CN101171157A

CN101171157A - Hybrid bumper with trim

Info

Publication number: CN101171157A
Application number: CNA2006800150515A
Authority: CN
Inventors: D·埃文斯
Original assignee: NetShape Energy Management LLC
Current assignee: NetShape Energy Management LLC
Priority date: 2005-05-02
Filing date: 2006-05-02
Publication date: 2008-04-30

Abstract

A hybrid bumper system includes a polymeric reinforcement beam with end sections and structural covers attached to the ends sections to considerably strengthen the end sections. Bracketry stably supports the reinforcement beam on a vehicle frame. A fascia covers at least part of the reinforcement beam but leaves a portion of the structural covers in a visible position. The structural covers are treated for aesthetics, such as by painting, chroming, or other surface treatment. In one aspect, the beam includes a molded polymeric beam component, structural L-shaped covers attached to its end sections, and a tie bar along it rear side that stiffens and rigidifies a center of the polymeric beam component. In another aspect, a tow bar or rail-to-rail metal reinforcement beam front system (or rear with tow bar) is incorporated.

Description

Hybrid bumper with ornamental trimming

The application requires in the provisional application No.60/676 of submission on May 2nd, 2005,820 preceence, and its name is called " hybrid bumper with ornamental trimming ".

Technical field

The present invention relates to vehicle bumper system, especially relate to a kind of hybrid bumper system, it is suitable for providing style alerting ability, cost effectiveness/competitive power, make assembly set, weight is less and the intensity height, during impact to carrying out efficient and predictable energy management along the energy that various piece absorbed of bumper/spoiler extruding order and the energy that is delivered to vehicle frame.

Background technology

The bumper assembly that is used for current passenger vehicle constantly develops in function aspects and aesthetic.These demands are often conflicted, and therefore need a kind of hybrid bumper system, and it is suitable for utilizing different materials, and it still keeps for example optimal control of time of setting up, cost and energy management etc.For example, recently, government and underwriting standard begin to pay close attention to the optimization bumper assembly, reducing the injury to the pedestrian when impacting, and continue at a high speed and optimized energy management is provided during low velocity impact.This just requires energy absorbing and impacts feature and design, so that have specific energy absorbing to distribute in the different piece of bumper collision.Yet bumper assembly must be realized impact energy management, keeps style alerting ability, low weight, low cost, high strength-to-weight ratio simultaneously and the time of delivery of the weak point that is used to process.Require the style alerting ability,, comprise chrome look can be provided to allow product differentiation.Preferably, this bumper assembly should use the environment amenable reusable and/or material that can be recycled.In addition, wish that the number of components that is used in the bumper assembly is minimum, comprise attachment erection structure (for example, integrated fog lamp supporting construction, integrated grill support structure), integrated airflow management, other incorporate bumper functions (for example step, licence plate are installed and/or the towing ability) or the like.

Except that functional requirement, the bumper assembly that is desirable to provide is distinctive, and also has ability and the alerting ability that different aesthetic properties can be provided.Yet, client generally need seem to design integrated preferably scheme.Only additional member being installed on the outside of existing system generally is not acceptable scheme, appends because the result can make non-integration component outward appearance on the assembly set look like afterwards.And " adding " member has increased the weight and the cost of assembly set, does not have substantial benefit.

Use provides chance optimization to be used for the special component that particular design requires by the hybrid bumper system of the member that different materials is made.Yet this also can cause the increase of increasing of number of components and/or assembly cost.In addition, can cause with material do not match and material in the relevant various quality problems of the heterogeneity under the different temperatures.For example, dissimilar material can cause the dimensional control problem with tolerance/accumulation problem, thermal expansion problem be connected difficulty, thereby makes troubles and durability attenuating etc.

Therefore, need a kind of bumper assembly that has above-mentioned advantage and address the above problem.

Summary of the invention

In one aspect of the invention, the hybrid bumper system that is used for vehicle comprises the polymeric material deep beam with centre portion and end sections, and comprise the rack system that engages securely with this deep beam, it is suitable for being connected to vehicle, is used for deep beam is supported on vehicle frame with stabilized conditions.Panel covers the top of this deep beam at least.Structural cover connects and covers at least a portion of this deep beam end sections, and this structural cover is united with this end sections, so that the intensity of corner structure is greater than independent end sections, and structural cover comprises the visible surface that is not covered by panel.

Another aspect of the present invention, the bumper assembly that is used for vehicle comprises hybrid deep beam, it is made of polymeric beam member and the L shaped structural cover components that is fixed to the outer end portion of this polymeric beam member.Rack system engages deep beam securely, and is suitable for being connected to vehicle, is used for deep beam is supported on vehicle frame with stabilized conditions.Panel covers at least a portion of deep beam centre portion, and does not cover the viewable portion of L shaped structural cover components.In panel and the structural elements at least one comprise with panel and constructional delails in another different surface treatment.

