阅读说明：本技术 用于机动车辆的复合安装支架及其制造方法 (Composite mounting bracket for motor vehicle and method of manufacturing the same ) 是由 G·苏布拉马尼安 S·萨西德哈兰 R·A·纳拉亚南 R·拉维桑卡尔 于 2021-06-15 设计创作，主要内容包括：本发明涉及一种用于机动车辆的复合安装支架(100)。安装支架(100)具有金属基板(110)和包覆成型塑料(120)。金属基板(110)被配置为固定在机动车辆的第一部件上。包覆成型塑料(120)被配置成接收机动车辆的第二部件,从而将第一部件和第二部件耦接。(The invention relates to a composite mounting bracket (100) for a motor vehicle. The mounting bracket (100) has a metal substrate (110) and an overmolded plastic (120). The metal substrate (110) is configured to be secured to a first component of a motor vehicle. The overmolded plastic (120) is configured to receive a second component of the motor vehicle, thereby coupling the first component and the second component.)

1. A composite mounting bracket (100) for a motor vehicle, the mounting bracket (100) comprising: a metal substrate (110), the metal substrate (110) being configured to be fixed on a first component of the motor vehicle; and an overmolded plastic (120) formed on the metal substrate (110), the overmolded plastic (120) configured to receive a second component of the motor vehicle to couple the first component and the second component.

2. The composite mounting bracket (100) of claim 1, wherein the metal substrate (110) is configured to rigidly clamp the overmolded plastic (120).

3. The composite mounting bracket (100) of claim 1, wherein the metal substrate (110) includes a portion (110a) that protrudes inside the overmolded plastic (120).

4. The composite mounting bracket (100) of claim 1, wherein the overmolded plastic (120) comprises a housing (128) having a plurality of stiffening ribs (128b) disposed inside the housing (128) and secured between walls (128a) of the housing (128).

5. The composite mounting bracket (100) of claim 1, wherein the overmolded plastic (120) of the mounting bracket (100) comprises at least one of a C-shaped cross-section, an I-shaped cross-section, and a D-shaped cross-section.

6. A method (700) of manufacturing a composite mounting bracket for a motor vehicle, the method comprising the steps of:

forming (710) a metal substrate (110) to conform to a geometry of a space defined by a first component of the motor vehicle;

positioning (720) the metal substrate (110) in a mold; and

overmolding (730) a plastic on the metal substrate (110), the overmolded plastic (120) configured to receive a second component of the motor vehicle.

7. The method (700) of claim 6, the method (700) comprising the steps of: applying an adhesive to an edge of the composite mounting bracket to chemically bond the metal substrate (110) and the overmolded plastic (120).

8. A composite mounting bracket (100) for mounting a fuel tank (20) to a main pipe (24) of a motor vehicle (10), the composite mounting bracket (100) comprising:

a metal substrate (110), the metal substrate (110) configured to be fastened on a portion of the fuel tank (20); and an overmolded plastic (120) formed on the metal base plate (110), the overmolded plastic (120) being configured to receive a bushing (24b) coupled with a mounting stem (24a) fastened to the main pipe (24) for mounting the fuel tank (20) on the main pipe (24).

9. The composite mounting bracket (100) of claim 8, wherein the mounting bracket (100) comprises a C-section overmolded plastic (120), the C-section overmolded plastic (120) having a web (122) and a pair of flanges (124, 126) extending from ends of the web (122).

10. The composite mounting bracket (100) of claim 9, wherein the metal substrate (120) extends between the pair of flanges (124, 126) of the overmolded plastic (120) to rigidly clamp the overmolded plastic (120).

11. The composite mounting bracket (100) of claim 9, wherein the C-section overmolded plastic (120) has a width equal to the width of the bushing (24 b).

12. The composite mounting bracket (100) of claim 8, wherein the metal substrate (110) includes a flat flange (110b) configured to be welded to the fuel tank (20).

Technical Field

The present invention relates to a composite mounting bracket for a motor vehicle and a method of manufacturing the same.

