Claims:WE CLAIM:
1. A mounting structure (100) for a vehicle (10) comprising: a first bracket (110) having a first top wall (112a) and a first bottom wall (112b) extending from longitudinal ends of a first vertical wall (112), the first bottom wall (112b) further extending perpendicularly downwards into a first flange (114); and a second bracket (120) having a second top wall (122a) and a second bottom wall (122b) extending from longitudinal ends of a second vertical wall (122), the second bottom wall (122b) further extending perpendicularly downwards into a second flange (124), whereby the first bracket (110) is configured to receive the second bracket (120), thereby forming a substantially rectangular mounting structure (100) for mounting components of the vehicle (10).

2. The mounting structure (100) as claimed in claim 1, wherein the first flange (114) is fixedly attached to the second flange (124).

3. The mounting structure (100) as claimed in claim 1, wherein a portion (112a’) of the first top wall (112a) of the first bracket (110) is extruded co-planarly in order to receive a portion (122a’) of the second top wall (122a) of the second bracket (120) and is fixedly attached to form the substantially rectangular mounting structure (100).

4. The mounting structure (100) as claimed in claim 1, wherein the first vertical wall (112) comprises at least one hole (116) made therethrough in order to mount the mounting structure (100) on a part of the vehicle (10).

5. The mounting structure (100) as claimed in claim 1, wherein the first vertical wall (112) comprises an opening (119) for reducing weight of the first bracket (110).

6. The mounting structure (100) as claimed in claim 1, wherein the second vertical wall (122) comprises a hole (126) made therethrough in order to receive a light source (140).

7. The mounting structure (100) as claimed in claim 1, wherein the first bottom wall (112b) comprises an opening (118) to allow passage of light emitted by the light source (140).

8. The mounting structure (100) as claimed in claim 1, wherein each of the first flange (114) and the second flange (124) comprise a plurality of holes (P) of different sizes made therethrough, whereby the plurality of holes on the first flange (114) and the second flange (124) are emulated.

9. The mounting structure (100) as claimed in claim 8, wherein a licence plate (150) of the vehicle (10) is mounted on the first flange (114) and the second flange (124) by fixating means (X).

10. The mounting structure (100) as claimed in claim 4, wherein the mounting structure (100) is disposed on a rear end (20b) of a loading deck (20) of the vehicle (10) in a vehicle front-rear direction (F-R).

11. The mounting structure (100) as claimed in claim 4, wherein the mounting structure (100) is disposed on a rear bumper bracket (22) of the vehicle (10).

12. The mounting structure (100) as claimed in claim 4, wherein the mounting structure (100) is disposed on a cross tube (24) of the vehicle (10), the cross tube (24) disposed rearwardly in the vehicle front rear direction (F-R) between a pair of long frame members forming part of main frame of the vehicle (10).

13. A method (200) for manufacturing a mounting structure (100) for a vehicle (10), the method (200) comprising the steps of:
obtaining (210) a first sheet of metal and a second sheet of metal;
blanking (220) the first sheet of metal into a first blank;
blanking (230) the second sheet of metal into a second blank;
forming (240) the first blank to obtain a first bracket (110);
forming (250) the second blank to obtain a second bracket (120); and
joining (260) the first bracket (110) and the second bracket (120) to obtain a substantially rectangular mounting structure (100) for mounting components of the vehicle (10).

14. The method (200) as claimed in claim 13, wherein the blanking (220) comprises: cutting (220a) an outer periphery of the first sheet metal; and punching (220b) a plurality of holes and openings through the first sheet metal to obtain the first blank.

15. The method (200) as claimed in claim 14, wherein the forming (240) of the first blank comprises: bending the first blank to form the first bracket (110), wherein the first bracket (110) comprises a first top wall (112a) and a first bottom wall (112b) extending from longitudinal ends of a first vertical wall (112), the first bottom wall (112b) further extending perpendicularly downwards into a first flange (114); and extruding a portion (112a’) of the first top wall (112a) of the first bracket (110) co-planarly to receive the second bracket (120).

