CN101346259A - Vehicle bumper beam constructed of metal and plastic - Google Patents

Vehicle bumper beam constructed of metal and plastic Download PDF

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Publication number
CN101346259A
CN101346259A CNA2006800493356A CN200680049335A CN101346259A CN 101346259 A CN101346259 A CN 101346259A CN A2006800493356 A CNA2006800493356 A CN A2006800493356A CN 200680049335 A CN200680049335 A CN 200680049335A CN 101346259 A CN101346259 A CN 101346259A
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China
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parts
bumper assembly
vehicle
metal parts
metal
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CNA2006800493356A
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Chinese (zh)
Inventor
D·W·希瑟林顿
S·C·格拉斯高
B·W·莱昂斯
D·埃文斯
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Shape Inc
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Shape Inc
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Publication of CN101346259A publication Critical patent/CN101346259A/en
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Abstract

A bumper system for a vehicle comprising a stamped metal component and a second polymeric component fixedly attached to form a beam with particular localized energy absorber characteristics. The metal component is formed from a sheet and has a thickness in a width direction along a majority of the length when in a vehicle-mounted position. The second polymeric component engages a face of the first component and is rigidly attached to the first component in at least several locations along the length to form a structural beam with the first component. The second polymeric component has sufficient structure to form an integral part of the structural beam and interconnected walls extending in the width direction to form energy-absorbing cells at centered and corner locations configured to crush and absorb energy upon a vehicle impact.

Description

The vehicle bumper beam that constitutes by metal and plastics
CROSS-REFERENCE TO RELATED APPLICATIONS
The application requires to be filed in the U.S. Provisional Patent Application No.60/754 that is called " vehicle bumper beam that metal and plastics constitute " on December 27th, 2005,079 preceence.
Technical field
The present invention relates to a kind of endergonic efficiently bumper/spoiler design of when distortion between impact epoch.Application of the present invention comprises vehicle bumper system, side impact, instrument carrier panel cross bar substructure and sill plate (sill plate).
Background technology
Modern collision prevention girders is designed to absorb at given stroke the impact energy of maximum.Simultaneously, be designed to reduce the peak value of load, and when the load of being impacted to promote the mode that evenly reaches predictable flattening to come distribute energy.In addition, each parts of energy absorber system must combine with other energy absorbing member is fine.
Particularly, require the global facility of improvement with the bumper assembly of optimization Passenger motor vehicle.For example, many traditional modern vehicle bumper assemblies comprise the structural metal beam than rigidity, and this structural beams is directly connected between the chassis frame or combines suitably to locate and to make bumper assembly adapt to various terms of packings with the chassis frame extension bracket of centre.Typically, polymeric energy absorber is placed on the surface of beams of metal, with the space between padding girder and outside face or the stylized appearance surfaces, and provides additional energy management capabilities to the system of this combination.The structural metal beam of rigidity is intended to be used to provide main energy absorbing structure, and the poly-mer energy absorbing tube are configured as and are crushed when beginning to impact and absorb energy (also distribute stress).But, for along the shock absorbing capability of the specific location of the different piece of beams of metal and adjust beams of metal so that the system performance optimization is very difficult.Because beams of metal will often want " surdimensionnement " to satisfy minimum strength and the structure that requires along beam as main energy absorbing structure, this causes a lot of vertically sections firmer and heavier than needed.In addition, the manufacture method that some are economic as rolling forming, requires constant section and constant material thickness, and this makes the part of structure adjust difficulty.Owing to some reasons, this is bad.At first, than needed more crash-resistant vertical section needed heavier than it simultaneously.In addition, " too crash-resistant " section can cause that in fact impact energy passes to vehicle frame prematurely, causes otherwise the damage of evitable car body.Another reason relates to the space that bumper assembly consumes.Structural metal beam has occupied " packing " space, and this has reduced the available space of other object or has forced designer's design of vehicle to have bigger vehicle than desired littler design flexibility.In addition, structural metal beam has the flat greatly and front surface that is suitable for engaging and supporting softer plastic energy absorber traditionally, and this good crush characteristics for energy absorber is necessary.But, must form or form by bonded assembly accessory (for example being soldered to the punching press carriage of beams of metal) separately there being big front surface to mean on the structural metal beam by passing through the surface that complement operation (for example brill on the beams of metal end, cutting, welding and/or deformation operation) forms at the vehicle frame erecting device of the back of structural metal beam.Accessory and complement operation are expensive, time-consuming and undesirably increase manufacturing cost, and the quality control difficulty.