Background

Various large components, such as fuel tanks, seats, headlamps, tires, engines, handlebars, etc., as well as various small components, such as mirrors, indicators, fenders, guards, foot pedals, etc., are mounted on and around the chassis of the motor vehicle. Such mounting of various components of the motor vehicle is done either by welding; or by using a fixing means such as a nut, bolt, screw, zipper, etc., or by using a wire harness; or by using a mounting bracket.

The mounting bracket is basically manufactured and configured according to its intended use. The mounting bracket typically has two regions, one of which is typically secured to the respective component by welding or using a securing means such as a screw, nut, bolt, or the like; and another area for receiving and holding another corresponding component. In this way, one mounting bracket is used to couple two or more components of a motor vehicle. For example, mounting brackets are used to mount a fuel tank to a chassis; or mounting a headlamp or tail lamp assembly to the chassis; or mounting a set of carriers to the chassis; or a turn indicator is mounted to a head lamp assembly or a tail lamp assembly or the like.

Thus, mounting brackets are an integral part of any motor vehicle and have been widely used. However, the mounting brackets known in the prior art have several disadvantages. The most important drawback is that the known mounting brackets are made entirely of metal. Thus, as described above, one region of the mounting bracket is welded to a portion of one component, while another region of the mounting bracket receives another component and is secured to the received component by a securing means such as a nut, bolt, or the like, or by welding. When multiple such metal mounting brackets are used on a motor vehicle, this can add significantly to the overall weight of the motor vehicle, which is undesirable.

Another disadvantage of known metal mounting brackets is that although the entire mounting bracket is strong, it does not have flexibility. Thus, due to negligible flexibility, the metal bracket deforms when subjected to high stress/strain conditions and ultimately causes damage to the associated components. Under further stress/strain conditions, metal hybrid stents often yield and crack. Thus, breakage or deformation of the mounting bracket requires replacement of not only the mounting bracket but also the corresponding component.

Accordingly, there is a need in the art for a mounting bracket that addresses at least the above-mentioned problems.

Disclosure of Invention

In one aspect, the present invention relates to a composite mounting bracket for an automotive vehicle. The composite mounting bracket of the present invention has a metal substrate configured to be secured to a first component of a motor vehicle, and an overmolded plastic formed on the metal substrate. The overmolded plastic is configured to receive a second component of the motor vehicle to couple the first component and the second component.

In an embodiment of the invention, the metal substrate is configured to rigidly clamp the overmolded plastic.

In another embodiment of the invention, the metal substrate includes a portion that protrudes into the interior of the overmolded plastic.

In another embodiment of the invention, the overmolded plastic has a housing with a plurality of reinforcing ribs disposed inside the housing and secured between the walls of the housing.

In yet another embodiment of the present invention, the overmolded plastic of the mounting bracket includes at least one of a C-shaped cross-section, an I-shaped cross-section, and a D-shaped cross-section.

In another aspect, the present invention relates to a method of manufacturing a composite mounting bracket for a motor vehicle. The method comprises the following steps: forming a metal substrate to conform to the geometry of a space defined by a first component of a motor vehicle; positioning a metal substrate in a mold; and overmolding plastic on the metal substrate, the overmolded plastic configured to receive a second component of the motor vehicle.

In another embodiment of the invention, the method comprises the steps of: an adhesive is applied to the edges of the composite mounting bracket to chemically bond the metal substrate and the overmolded plastic.

In another aspect, the present invention relates to a composite mounting bracket for mounting a fuel tank to a main pipe of a motor vehicle. The mounting bracket has a metal base plate configured to be secured to a portion of the fuel tank; and an overmolded plastic formed on the metal substrate. The overmolded plastic is configured to receive a bushing coupled with a mounting stem secured to the main tube for mounting the fuel tank on the main tube.

In an embodiment of the invention, the mounting bracket has a C-section overmolded plastic having a web and a pair of flanges extending from the ends of the web.

In another embodiment of the invention, the metal base plate extends between a pair of flanges of the overmolded plastic, thereby rigidly clamping the overmolded plastic.