16. The method (200) as claimed in claim 13, wherein the blanking (230) comprises: cutting (230a) an outer periphery of the second sheet metal; and punching (230b) a plurality of holes through the second sheet metal to obtain the second blank.

17. The method (200) as claimed in claim 16, wherein the forming (250) of the second blank comprises: bending the second blank to form the second bracket, wherein the second bracket (120) comprises a second top wall (122a) and a second bottom wall (122b) extending from longitudinal ends of a second vertical wall (122), the second bottom wall (122b) further extending perpendicularly downwards into a second flange (124).
, Description:FIELD OF THE INVENTION
[001] The present invention relates to a mounting structure for a vehicle and a method of manufacturing the same.

BACKGROUND OF THE INVENTION
[002] Vehicles are required to have license plates mounted on front and rear ends in accordance with various government regulations. There is a further requirement that the license plates must be clearly visible at all times. Hence, various regulatory authorities have made further rules regarding colour of the license plates, size and structure of the license plates, illumination of the license plates especially during night times etc., to have clear visibility of the license plates.
[003] License plates per se do not play a role in functions of the vehicle and is more of a regulatory requirement. Thus, vehicle manufacturers, especially cargo vehicle manufacturers, provide makeshift arrangements to mount the license plates on the front and the rear ends of the vehicle on respective conspicuous parts. Since the front ends of the vehicles generally contain planar surfaces and also have a light source in the form of a headlight, mounting the license plate at the front end of the vehicle is fairly easy. However, problems arise in mounting the license plates on the rear end of the vehicle.
[004] As regards illumination of the license plates in the vehicles is concerned, only a few vehicle manufacturers provide an arrangement - although the same being another makeshift provision - on the rear ends of the vehicles with a loose wire and a hole to mount a light source.
[005] Due to the this, the license plates and the respective light sources mounted on the rear ends of the vehicles are exposed to external factors such as water and dust ingression in the light sources. In most cases mud splashing on the license plate hinders the digits on the license plates. This increases maintenance and repair cost. Other external factors are breakage of the light sources and damage caused to the license plates due to stones and gravel, etc. which further adds on to repair costs. Further, in existing vehicles, the license plate and the light source are mounted on a rear grill (i.e. bumper). Thus, any rear side impact causes damage to the license plate and light source.
[006] Furthermore, dedicated mounting brackets are required to mount the light source and the license plate, thereby increasing part count and manufacturing cost. Further, regulations with respect to size and illumination of the license plates varies from country to country. Thus, when the vehicles are exported to various countries, provisions to mount the license plate have to be changed in accordance with the regulations subsisting in the exporting country. This further increases the manufacturing costs.
[007] Thus, there is a need in the art for a mounting structure which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] The present invention in one aspect is directed to a mounting structure for a vehicle having a first bracket, the first bracket having a first top wall and a first bottom wall extending from longitudinal ends of a first vertical wall, the first bottom wall further extending perpendicularly downwards into a first flange. The mounting structure has a second bracket having a second top wall and a second bottom wall extending from longitudinal ends of a second vertical wall, the second bottom wall further extending perpendicularly downwards into a second flange, whereby the first bracket is configured to receive the second bracket, thereby forming a substantially rectangular mounting structure for mounting components of the vehicle.