Summary of the invention
One aspect of the present invention provides a kind of bumper assembly of vehicle, and described vehicle has the vehicle frame of band chassis frame, and described bumper assembly comprises the metal parts and second parts.Metal parts has the opposed end and the length of the chassis frame that is suitable for being connected to vehicle frame.Second parts engage with the face of metal parts and are connected to metal parts rigidly in the some positions along the interface continuously or at least along public interface, to form structural beams with metal parts.Second parts comprise polymeric material and enough structures are arranged to form the integral part of structural beams, and having interconnective wall, described wall is crushed and endergonic energy absorption units (cell) when extension on the transverse width direction is configured at vehicle collision with formation.
Another aspect of the present invention provides a kind of bumper assembly of vehicle, and described vehicle has the vehicle frame of band chassis frame, and described bumper assembly comprises first parts and second parts.First parts have the opposed end and the length of the chassis frame that is suitable for being connected to vehicle frame.Second parts engage with the face of first parts and are connected to first parts rigidly, to form structural beams with first parts.Described second parts are molded into by the material that comprises poly-mer, and have and be configured to be crushed when Vehicular impact and endergonic energy absorption units, thereby have avoided the needs to the energy absorber that separates on the face of structural beams substantially.
Another aspect of the present invention provides a kind of bumper assembly that is used to have the vehicle of isolated chassis frame, and it comprises metal parts and polymer elements.Metal parts is formed by the plate of material, and the length of metal parts is enough and be suitable for extending between the isolated chassis frame of described vehicle.The feature of described metal parts is the more flat geometric configuration owing to metal parts, and therefore conduct independently makes described metal parts itself can not be used as the bumper/spoiler strength beam forwards to there not being good bending strength in the parts edge.The length of polymer elements approximates the length of described metal parts, and is fixedly connected to metal parts to form the bumper/spoiler strength beam from the supporting rigidity structure of bending resistance continuously or in a plurality of positions.Described polymer elements comprises and is configured to be crushed when receive impacting and endergonic a plurality of integrally formed energy absorbing section of extending forward.
Another aspect of the present invention provides a kind of method of making bumper assembly.Described method comprises first parts that form first material; Form second parts of second material, described first material is different with second material.Described method comprises that also the face with described second parts and described first parts is joined together, and on some at least positions of length described second parts is being connected to described first parts rigidly, to form a structural beams with described first parts.Described method also comprises to described second parts provides enough structure forming the integral part of structural beams, but also has the interconnective wall that broad ways is extended, and is configured to be crushed and endergonic energy absorption units when the car impact with formation.
Correspondingly, another aspect of the present invention comprises the bumper assembly that a kind of Passenger motor vehicle is provided, and described bumper assembly comprises: metal parts, it has opposed end, described opposed end have the chassis frame that is suitable for being connected to vehicle frame towards after installation surface; Second parts, it comprises the front that is located at metal parts and extends the poly-mer of at least one length of metal parts; The metal parts and second parts comprise antetheca and rear wall respectively, described antetheca and rear wall are fixed together along top margin and base, to form the mono-beam that length is enough extended between chassis frame, the antetheca of mono-beam and rear wall form tubular along at least one cross-sectional plane; Second parts also have a plurality of strengthening ribs that extend in the depressed part that contiguous this at least one cross-sectional plane limits by the mono-beam.
Another aspect of the present invention provides the described bumper assembly of top paragraph, has any one in the following characteristics: wherein said depressed part limits by metal parts at least in part; Wherein attachment face is a coplane; Wherein second parts also comprise one group of interconnective wall, and the position of described wall outside the car of metal parts opposed end forms the collapsed box that corner impact intensity is provided; Wherein second parts also comprise one group of interconnective wall, and the position of described wall outside the car of metal parts opposite end forms structure bight and bumper/spoiler shape; Wherein second parts comprise the wall thickness of the variation that is used to adjust local energy absorbing; Wherein second parts are injection mouldings; Wherein second parts comprise the integrally formed link that is used for plastic components is connected to metal parts; Wherein second parts folder thing is molded on the metal parts; Wherein metal parts stamps out; Wherein second parts and metal parts along being connected of top and bottom be mechanical; Wherein top margin and base comprise overlap joint parts (and want wherein to overlap parts comprise when in the vehicle installation site horizontally extending when being close to surface or overlap joint parts and being included in installation site vertically extension be close to the surface); Or wherein the top margin and one of the base qualification of second parts are used for along the recess of the flange connector of top margin and base reception metal parts.