In another embodiment of the invention, the width of the C-section overmolded plastic is equal to the width of the bushing.

In yet another embodiment of the invention, the metal base plate has a flat flange configured to be welded to the fuel tank.

Drawings

Reference will now be made to embodiments of the invention, examples of which may be illustrated in the accompanying drawings. The drawings are intended to be illustrative, not limiting. While the invention will be described in the context of these embodiments generally, it will be understood that it is not intended to limit the scope of the invention to these particular embodiments.

FIG. 1 illustrates an exemplary motor vehicle according to an embodiment of the present invention.

FIG. 2 illustrates a composite mounting bracket according to an embodiment of the present invention.

FIG. 3 is a cross-sectional view (section A-A) of the composite mounting bracket of FIG. 2 of the present invention.

FIG. 4 illustrates a method of manufacturing a composite mounting bracket according to an embodiment of the present invention.

FIG. 5 illustrates a composite mounting bracket according to an embodiment of the present invention.

FIG. 6 is a side view of the motor vehicle showing the fuel tank mounted on the frame of the vehicle.

FIG. 7 illustrates a composite mounting bracket secured to a fuel tank in accordance with an embodiment of the present invention.

Fig. 8 is a sectional view showing that the fuel tank is mounted on the main pipe.

Detailed Description

The present invention relates to a composite mounting bracket for a motor vehicle and a method of manufacturing the same.

FIG. 1 illustrates an exemplary motor vehicle according to an embodiment of the present invention. The motor vehicle 10 includes a vertically disposed internal combustion engine 12. Preferably, the internal combustion engine 12 is a single cylinder type internal combustion engine. The two-wheeled vehicle 10 includes a front wheel 14, a rear wheel 16, a frame member, a seat 18, and a fuel tank 20. The frame members include a head pipe 22, a main pipe 24, a down pipe (not shown), and seat rails (not shown). The head pipe 22 supports a steering shaft (not shown) and two telescopic front suspensions 26 (only one shown) attached to the steering shaft by a lower bracket (not shown). Two telescoping front suspensions 26 support the front wheels 14. The upper portion of the front wheel 14 is covered by a front fender 28, and the front fender 28 is mounted to the lower portion of the telescopic front suspension 26 at the end of the steering shaft. The handle bar 30 is fixed to an upper bracket, not shown, and can be rotated to both sides. The head lamp 32, the visor guard (not shown), and the cluster (not shown) are disposed at an upper portion of the head pipe 22. The frame member includes a down tube, which may be located in front of the internal combustion engine 12 and extends obliquely downward from the head pipe 22. The main tube 24 of the frame member is located above the engine 12 and extends rearwardly from the head tube 22. The engine 12 is mounted forward of the down tube and the rear of the engine 12 is mounted rearward of the main tube 24. In the embodiment, the internal combustion engine 12 is mounted vertically with its cylinder block extending vertically above the crankcase. In an alternative embodiment, the engine 12 is mounted horizontally (not shown) with its cylinder block extending horizontally forward from the crankcase. In an embodiment, the cylinder block is disposed rearward of the down tube.

The fuel tank 20 is mounted on a horizontal portion of the main pipe 24. The seat rails are joined to the main tube 24 and extend rearward to support the seat assembly 18. A rear swing arm 34 is connected to the frame member to swing vertically, and a rear wheel 16 is connected to a rear end of the rear swing arm 34. Typically, the rear swing arm 34 is supported by a single rear suspension 36 (as shown in the present embodiment), or by two suspensions on either side of the motor vehicle 10. A tail light unit (not shown) is provided at the end of the motor vehicle 10 and rearward of the seat assembly 18. Armrests (not shown) are also provided at the rear of the seat rails. The rear wheel 16 disposed below the seat 18 is rotated by the driving force of the internal combustion engine 12, which is transmitted from the internal combustion engine 12 through a chain transmission (not shown). A rear fender 38 is disposed above the rear wheel 16.

Further, the exhaust pipe 40 of the vehicle extends vertically downward from the internal combustion engine 12 to a point, then extends longitudinally along the length of the vehicle below the internal combustion engine 12, and then terminates at a muffler 42. The muffler 42 is typically disposed adjacent the rear wheel 16.