[009] In an embodiment of the invention, the first flange is fixedly attached to the second flange.
[010] In another embodiment of the invention, a portion of the first top wall of the first bracket is extruded co-planarly in order to receive a portion of the second top wall of the second bracket and is fixedly attached to form the substantially rectangular mounting structure.
[011] In yet another embodiment, the first vertical wall includes at least one hole made therethrough in order to mount the mounting structure on a part of the vehicle. In another embodiment, the first bottom wall includes an opening to allow passage of light emitted by the light source. In an embodiment of the invention, the first vertical wall includes an opening for reducing weight of the first bracket.
[012] In a further embodiment, the second vertical wall includes a hole made therethrough in order to receive a light source.
[013] In yet another embodiment, each of the first flange and the second flange include a plurality of holes of different sizes made therethrough, whereby the plurality of holes on the first flange and the second flange are emulated. In an embodiment, a licence plate of the vehicle is mounted on the first flange and the second flange by fixating means.
[014] In a further embodiment of the invention, the mounting structure is disposed on a rear end of a loading deck of a vehicle in a vehicle front-rear direction. In yet another embodiment, the mounting structure is disposed on a rear bumper bracket of the vehicle. In a further embodiment, the mounting structure is disposed on a cross tube of the vehicle, the cross tube disposed rearwardly in the vehicle front rear direction between a pair of long frame members forming part of main frame of the vehicle.
[015] The present invention, in another aspect, is directed to a method for manufacturing a mounting structure for a vehicle. The method includes the steps of: obtaining a first sheet of metal and a second sheet of metal; blanking the first sheet of metal into a first blank; blanking the second sheet of metal into a second blank; forming the first blank to obtain a first bracket; forming the second blank to obtain a second bracket; and joining the first bracket and the second bracket to obtain a substantially rectangular mounting structure for mounting components of the vehicle.
[016] In an embodiment, the blanking includes cutting an outer periphery of the first sheet metal; and punching a plurality of holes and openings through the first sheet metal to obtain the first blank.
[017] In a further embodiment, the forming of the first blank includes bending the first blank to form the first bracket, wherein the first bracket comprises a first top wall and a first bottom wall extending from longitudinal ends of a first vertical wall, the first bottom wall further extending perpendicularly downwards into a first flange; and extruding a portion of the first top wall of the first bracket co-planarly to receive the second bracket.
[018] In an embodiment the blanking includes cutting an outer periphery of the second sheet metal; and punching a plurality of holes through the second sheet metal to obtain the second blank.
[019] In an embodiment of the invention, the forming of the second blank comprises: bending the second blank to form the second bracket, wherein the second bracket comprises a second top wall and a second bottom wall extending from longitudinal ends of a second vertical wall, the second bottom wall further extending perpendicularly downwards into a second flange.