Aspect another, the hybrid bumper system that is used for vehicle comprises draw bar and rack system of the present invention, and rack system engages this draw bar securely, and is suitable for being connected to vehicle, is used for draw bar is supported on vehicle frame with stabilized conditions.Deep beam is connected to rack system and draw bar.Panel covers the part of deep beam.Structural cover is connected to the end sections of deep beam, to form structural corners with deep beam.

The purpose of this invention is to provide a kind of hybrid bumper system, it provides considerable saving on tooling cost, and for example 20%, and considerable weight saving, for example reach about 15% (having reduced about 25 pounds for instance), but still have design flexibility.

Those skilled in the art will understand and understand these and other aspect of the present invention, purpose and feature by research specification sheets, claim and accompanying drawing subsequently.

Description of drawings

Fig. 1-2 is the front and back transparent view that has embodied rear bumper of the present invention system.

Fig. 3 is the decomposition diagram of the bumper assembly in Fig. 1.

Fig. 4-the 6th shows the transparent view of number of assembling steps in succession.

Fig. 7 is the transparent view of embodiment of the bumper assembly of remodeling of the present invention.

Fig. 8 is the decomposition diagram of the bumper assembly in Fig. 7.

Fig. 9 is the rear perspective view that has embodied front bumper system of the present invention.

Figure 10 is the exploded drawings of Fig. 9.

The specific embodiment

The hybrid bumper system 20 (Fig. 1-3) that is used for vehicle comprises the deep beam 24 that is adapted to pass through on the front-axle beam that rack system 22/23 is supported on vehicle frame.Draw bar 21 passes the hole in the rack system 22/23 and engages rack system 22/23, thereby draw bar 21 is supported on the vehicle frame securely.Bumper assembly 20 also comprises panel 25, it covers the first of deep beam 24 and covers draw bar 21 at least in part, and bumper assembly 20 comprises the structural cover 26/27 that is connected to deep beam 24 ends, be used to the end of crossbeam 24 to increase structure, also be for the end (and panel 25) that covers deep beam 24 attractive in appearancely to become assembly set.In one aspect, panel 25 by can japanning or the material of chromium plating or mould intrinsic color make.In addition, but lid 26/27 also make by japanning or chrome faced material.What can envision is that the lid of japanning can be made by first material cheaply that is suitable for japanning, and the second identical shaped lid can be made by being suitable for chrome faced second material.The existence of the member 25-27 that can select to carry out japanning or chromium plating or be shaped with difformity has increased existing design-calculated alerting ability, with the identification of satisfying different product and the standard attractive in appearance of different automobile types.

Draw bar 21 (Fig. 3) comprises the tubular cross bearer with sufficient intensity, to support the tow ball coupling, is used for supporting and breakdown trailer.According to required towability draw bar 21 is made and to be had suitable intensity, and draw bar 21 comprise one or more holes 21 ', to be used to admit the tow ball coupler member.

Main Support bracket 22 (Fig. 3) is by the rammed bearing of metal sheet, is used for bumper assembly 20 is installed to vehicle frame.Each carriage 22 comprises first end 30, the extendible portion 31 that is used to be installed to vehicle frame and has the second end 32 (be illustrated as porose flange) of enough structures with firm engagement and supporting traction bar 21.

The stabilizer bracket 23 (Fig. 3) of U-shaped is also dashed by metal sheet and forms, and comprises the inner 34 that is connected carriage 22 sides, and extends to second outer end 35 that is connected in crossbeam 24 from inner 34 with certain angle.Carriage 23 is suitable for supporting and the end of stable crossbeam 24.Graphic carriage 23 is U-shapeds, and carriage 22 also has special shape, but what it is contemplated that is that

carriage

22 and 23 can be other shape and structure.

Graphic deep beam 24 (Fig. 3) is made by structural plastic material, and for example compound or reinforced plastic material is as PC/PBT.It comprises each integrally formed connection structure, for example be used to admit the porose boss of thread-forming screw and/or comprise the recess that is used to admit snap-in fasteners and clip 37, this snap-in fasteners and clip 37 for example can be used for licence plate and be connected or be used to make electric wire to extend to the wire management of the outer lamp of vehicle and be used for admitting the hole that is used for carriage (22/23) bonded assembly bolt.It also comprises the hole 38 that is used for registration mark light and the mounting structure that integrally forms, be used for the mounting structure 38 of turning indicator ', be used to support being used for managing and keeping extending to the clip of electric wire of registration mark light and turning indicator and mounting structure of retainer or the like.The end of crossbeam 24 enlarges, and comprises that strengthening rib and comprising has formed the wall construction of smooth (or trampling/trough of belt/coarse) end face of step.