Fig. 2 illustrates a composite mounting bracket 100 according to an embodiment of the present invention. The composite mounting bracket 100 has a metal substrate 110 and an overmolded plastic 120 formed on the metal substrate 110. The metal substrate 110 is configured to be secured to a first component of a motor vehicle. In this regard, in an embodiment of the invention, the metal base plate 110 is a metal plate formed to conform to the geometry of the space defined by the first component of the motor vehicle. The space defined by the first member receives the metal substrate 110. In an embodiment of the present invention, the metal substrate 110 is welded in a space defined by the first member.

Further, the overmolded plastic 120 is configured to receive a second component of the motor vehicle. As such, the shape and size of the overmolded plastic 120 will depend on the geometry and size of the second component received by the overmolded plastic 120. In embodiments of the invention, the overmolded plastic 120 of the mounting bracket 100 has a C-shaped cross-section, while in other embodiments the overmolded plastic 120 of the mounting bracket 100 has an I-shaped cross-section or a D-shaped cross-section. In another embodiment of the invention, the overmolded plastic 120 is further configured to rigidly clamp the second component, whereby the mounting bracket 100 couples the first component and the second component when the metal substrate 110 is secured to the first component.

In an embodiment of the present invention, the overmolded plastic 120 is defined by guest 128. The housing has walls 128a defining an interior region, and reinforcing ribs 128b are disposed in the interior region and secured between the walls 128 a. Such ribs provide structural rigidity and strength to the overmolded plastic 120.

Thus, the overmolded plastic 120 may be any shape and size, and this depends on the geometry of the part that the overmolded plastic 120 is to receive. Similarly, the shape and size of the metal substrate 110 will depend on the geometry of the component to which it is desired to secure and the shape and size of the overmolded plastic 120. In this regard, the metal substrate 110 is formed in a shape that can integrally sandwich the over-molded plastic 120, thereby providing rigidity and strength to the over-molded plastic 120.

FIG. 3 is a cross-sectional view (section A-A) of the composite mounting bracket of the present invention shown in FIG. 2. In an embodiment of the present invention, as shown in fig. 3, a portion 110a of the metal substrate 110 protrudes into the interior of the over-molded plastic 120, thereby increasing the contact area between the metal substrate 110 and the over-molded plastic 120. Such a configuration provides additional rigidity and strength to the overmolded plastic 120.

Further, as shown in fig. 3, a portion of the metal base plate 110 also protrudes outward from the mounting bracket 100, forming a flat flange 110 b. The flat flange 110b is configured to be secured to a first component of a vehicle to secure the mounting bracket 100 to the vehicle.

Further, in embodiments, referring to section a-a shown in fig. 2, it can be appreciated that the metal substrate 110 is inserted into the overmolded plastic 120 and bent to increase the contact area between the metal substrate 110 and the overmolded plastic 120, which in turn is intended to increase the pull-off strength or tensile strength of the mounting bracket 100, enabling the mounting bracket 100 to increase its strength-to-weight ratio and have enhanced dimensional stability to overcome dimensional variations and increased weight.

Fig. 4 shows a method 700 of manufacturing composite mounting bracket 100. At step 710 of method 700, a metal substrate is formed to conform to the geometry of a space defined by a first component of a motor vehicle. In an embodiment of the invention, the metal substrate is a stamped metal substrate. At step 720, the metal substrate is positioned in a mold, and the method proceeds to step 730. At step 730, plastic is overmolded onto the metal substrate. In this regard, the mold generally conforms to the desired shape of the overmolded plastic. Further, at step 730, the overmolded plastic is configured to receive a second component of the motor vehicle. In an embodiment of the present invention, method 700 further includes the step of applying an adhesive to the edge of the composite mounting bracket, thereby chemically bonding the metal substrate and the overmolded plastic.

In another embodiment of the invention, the plastic is overmolded on the metal substrate by injection molding. To this end, the overmolded plastic has a plurality of mounting holes 150 for mechanical interlocking, as shown in FIG. 5.

