FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, rule 13]
TITLE: “VEHICLE BUMPER-BEAM ASSEMBLY”
NAME AND ADDRESS OF THE 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.
Nationality: Indian
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
The present invention generally relates to vehicle bumper assemblies and particularly, but not exclusively, to a front bumper-beam assembly for vehicles. Aspects of the invention relate to a bumper-beam, to a vehicle front end and to a vehicle.
BACKGROUND OF THE INVENTION
Generally, a vehicle bumper-beam assembly includes a bumper structure mounted on bumper-beams at front and rear of the vehicle. The bumper-beams extend laterally across the longitudinal members of the vehicle frame, and generally attached to the end portions of the main longitudinal members. The bumper-beams are provided to impart torsional rigidity and also to absorb impact energy during the event of accident. Various designs of front bumper cross members are presently available in automotive domain. The most common of such designs is a C-in-C channel box type cross member design. The vehicle systems like radiator, condenser and intercooler, which are cooled by the ramming air, are placed behind the front bumper-beam. However, the common design of bumper-beam covers considerable front area of the vehicle and therefore affects air flow on cooling system like radiator, condenser and intercooler, which may affect the power train and other auxiliary systems efficiency drastically.
OBJECTS OF THE INVENTION
The objective of the invention is to provide a vehicle bumper-beam assembly, a vehicle front end and a vehicle as claimed, in the appended claims.
Another objective of invention is to provide a vehicle bumper-beam assembly that covers less front area of the vehicle for allowing passage of cooling air, thereby enabling enhanced performance of the cooling systems.
Yet another objective of the preset invention is to provide a vehicle bumper-beam assembly that enables efficient mounting of aggregates such as a front bumper, a radiator, a condenser, an intercooler and the like, thereon.

Yet another objective of the preset invention is to provide a vehicle bumper-beam assembly which is composed of dismantlable components, resultantly the cost associated with repair of damages caused by frontal collisions of vehicle at slow speeds is reduced.
Further objects and features of the invention will become apparent from the following detailed description when considered in conjunction with the drawings.
SUMMARY OF THE INVENTION
The various embodiments of the present invention disclose a vehicle bumper-beam assembly for a vehicle. The bumper-beam assembly comprises a pair of tubular bumper-beams positioned laterally with respect to the longitudinal members of the vehicle frame. The first tubular bumper-beam includes distal end portions aligned to one another and an intermediate portion, connecting the distal end portions. The distal end portions of the first tubular bumper-beam being directly or indirectly for example through crash boxes, connected to the longitudinal members of the vehicle frame. A second tubular bumper-beam with two end portions removably connected to the two distal portions of the first tubular bumper-beam respectively. A plurality of mounting brackets provided on each of the first tubular bumper-beam and the second tubular bumper-beam for mounting cooling elements like radiator, intercooler and condenser.
In an embodiment, two bumper-beams are spaced apart and end portions of the second bumper-beam is connected to the end portions of the first bumper-beam respectively. The end portions of the first bumper-beam further connected to the crash boxes on the main longitudinal members of the vehicle. In an exemplary embodiment, the end portions of the first bumper-beam is mounted and supported on the crash boxes.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 illustrates a front perspective view of a portion of a vehicle having a vehicle bumper-beam assembly, according to an embodiment of the invention,

FIG. 2 illustrates an exploded perspective of the vehicle bumper-beam assembly with support structure, according to an embodiment of the present invention,
FIG. 3 illustrates a perspective view the vehicle bumper-beam assembly, according to an embodiment of the present invention,
FIG. 4 illustrates another perspective view of the radiator and condenser mounted on the bumper-beam assembly, according to an embodiment of the present invention, and
FIG. 5 illustrates a side view of the vehicle bumper-beam assembly, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same.
Figures 1 through 5 illustrate various views of a vehicle bumper-beam assembly 10, in accordance with various embodiments of the present invention. The vehicle bumper-beam assembly 10 may be used with a vehicle 12, for example, as a front end module of the vehicle. The vehicle 12 may be any vehicle having a vehicle frame 14 and a vehicle body 16. The vehicle body 16 is supported on the vehicle frame 14. The vehicle frame 14 includes two longitudinal rails (also referred to as “long members”) extending longitudinally along a length of the vehicle 12, and a set of laterally extending rails (not shown) connecting the two longitudinal rails. In various embodiments of the present invention, the vehicle body 16 may or may not be integral to the vehicle frame 14. It may herein be noted that the integration of the vehicle body 16, and the vehicle frame 14 with each other may be done in conventional manner which is known to those skilled in the art and therefore for the purpose of brevity, a detailed description of the same has been omitted. Each of a first longitudinal member 18 and a second longitudinal member 20, (collectively called as the “two longitudinal members 18, 20”) include a first front end portion 22 and a second front end portion 24, respectively. As best seen in FIG. 2, the front end portions 22 and 24 are positioned towards the front of the vehicle 12.