Another aspect of the present invention provides the bumper assembly of Passenger motor vehicle, and this bumper assembly comprises: metal parts, and it has opposed end, and described opposed end has the installation surface that is configured to and is suitable for being connected to the chassis frame of vehicle frame; Be located on the metal covering and extend second parts of metal parts length at least with comprising; The metal parts and second parts comprise along top margin and base and being fixed together with antetheca and the rear wall that forms single beam that single beam is tubular along at least one cross-sectional plane, and enough length is arranged to extend between the vehicle frame; And second parts also have the end segments in the formation bight of the attachment face that extends beyond metal parts, and the end segments that forms the bight comprises and is configured to and is suitable for endergonic at least one group of interconnective rib when Passenger motor vehicle suffers the bight bump.
Another aspect of the present invention provides a kind of bumper assembly that is used for Passenger motor vehicle, this bumper assembly comprises: metal parts, it has the opposed end that limits in the face of the installation surface of vehicle, and described installation surface is configured to and is suitable for being connected to the chassis frame of vehicle frame; With comprise second parts that are located at metal parts fwd poly-mer; The metal parts and second parts comprise antetheca and the rear wall that is fixed together along top margin and base, to form the single beam that length is enough extended between chassis frame; Second parts also have the end segments that single-piece forms the bight, described end segments extend beyond metal parts and have be suitable for limiting the vehicle bight towards outer surface.
Another aspect of the present invention provides above-mentioned paragraph described bumper assembly, and it has in the following characteristics any one: wherein the surface of end segments is suitable for panel (fascia) is bearing on the vehicle; Or wherein the surface and the middle part outside face of second ends limit curve shape, and the outside of the surface ratio middle part outside face of its medial end portions is more to retreading.
Another aspect of the present invention provides the bumper assembly of Passenger motor vehicle, bumper assembly comprise have limit be configured as and be suitable for being connected to vehicle frame chassis frame, towards the metal parts of the opposed end of the installation surface of vehicle; With second parts that comprise the poly-mer on the face that is located at metal parts; Metal parts and polymer elements comprise antetheca and the rear wall that is fixed together along top margin and base, enough extend in mono-beam between the chassis frame to form length; Second parts also have roof and diapire and the enhancing wall that extends between roof and the diapire are arranged, and strengthen wall and are positioned at and are arranged to provide along centre portion and with bight along second parts different energy absorption characteristics is arranged.
Another aspect of the present invention provides earlier paragraphs described bumper assembly, and it has in the following characteristics any one: wherein antetheca, diapire and the thickness of enhancing wall are adjusted to different gauges to reach the energy absorbing of required amount; Its mesospore respectively is positioned to along a plane, and the plane of two walls is not a coplane; Or the sequential and energy absorbing profile that increases when wherein the enhancing wall in the stage casing has the trailing edge that separates with rear wall to impact to be created in.
Another aspect of the present invention provides a kind of bumper assembly that is used for Passenger motor vehicle, and this bumper assembly comprises: have the stamped metal parts that are shaped and are suitable for being connected to installation surface chassis frame, coplane of vehicle frame; With the injection moulding parts that comprise the poly-mer that engages with the face of metal parts; Injection moulding parts and metal parts comprise being fixed together along top margin and base and enough extend in mono-beam between the chassis frame to form length; And the injection moulding parts also have to small part pack into the metal parts of punching press be used for along beam predetermined vertical section to beam provide added strength, the monolithic molding part.
Another aspect of the present invention provides the bumper assembly of above-mentioned paragraph, has any of following characteristics: the monolithic molding of the stamped metal parts of wherein packing into partly includes the energy absorbing rib group of the rear surface that the rear wall with the stamped metal parts separates.