BRIEF DESCRIPTION OF THE DRAWINGS
[020] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 shows a left side view of a vehicle in accordance with an embodiment of the invention.
Figure 2 shows a rear side view of the vehicle in accordance with an embodiment of the invention.
Figure 3 shows a schematic diagram of the mounting structure in accordance with an embodiment of the invention.
Figure 4a shows the mounting structure and a mounted license plate in accordance with an embodiment of the invention.
Figure 4b shows the mounting structure mounted to a part of the vehicle in accordance with an embodiment of the invention.
Figure 5 shows an exploded view of the mounting structure in accordance with an embodiment of the invention.
Figure 6 shows a method of manufacturing the mounting structure in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[021] The present invention relates to a mounting structure for a vehicle and a method of manufacturing the same.
[022] Figure 1 illustrates an exemplary cargo vehicle 10, in accordance with an embodiment of the invention. The vehicle 10 has an internal combustion (IC) engine (not shown) or an electric powertrain (not shown) for driving the vehicle 10. The vehicle 10 has a main frame and a driver compartment 16 disposed towards front portion of the vehicle 10 in the vehicle front rear F-R direction, on the main frame. The driver compartment 16 has a soft top 16a and a seat assembly 18. In an embodiment, the IC engine or an electric motor is disposed on the main frame of the vehicle 10 substantially rearwards from the seat assembly 18 in the vehicle front-rear direction F-R.
[023] The vehicle 10 has a head pipe (not shown) in the driver compartment 16 which supports a steering shaft and front suspensions attached to the steering shaft through a lower bracket (not shown). As seen in Figure 1, one or more headlights 14 are provided on a front face of the driver compartment 16. Further, the vehicle 10 also has a windscreen 12 disposed on a front end of the driver compartment 16.
[024] Referring to Figure 1, the vehicle 10 has a loading deck 20. The loading deck 20 extends rearwards in the vehicle front rear direction F-R between a first end 20a and a second end 20b. Towards the rear side in the vehicle front rear direction F-R, the vehicle 10 has a rear bumper bracket 22. Further, as seen in Figure 2, the vehicle 10 has a cross tube 24 disposed rearwardly in the vehicle front rear direction F-R between a pair of long frame members forming part of the main frame of the vehicle 10.
[025] Referring to Figure 3, in one aspect the present invention discloses a mounting structure 100 for mounting components of the vehicle 10. According to the invention, the mounting structure 100 has a first bracket 110. As seen in Figure 3, the first bracket 110 a first top wall 112a and a first bottom wall 112b extending from longitudinal ends of a first vertical wall 112. The first top wall 112a and the first bottom wall 112b extend substantially perpendicular from the first vertical wall 112. According to the invention, the first bottom wall 112b further extends perpendicularly downwards into a first flange 114. Referring to Figure 4a, in an embodiment of the invention, the first bottom wall 112b has an opening 118. In yet another embodiment, and as shown in Figure 4a, the first vertical wall 112 also has an opening 119. The opening 119 is made in order to reduce weight of the first bracket 110.
[026] Referring yet to Figure 3, the mounting structure 100 has a second bracket 120. The second bracket 120 has a second top wall 122a and a second bottom wall 122b extending from longitudinal ends of a second vertical wall 122. The second top wall 122a and the second bottom wall 122b extend substantially perpendicular from the second vertical wall 122. According to the invention, the second bottom wall 122b further extends perpendicularly downwards into a second flange 124. According to the invention, the first bracket 110 is configured to receive the second bracket 120, thereby forming the substantially rectangular mounting structure 100 for mounting components of the vehicle 10.
[027] As seen in Figure 3, in an embodiment of the invention, a portion 112a’ of the first top wall 112a of the first bracket 110 is extruded co-planarly. A portion 122a’ of the second top wall 122 of the second bracket 120 is received by the portion 112a’ of the first bracket 110 and is thereby fixedly attached in order to form the substantially rectangular mounting structure 100.
[028] Referring to Figure 4b, in an embodiment of the invention, the second vertical wall 122 of the second bracket 120 has a hole 126 made therethrough. As seen in the Figure 5, the hole 126 receives a light source 140. The light source 140thereby being received inside the mounting structure 100. As described hereinabove, the first bottom wall 112b of the first backet 110 has the opening 118. Accordingly, the opening 118 on the first bracket allows passage of light emitted by the light source 140.
[029] In another embodiment of the invention, the first flange 114 of the first bracket 110 and the second flange 124 of the second bracket 120 are fixedly attached to each other. In yet another embodiment, as seen in Figure 4b, the first flange 114 and the second flange 124 include a plurality of holes P. In the present embodiment, the plurality of holes P on the first flange 114 and the second flange 124 are emulated. Thus, as seen in Figures 4a and 5, depending on regulatory norms in a particular country, such sized licence plate is detachably mounted on a suitable pair of holes by using fixating means X. In an embodiment the fixating means X includes nuts, bolts, screws etc.
