mount and at least one second vibration isolator 60b disposed between the integrated sub-frame system 10 and an under body structure/ chassis “C” of the vehicle. In accordance with an embodiment, the at least two first vibration isolator/ primary isolator 60a are disposed between the at least two engine mounts 50 and the engine (not illustrated in Figures) and the second vibration isolator/ secondary isolator 60b is disposed between the integrated sub-frame system 10 and the under body structure/ chassis “C” of the vehicle. Such a configuration reduces noise and vibration transmitted to passengers and enhances riding comfort and product reliability. With such configuration of the isolators, dual isolation of tactile engine vibration is possible and the Engine load transfer path can be effectively managed.

In accordance with an embodiment of the present disclosure, such dual vibration isolator arrangement is provided for all mounts, wherein first vibration isolator/primary isolator 60a disposed between at least one of the mounts and the corresponding vehicle component mounted on the mount and at least one second vibration isolator 60b disposed between the integrated sub-frame system 10 and an under body structure/ chassis “C” of the vehicle. The present disclosure is not limited to any particular configuration of the vibration isolators and any kind of vibration isolators can be used.
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.
Advantages:
The present disclosure provides an integrated sub-frame system for supporting, locating and assembling various vehicle elements such as the LCA mount, the steering gear mount, the ARB mount and the engine mount without compromising with the structural stability of the vehicle frame. The integrated sub-frame system provides desirable mounting pitch and enough space for mounting the different vehicle components. The integrated sub-frame system reduces noise and vibration transmitted to passengers and enhances riding comfort and product reliability. The integrated sub-frame system reduces chances of misalignment of suspension hard points at which the various vehicle elements are mounted on vehicle frame. The integrated sub-frame system exhibits good NVH performance and improves durability. The integrated sub-frame system enhances stiffness to weight ratio of vehicle frame and reduces overall weight of the vehicle frame and vehicle. The integrated sub-frame system reduces assembly time. The integrated sub-frame system involves fewer number of child parts, thereby easing manufacturing thereof and improving production rate.

Referral Numerals:

Reference Number Description
10 integrated sub-frame system
“C” chassis
10a an operative top portion
10b an operative bottom portion
20 Lower Control Arm (LCA) mount
22 Lower Control Arm
30 steering gear mount
32 steering rack
40 an Anti-Roll Bar (ARB) mount
42 Anti-Roll Bar (ARB)
60a first vibration isolator/primary isolator
60b second vibration isolator/secondary isolator

We Claim:
1. An integrated sub-frame system (10) for a vehicle, said integrated sub-frame system (10) comprising an operative top portion (10a) and an operative bottom portion (10b), with at least one Lower Control Arm (LCA) mount (20), a steering gear mount (30), an Anti-Roll Bar (ARB) mount (40) and at least two engine mounts (50) integrally configured thereon, wherein each of said mounts adapted to stably support at least one Lower Control Arm (LCA) (22), a steering gear (32), an Anti-Roll Bar (ARB) (42) and an engine respectively.
2. The integrated sub-frame system (10) as claimed in claim 1, wherein said at least two engine mounts (50) are load bearing engine mounts.
3. The integrated sub-frame system (10) as claimed in claim 1, wherein said at least two engine mounts (50) are A and B engine mounts.
4. The integrated sub-frame system (10) as claimed in claim 1, further comprises an anti-roll engine mount integrally configured thereon.
5. The integrated sub-frame system (10) as claimed in claim 1, further comprises a C engine mount integrally configured thereon.
6. The integrated sub-frame system (10) as claimed in claim 1, further comprising at least two first vibration isolators (60a) disposed between said engine mounts (50) and said engine and at least one second vibration isolator (60b) disposed between said integrated sub-frame system (10) and an under body structure of said vehicle.
7. The integrated sub-frame system (10) as claimed in claim 1, further comprising at least one first vibration isolator (60a) disposed between said at least one mount and said vehicle component mounted on said mount and at least one second vibration

isolator (60b) disposed between said integrated sub-frame system (10) and said under body structure.
8. The integrated sub-frame system (10) as claimed in claim 1, wherein said mounts are configured on said integrated sub-frame system (10) for enhancing dimensional consistency of mounting pitch.
9. The integrated sub-frame system (10) as claimed in claim 1 further comprising internal reinforcement structures welded thereto.