The front end portion of the longitudinal members includes a first crash-box 102 is connected to the first longitudinal member 18 of the vehicle frame 14, and a second crash-box 104 is connected to the second longitudinal member 20. Particularly, the first crash-box 102 is removably connected to the front end portion 22 of the first longitudinal member 18 of the vehicle frame 14. Likewise, the second crash-box 104 is removably connected to the front end portion 24 of the second longitudinal member 20 of the vehicle frame 14. As best shown in FIG, 2, the first crash-box 102 and the second crash-box 104 is fastened to the first longitudinal member 18 and the second longitudinal member 20, respectively. Advantageously, such removable engagement of the first crash-box 102 and the second crash-box 104 with the first longitudinal member 18 and the second longitudinal member 20, respectively, allows for removal of just one or two crash-box, in case one or more of the crash-boxes gets damaged. Further, fastening of the first crash-box 102 and the second crash-box 104 to the first longitudinal member 18 and the second longitudinal member 20 respectively enables easy, quick and convenient removal of the first crash-box 102 and the second crash-box 104 from the first longitudinal member 18 and the second longitudinal member 20, respectively. Furthermore, the removability of the first crash-box 102 and the second crash-box 104 also results in reduction in cost of repair.
In one embodiment of the present invention, each of the first crash-box 102 and the second crash-box 104 include a top tab (not numbered) adapted to support portions of a radiator assembly 26, best shown in FIG. 4.
Referring now to FIG. 2, which illustrates an exploded view of the vehicle bumper-beam assembly 10, the vehicle bumper-beam assembly 10 include a first tubular bumper-beam 106 and a second tubular bumper-beam 108. The first tubular bumper-beam 106 is adapted to be positioned laterally with respect to the longitudinal members (shown in FIG. 1) of the vehicle frame 14. The first tubular bumper-beam 106 includes distal end portions 110, 112 aligned to one another and an intermediate portion 114 connecting the distal end portion 110, 112.

The intermediate portion 114 of the first tubular portion 106 includes at least one bracket, such as a bracket 116, for facilitating mounting of different vehicle aggregates. In one embodiment of the present invention the bracket 116 may be a tie member support mounting bracket. Additionally, the intermediate portion 114 of the first tubular portion 106 may also include steering fluid pipe mounting bracket (not numbered) and intercooler mounting bracket. Typically, the bracket 116, the steering fluid pipe mounting bracket, and the like are welded to the first tubular portion 106.
The distal end portions 110, 112 (also refereed to as first distal end portion 110, and second distal end portion 112) may be connected directly to the first longitudinal member 18 and the second longitudinal member 20 respectively. Alternatively, the distal end portions 110, 112 may be connected to the first crash-box 102 and the second crash-box 104, respectively. In one embodiment of the present invention the distal end portion 110 of the first tubular bumper-beam 106 is welded to a lateral face (not numbered) of the first crash-box 102. Likewise, in the same embodiment, the distal end portion 112 of the first tubular bumper-beam 106 is welded to a lateral face of second crash-box 104.
Referring again now to FIGS. 2 and 3, which illustrates the vehicle bumper-beam assembly 10 in accordance to an alternative embodiment thereof. In this embodiment, the first distal end portion 110 of the first tubular bumper-beam 106 includes a plate 118 with oval shaped slots. The first distal end portion 110 of the first tubular bumper-beam 106 being configured to be joined with the first crash-box 102 but inserting fastening members, such as screws 103, through the oval shaped slots of the plate 118 and the lateral face of the first crash-box 102.
Further, the second distal end portion 112 of the first tubular bumper-beam 106 includes a plate 120 with oval shaped slots. The second distal end portion 112 of the first tubular bumper-beam 106 being configured to be joined with the second crash-box 104 but inserting fastening members, such as screws 103, through the oval shaped slots of the plate 120 and the lateral face of the second crash-box 104. The oval shaped slots on the plates 118 and 120 enable limited movement of a fastener connecting the plate 118 to the first crash-box 102 and fastener connecting the plate 120 to the second crash-box 104,