Panel 25 (Fig. 3) is the TPO moulded parts, is suitable for being installed on crossbeam 24, carriage 22/23 and the draw bar 21 with mating and covering them.Especially, panel 25 is included in the top shelf part 41 that forms step on the crossbeam 24, and is included in the recessed centre portion 42 that covers draw bar 21 middle parts under the license plate area.In addition, the vertical wall 44 of U-shaped extends around license plate area, and connects described part 41 and 42.Yet vertically wall 44 is united to form recess 45 and 46 with top shelf part 41, and recess 45 and 46 makes the side of crossbeam 24 ends open wide and exposure.What it is contemplated that is, panel 25 by can japanning, mould intrinsic color or selection carry out the material that light processing obtains optimal appearance and make, this depends on the demand attractive in appearance of vehicle.Do not change the required basic structure of product differentiation and need not redesign this system, the style of these parts (24 or other) also can change.

Structural cover 26/27 (Fig. 3) be connected to around the recess 45 of panel 25 and 46 and crossbeam 24 in the zone that recess 45 and 46 extends previously on flange.Lid 26/27 is preferably made by being shaped and pass through the metal handled of japanning or glossy surface processing (for example chromium plating).Yet what it is contemplated that is that in the relatively low bumper applications of some bight requirement of strength, lid 26/27 can be made by structural polymeric material.In addition, lid 26/27 can mould intrinsic color (plastics), or powder coating (plastics or metal), or chromium plating (plastics or metal), or covers to have outward appearance chromium or gloss or non-gloss (plastics or metal).Porose flange 48 forms along the edge of lid 26/27, is used to be connected to crossbeam 24 and angle bracket 23.Graphic porose flange 48 is L shaped, and is provided with along top, bottom, the edge (Fig. 2) inboard and the outside of lid 26/27.

Structural cover

26 and 27 shape and be connected the intensity that has increased the beam-end part widely with polygon edge between the crossbeam 24 are especially because the L shaped shape of lid and the opening form of beam-end.Yet, what it is contemplated that is, porose flange 48 can only need connect along three edges or along the edge that opposes, this depends on the requirement of strength of crossbeam 24 ends, and depend on the shape of beam-end and intensity (before the connection structure lid), and depend on requirement of strength and other functional requirements that is connected the intensity that disposes and depends on bumper assembly.

The existence of structural cover 26/27 has increased the design flexibility of polymeric beam 24 shapes widely, and having kept simultaneously provides high-intensity ability for crossbeam 24 ends.This is for corner impact, for step being provided on the top of beam-end and being important for other construction reasons.For example: there is the open area end that polymeric beam 24 can be formed in it, perhaps in its end thinner wall is arranged, and perhaps there are more open areas the end around it.More than these each all improved moldability, alleviated weight, and the shape and the structure that allow the product designer to come need customize by the client assembling crossbeam so that along the optimization of strength characteristics it of crossbeam specific region, and do not need to make complicated instrument.In addition, the instrument that is used for molded crossbeam 24 can be simplified by having eliminated at the needs of beam-end formation undercutting.In addition, the exposed surface of (promptly vehicular sideview appreciiable crossbeam that part of) has been eliminated on crossbeam outermost end surfaces in this design.It should be noted that, be difficult in and keep the special quality surface on the crossbeam outermost end surfaces, because difficultly keep pressure (be noted that the matched moulds direction, rather than perpendicular to the external side end surface of crossbeam) usually perpendicular to the front of crossbeam to plastics in direction perpendicular to the matched moulds direction.Carry one along band, notice that panel 25 can extend to cover the bottom front surface of crossbeam 24 ends downwards, still this can increase the expenditure of panel 25 certainly, and can change the outward appearance of this bumper/spoiler assembly set significantly.By using independently mould, ornamental trimming makes the degree of freedom of style bigger, otherwise since the cause of the complex geometric shapes of big part can be very complicated and be not easy moulding.

The preferred assembling sequence of member 21-27 is shown in Fig. 4-6.At first, draw bar 21 is connected to

carriage

22 and 23, and deep beam 24 is connected with fastener by screw and is fixed.Select required surface working (being japanning or chromium plating) for covering 26/27, then lid 26/27 is connected to deep beam 24, last, panel 25 is connected to this sub-portfolio part.The result be the modularization style that obtains having a great attraction according to the bumper/spoiler that needs chromium plating or japanning, and help the outward appearance of having assembled and provide attractive in appearance, even under the situation that has draw bar 21.In addition, the smooth step formation face that maybe can trample be formed on the recessed installation portion of licence plate below, and the step of projection is near the vehicle corner and be positioned at the next door and the top of the recessed installation portion of licence plate.