Fig. 6 is a side view of the motor vehicle 10 showing the fuel tank 20 mounted on the frame of the vehicle 10. As described above, the frame includes the head pipe 22, the main pipe 24 (as shown in FIG. 8), the down tube 46, and the seat rails 44. The fuel tank 20 has an upper surface area 20a, side surface areas 20b, and a lower surface area 20c (shown in fig. 7 and 8). The fuel tank 20 is elongated in the front-rear direction and extends between a front end 20d and a rear end 20 e. At the rear end 20e of the fuel tank 20, a flange (not shown) is provided that protrudes from the lower surface region 20 c. The flange is provided with a slot to receive a mounting bracket (not shown) connected to the main pipe 24, whereby the rear end of the fuel tank 20 can be mounted on the main pipe 24.

As shown in fig. 7 and 8, the lower surface area 20c is formed with a recess 20f so as to pass through the main pipe 24 oriented in the vehicle front-rear direction. The mounting rod 24a is fixed to the main pipe 24 in the vehicle width direction. In an embodiment, the mounting bar 24a is welded to the main tube 24 and extends substantially equally on each side of the recess 20 f. Each end of the mounting rod 24a is coupled with one bushing 24b of the plurality of bushings 24 b. In an embodiment, bushings 24b are mounted and secured to each end of mounting bar 24 a. The mounting rod 24a is positioned on the main pipe 24 such that each bushing 24b can be coupled with the recess 20f of the fuel tank 20 on each side of the recess 20 f.

Fig. 7 shows the composite mounting bracket 100 secured to the fuel tank 20. As described above, the composite mounting bracket 100 has the metal substrate 110 and the overmolded plastic 120 formed on the metal substrate 110. In an embodiment of the present invention, as shown in fig. 7 and 8, the mounting bracket 100 is fixed on the concave portion 20f of the fuel tank 20 on each side of the concave portion 20f of the fuel tank 20. Thus, the metal base plate 110 of each mounting bracket 100 is shaped and sized to be fixed on the recess 20f of the fuel tank 20. In an embodiment of the present invention, as described above, the metal base plate is provided with a flat flange 110b, the flat flange 110b being configured to be welded to the fuel tank 20.

Further, the overmolded plastic 120 on each mounting bracket 100 is configured to receive the bushing 24 b. The overmolded plastic 120 is also configured to rigidly clamp the liner 24b, whereby the fuel tank 20 is mounted on the main tube 24. To this end, in an embodiment of the present invention, the mounting bracket 100 has a C-section overmolded plastic 120.

As shown in fig. 2, the C-section overmolded plastic 120 is defined by a web 122 and a pair of flanges 124, 126 extending from the ends of the web 122. In the installed configuration, the bushing 24b is received between the pair of flanges 124, 126. In this regard, in an embodiment of the invention, the width of the C-section overmolded plastic 120 is equal to the width of the bushing 24b such that the bushing 24b fits snugly between the flanges 124, 126. The metal base plate 110 extends between a pair of flanges 124, 126, corresponding to the shape of the overmolded plastic 120, thereby sandwiching the overmolded plastic 120.

Advantageously, the composite mounting bracket of the present invention is significantly lighter in weight due to the overmolded plastic. Thus, when a plurality of such composite mounting brackets are mounted in place of the conventional brackets, significant weight savings of the motor vehicle can be realized. In addition, the composite material of the stent of the present invention provides high strength, thereby increasing the strength-to-weight ratio. Further, the overmolded plastic provides flexibility to the mounting bracket, whereby stresses/strains caused by vehicle roll are minimized and better dimensional stability is achieved. Therefore, the possibility of breakage or deformation of the mounting bracket is greatly reduced. Furthermore, since the second component is rigidly fitted into the overmolded plastic, no fastening means for securing the component to the mounting bracket are required. In this way, the installation and replacement of components on the composite mounting bracket is easier, thereby reducing assembly and maintenance time.

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 modifications may be made without departing from the scope of the invention as defined in the following claims.