when a force is applied thereto, for example in the event of a vehicle collision. In the event of a low speed impact, such movement of the crash-box with respect to the tubular bumper-beam 106 help absorb energy which results in a lesser damage to the vehicle bumper-beam assembly 10, and the same can thus be used again. Advantageously, the cost of damage repair in such an event may be reduced.
The second tubular bumper-beam 108, having a U-shaped configuration, is positioned below the first tubular bumper-beam 106. The second tubular bumper-beam 108 includes end portions 152, 154, connected to the distal end portions 110, 112, respectively of the first tubular bumper-beam 106. In one embodiment of the present invention, the end portions 152, 154 of the second tubular bumper-beam 108, are removably connected, say fastened, to the distal end portions 110, 112 respectively, of the first tubular bumper-beam 106.
In an embodiment of the present invention, all the components of the vehicle bumper-beam assembly 10, namely, the first crash-box assembly, the second crash-box assembly, the first tubular bumper-beam 106, the second tubular bumper-beam 108 and the like, are removably connected with each other. Therefore, in case of a collision in slow speed, only the damages component is required to be replaced and accordingly the need of replacing the entire vehicle bumper-beam assembly 10 is precluded. Further, the tubular structure of the first tubular bumper-beam 106 and a second tubular bumper-beam 108 increases power train performance by improving the air flow for cooling. The vehicle bumper-beam assembly 10 of the present invention provides a huge weight saving (about 60%) as compared to conventional designs of bumper-beam.
The foregoing description provides specific embodiments of the present invention. It should be appreciated that these embodiment are described for purpose of illustration only, and that numerous other alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

Referral Numerals:

Reference Number Description
10 Vehicle bumper-beam assembly
12 Vehicle
14 Vehicle frame
16 Vehicle body
18 First longitudinal member
20 Second longitudinal member
22 Front end portion
24 Front end portion
102 First crash-box
104 Second crash-box
106 First tubular bumper-beam
108 Second tubular bumper-beam
110 Distal end portions
112 Distal end portion
114 Intermediate portion
116 Bracket
118 Plate
120 Plate
152 End portion
154 End portion

We claim:
1. A vehicle bumper-beam assembly for a vehicle having a vehicle frame supporting
a vehicle body, the vehicle bumper-beam assembly comprising:
a first tubular bumper-beam positioned laterally with respect to the longitudinal members of the vehicle frame, the first tubular bumper-beam consists of distal end portions aligned to one another and an intermediate portion, wherein the distal end portions of the first tubular bumper-beam being connected to the first longitudinal member and the second longitudinal member, respectively; and,
a second tubular bumper-beam having end portions removably connected to the distal end portions of the first tubular bumper-beam respectively.
2. The vehicle bumper-beam assembly as claimed in claim 1 further comprising,
a first crash-box carried by a front end portion of the first longitudinal member of the vehicle frame; and
a second crash-box carried by a front end portion of the second longitudinal member, of the vehicle frame, the distal end portions of the first tubular bumper-beam being connected to the first crash-box and the second crash-box, respectively.
3. The vehicle bumper-beam assembly a claimed in claim 1 further comprising a plurality of mounting brackets provided on each of the first tubular bumper-beam and the second tubular bumper-beam.
4. The vehicle bumper-beam assembly as claimed in any one of the preceding claims, wherein a first distal end portion of the first tubular bumper-beam being welded to a lateral face of the first crash-box and a second distal end portion of the first tubular bumper-beam being welded to a lateral face of the second crash-box.
5. The vehicle bumper-beam assembly as claimed in any one of the preceding claims, wherein the distal end portion of the first tubular bumper-beam includes a

plates with oval shaped slots, the plates being connected to a lateral face of a crash-box.
6. The vehicle bumper-beam assembly as claimed in claim 5, wherein the oval shaped slots on the plate enable limited movement of fasteners connecting the plate to the crash-box, when a force is applied thereto.
7. The vehicle bumper-beam assembly as claimed in claim 1, wherein the intermediate portion of the first tubular portion includes at least one bracket.
8. The vehicle bumper-beam assembly as claimed in claim 7, wherein the bracket on the intermediate portion of the first tubular portion is a tie member support mounting bracket.
9. The vehicle bumper-beam assembly as claimed in claim 3, wherein at least one bracket on the second tubular bumper-beam is a bumper mounting bracket.
10. The vehicle bumper-beam assembly as claimed in claim 1, wherein the second tubular bumper-beam is fastened to the first tubular bumper-beam.
11. The vehicle bumper-beam assembly as claimed in claim 1, wherein the second tubular bumper-beam has a U-shaped configuration.