This arrangement makes crossbeam 24 be supported on securely on the vehicle frame best, is used to provide along the required resistance to impact level of crossbeam at the diverse location place.Panel 25 and

lid

26 and 27 cover crossbeam and are supported by crossbeam, and member 25-27 selects to carry out japanning or chromium plating for purpose attractive in appearance.Lid 26 and 27 is structural, and gains in strength when being fixed to the end of crossbeam 24, offers the intensity of hybrid beam with optimal at selection area, keeps low cost and low weight simultaneously.Draw bar 21 is done to replenish with crossbeam 24 associatings and for crossbeam 24 and is beneficial to overall strength under shock.General design is integrated well, and design flexible is provided, and has the functional character that is integrally molded in the crossbeam 24.

The bumper assembly 20A (Fig. 7-8) of remodeling is the rear bumper system, and it comprises the member 21A-25A that is similar to the above-mentioned member 21-25 that discusses.In bumper assembly 20A, similar with identical member and feature are used identical Digital ID, but many letters " A ", and doing like this is in order to reduce unnecessary narration.In bumper assembly 20A, structural cover 50A is an integrated support structure, and it has the horizontal expansion bar 51A with side cover part 26A/27A interconnection.Bar 51A extends below recessed centre portion 42A.In addition, a pair of mounting shell 53A is arranged among the recess 54A in the end cap part 26A/27A, is used to hold and supports turning indicator and/or the signal lamp that turns round.The connection structure that is used for this mounting shell can be the hook of global formation, or be formed among the cover 26A/27A and shape is suitable for other connection structure of engagement connection, perhaps can comprise being used for the porose flange of screw bonded assembly, and/or can comprise and be used for bonding surface.Panel member 25 by can japanning, mould intrinsic color or chrome faced material make.

The front bumper system 20B that Fig. 9-10 shows has also comprised many bumper assemblies 20 that show and the character of innovation of 20A in Fig. 1-8, comprise and to select member is carried out chromium plating and/or japanning, to realize the aesthetic appearance of distinctive especially " modularization style ".In bumper assembly 20B, similar with identical member and feature are used and Digital ID identical in

system

20 and 20A, but many alphabetical " B ".So just reduced unnecessary narration.

Hybrid bumper system 20B (Fig. 9-10) is disposed at the front portion of vehicle.Bumper assembly 20B comprises that bolt together is to the rack system 22B (being the beam installation bracket) of crossbeam 24B be used for beam tie bar 24B ' at vehicle frame upper support crossbeam 24B.Crossbeam 24B comprises the polymeric material transverse member of PC/PBT material, and pull bar 24B ' is the high-intensity crossbeam that is connected in the roll forming at its back side.Pull bar 24B ' can be made by material arbitrarily, comprises high strength steel (for example 80KSI) material and superhigh intensity (for example 120KSI or more than) material.Panel 25B is made of the upper and lower panel member 60B-61B that extends across bumper assembly.Graphic panel member 60B-61B extends, and extends along the length of crossbeam transverse member 24B ', and links together along overlapping abutting edge, and wherein each member covers the appropriate section of deep beam 24B.Structural cover 51B comprises integrally formed structural cover part 26B/27B, and structural cover part 26B/27B connects and cover the lower of crossbeam 24B, encases the end of crossbeam 24B.Cover 26B and 27B are L shaped, and are prolonging a plurality of edges (for example top, bottom, inboard and the edge outside) and be connected (referring to the flange among Fig. 2 48), thereby they have increased sizable intensity for the end of crossbeam 24B.What notice is, hybrid beam structure can be designed to have the structure that is similar at the hybrid crossbeam shown in Fig. 1-2, and wherein structural cover 26B and 27B are independent members.

Moulding part 24B comprises various integrally formed mounting structures and practical feature.For example, molded transverse member 24B ' comprises panel support wall 63B and supports surface with splice panel 25B for attractive in appearance and function.In addition, this molded transverse member 24B ' comprises integrally formed enhancing rib (for example vertical rib 64B, Figure 10) and surface undulation (for example horizontally extending fluctuating 65B), with the beam strength that is used to provide local, and also comprise crush box structures 66B and cellular structure, to be used for when flattening, absorbing impact energy.In addition, various mounting structures are integrally formed on the transverse member 24B ', comprise and be in porose boss or the hole that some positions are used for cylinder lever connecting rod 24B ' and rack system 22B, be used for fog lamp bonded assembly support 69B and structure and be provided for the curvilinear surface 70B that allows air to flow through and flow to the vehicle motor radiator.It is also noted that, panel member 60B and 61B also can comprise integrally formed structure, for example when combining, be formed for the hole of fog lamp 73B and/or the fitting surface of mounting structure, and (with the front edge of hood of vehicle) is formed for making air to flow to the surface of the expanded hole of vehicle radiator.