[030] As shown in Figures 4a and 4b, in order to mount the mounting structure 100 on a part of the vehicle 10, the first vertical wall 112 has at least one hole 116 made therethrough. Thus, in an embodiment of the invention and as shown in Figure 2, the mounting structure 100 is disposed on a rear end 20b of the loading deck 20 of the vehicle 10 in the vehicle front rear direction F-R. In another embodiment, the mounting structure is disposed on a rear bumper bracket 22 of the vehicle 10. In yet another embodiment, and as seen in Figure 2, the mounting structure 100 is disposed on a cross tube 24 of the vehicle 10. The cross tube 24 is disposed rearwardly in the vehicle front rear direction F-R between a pair of long frame members forming part of main frame of the vehicle 10.
[031] Referring to Figure 6, in another aspect the present invention discloses a method 200 for manufacturing the mounting structure 100 for the vehicle 10. Thus, the method 200 includes the steps of obtaining 210 a first sheet of metal and a second sheet of metal. The next step 220 includes blanking the first sheet metal into a first blank.
[032] Referring to Figure 6, in an embodiment, the blanking 220 of the first sheet metal includes cutting 220a an outer periphery of the first sheet metal. The step of blanking 220 further includes punching 220b a plurality of holes P and openings 118, 119 through the first sheet metal to obtain the first blank.
[033] According to the invention and as seen in Figure 6, once the first blank is obtained, the next step 240 incudes forming the first blank to obtain the first bracket 110. In an embodiment, forming the first blank includes bending the first blank to form the first bracket 110, whereby the first bracket 110 has a first top wall 112a and a first bottom wall 112b extending from longitudinal ends of a first vertical wall 112. The first top wall 112a and the first bottom wall 112b are substantially perpendicular to the first vertical wall 112. Further, the first bottom wall 112b is extended perpendicularly downwards thereby forming a first flange 114. The next step includes extruding a portion 112a’ of the first top wall 112a of the first bracket 110 co-planarly to receive second bracket 120. In an embodiment, the operations of bending and extruding the first blank to form the first bracket with extruded portion of the first top wall take place either simultaneously or sequentially.
[034] According to the invention and as seen in Figure 6, at step 230 the method includes blanking the second sheet of metal to form the second blank. In an embodiment, and as seen in Figure 6, blanking 230 the second sheet of metal includes cutting 230a an outer periphery of the second sheet metal, and punching 230b a plurality of holes P and 126 through the second sheet metal to obtain the second blank.
[035] According to the invention and as seen in Figure 6, once the second blank is obtained, the next step 250 incudes forming the second blank to obtain the second bracket 120. In an embodiment, forming the second blank includes bending the second blank to form the second bracket 120, whereby the second bracket 120 has a second top wall 122a and a second bottom wall 122b extending from longitudinal ends of a second vertical wall 122. The second top wall 122a and the second bottom wall 122b are substantially perpendicular to the second vertical wall 122. Further, the second bottom wall 122b is extended perpendicularly downwards thereby forming a second flange 124.
[036] According to the invention and as seen in Figure 6, in the next step 260, the first bracket 110 and the second bracket 120 are joined to form the substantially rectangular mounting structure 100 for mounting various components of the vehicle 10. In an embodiment, the first bracket 110 and the second 120 are joined by welding.
[037] Advantageously, the present invention provides a single dedicated protective casing for the light source along with a mounting provision for the license plate. This reduces the number of parts required and thus reduces the manufacturing cost. Further, owing to the mounting structure of the present invention, the light source remains effectively protected against external factors such as water and dust ingression. This further saves the frequent maintenance and repair costs to repair broken and damaged light sources. Furthermore, along with the light source, the license plate is also protected against breakage and damage caused due to stones and gravel. Thus, further reducing maintenance and repair costs due to damage. Additionally, the mounting structure being mounted on an inner surface of load deck skirt does not project outside the load deck. Therefore, a rear side impact does not damage the mounting structure of the present invention. Further, due to being box-shaped, the mounting structure has an improved section modulus, thereby protecting the license plate and the light source from any external impact. The present configuration of the mounting, the positioning of the light source and the license plate facilitates ample illumination of the license plate. Additionally, since both the license plate and the light source are mounted on a single mounting structure, there is no manufacturing deviation which would affect the illumination of the license plate. Further still, the mounting structure of the present invention facilitates mounting of various sizes of license plates in accordance with regulations of countries to which the mounting structure is exported to.
[038] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.