It should be understood that do not breaking away under the condition of the present invention design, can improve and change, in addition, it should be understood that design of the present invention is to be contained by subsequently claim, unless the statement of these claims spells out in addition to above-mentioned structure.

Claims

1. be used for the hybrid bumper system of vehicle, comprise: polymeric material deep beam with centre portion and end sections; Engage the rack system of deep beam securely, it is suitable for being connected to vehicle, is used for deep beam is supported on vehicle frame with stabilized conditions; Panel, it covers the top of deep beam at least; And structural cover, its connection and cover the part of this deep beam end at least, this structural cover is united with this end sections, so that bigger during the independent end sections of the intensity ratio of corner structure, and this structural cover comprises the visible surface that is not covered by panel.

2. bumper assembly according to claim 1, wherein, structural cover comprises the flange connector that is connected to described end sections along at least two neighboring edges of structural cover.

3. bumper assembly according to claim 2, wherein, structural cover comprises the flange connector that is connected to described end sections along at least three neighboring edges of structural cover.

4. bumper assembly according to claim 3, wherein, structural cover is L shaped, and is configured to extend along the front end surface and the outer end face of beam-end part.

5. bumper assembly according to claim 1, wherein, structural cover comprises that top, bottom, the inboard edge with the outside along structural cover is connected to the flange connector of end sections.

6. bumper assembly according to claim 1, wherein, structural cover is L shaped, and is configured to extend along the front end surface and the outer end face of beam-end part.

7. bumper assembly according to claim 1, wherein, panel with the lid at least one comprise with panel and the lid in another different surface treatment.

8. bumper assembly according to claim 1, wherein, structural cover is coated with the material of aesthetic property.

9. bumper assembly according to claim 1, wherein, structural cover is the mould intrinsic color.

10. bumper assembly according to claim 1, wherein, rack system comprises main Support bracket, also comprises the stabilizer bracket with the angled extension of main Support bracket.

11. bumper assembly according to claim 1, wherein, deep beam comprises that shape is suitable for admitting the recess of licence plate, and comprises the connection location that is used to connect licence plate.

12. bumper assembly according to claim 1 comprises the horizontal-extending bar, and wherein at least one in deep beam and the rack system comprises the structure that is used to engage and support this extension rod.

13. bumper assembly according to claim 12, wherein, described bar is draw bar and comprises the hole that is used to admit the tow ball coupling.

14. bumper assembly according to claim 1 wherein, comprises the pull bar that is fixed to deep beam.

15. bumper assembly according to claim 1, wherein, deep beam comprises integrally formed structure stand, is used for engaging and supporting the annex of selecting from the group that is made of vehicle identification plate illuminating lamp, fog lamp, Cornering Lamp, grid, stone protective cover and wire management clip.

16. be used for the bumper assembly of vehicle, comprise: hybrid deep beam, the L shaped structural cover components that it comprises the polymeric beam member and is fixed to the outer end portion of this polymeric beam member; Engage the rack system of deep beam securely, it is suitable for being connected to vehicle, is used for deep beam is supported on vehicle frame with stabilized conditions; Panel, it covers at least a portion of the centre portion of deep beam, and does not cover the visible part of L shaped at least structural cover components; And, at least one in panel and the structural elements comprise with panel and structural elements in another different surface treatment.

17. bumper assembly according to claim 16, wherein, the described surface treatment on structural cover components provides the chrome look surface.

18. be used for the bumper assembly of vehicle, comprise: draw bar; Engage the rack system of draw bar securely, it is suitable for being connected to vehicle to be used for that draw bar is supported on vehicle frame with stabilized conditions; Deep beam, it is connected to rack system and draw bar; Panel, it covers the part of deep beam; And structural cover, it is connected to the end sections of deep beam, to form structural corners with deep beam.

19. bumper assembly according to claim 18, wherein, structural cover has the top surface of relatively flat, and has enough intensity to be used to support the people who stands in above it.

20. bumper assembly according to claim 18, wherein, structural cover is L shaped.

21. bumper assembly according to claim 18, wherein, structural cover can be selected mould intrinsic color or plating, to have the surface of special color.