Another aspect of the present invention provides a kind of bumper assembly of Passenger motor vehicle, comprises the stamped metal parts of installation surface of coplane that have being configured as and be suitable for being connected to the chassis frame of vehicle frame; With injection moulding parts that comprise the poly-mer that engages with the face of metal parts; Injection moulding parts and metal parts comprise that having top margin and base is fixed together to form antetheca and the rear wall that length enough extends in the single beam between the chassis frame; The top margin of metal parts and base comprise a plurality of holes, and the top margin of injection moulding parts and base comprise that the projection that adult is shaped, projection extend through the head that hole and end band are fixed to projection the expansion in hole.
Another aspect of the present invention provides a kind of bumper assembly of Passenger motor vehicle, comprises the stamped metal parts of installation surface of coplane that have being configured as and be suitable for being connected to the chassis frame of vehicle frame; With injection moulding parts that comprise the poly-mer that engages with the face of metal parts; Injection moulding parts and metal parts comprise that having top margin and base is fixed together to form antetheca and the rear wall that length enough extends in the single beam between the chassis frame; The top margin of metal parts and base comprise a plurality of holes, and the top margin of injection moulding parts and base comprise that the projection that adult is shaped, projection extend through the head that hole and end band are fixed to projection the expansion in hole.
Another aspect of the present invention provides a kind of bumper assembly of Passenger motor vehicle, and it comprises: have being configured as and be suitable for being connected to the metal parts of punching press of installation surface of coplane of the chassis frame of vehicle frame; With the injection moulding parts that comprise the poly-mer that engages with the face of metal parts; Injection moulding parts and metal parts comprise that having top margin and base is fixed together to form antetheca and the rear wall that length enough extends in the single beam between the chassis frame; The top margin of the top margin of injection moulding parts and base protection metal parts and base make when bump; the top margin of metal parts and base are protected and can not open too early bending and intensity flattening, increase of opposing when the feasible mono-beam that so forms has collision.
Those skilled in the art can be understood of the present invention aspect these and other, purpose and characteristics behind specification sheets below having read, claims drawings attached.
Description of drawings
Fig. 1 is the top view of bumper assembly of the present invention;
Fig. 2 is the rear view of center beam of bumper of the present invention;
Fig. 3 is the front perspective view of center beam of bumper of the present invention;
Fig. 4 is the rear view of center beam of bumper of the present invention, and wherein the part of first parts of center beam of bumper is removed;
Fig. 5 is the back view of first parts of center beam of bumper of the present invention;
Fig. 6 is the front elevation of first parts of center beam of bumper of the present invention;
Fig. 7 is the back view of second parts of center beam of bumper of the present invention;
Fig. 8 is the front elevation of second parts of center beam of bumper of the present invention;
Fig. 9-9F is the sectional elevation figure that the embodiment of a plurality of beams that the connection that comprises multiple overlap joint arranges is shown;
Figure 10 is the transparent view of girder system system that the remodeling of the back metal parts that has punching press and injection molding poly-mer forepiece is shown, and wherein the poly-mer forepiece has a plurality of difform strengthening rib group of the energy absorbing section with adjustable energy absorbing characteristics of formation shown in Figure 10 A and 10B;
Figure 11 is the lateral plan of signal of forming method of making the bumper assembly of Figure 10, and wherein metal parts is located in the forming module of injection mold and is used for the polymer elements insert moulding to metal parts;
Figure 12 has the metal parts of engaged with vehicle and is connected on the metal parts top view with the signal of the bumper assembly of the alternative modified of the outer polymer elements that forms beam, wherein polymer elements has and forms interconnective rib group central authorities, collapsed box middle, the bight, and each unit is designed for especially in the concrete crush characteristics along the relevant position in central authorities, installation position and the bight of bumper assembly.
The specific embodiment
Here be illustrative purposes, term " on ", D score, " right side ", " left side ", " back ", " preceding ", " vertically ", " level " and their term of deriving should relate to the present invention as Fig. 1 orientation.But the present invention of Ying Ming can adopt the orientation of multiple replacement.Particularly, for the purpose of speech " preceding " and " back " are intended for use conveniently here, and be used for understanding specification sheets and claims, be to use the bumper assembly that is used in vehicle front or rear end but be intended to these terminological interpretations one-tenth with being equal to.The also embodiment that simply gives an example of the inventive concept that just in appending claims, limits in special apparatus and method shown in the drawings and that illustrate in the specification sheets below of Ying Ming.Relate to the specific dimensions of embodiment disclosed herein and other physical property and can not be considered as restrictively, be not like this unless claims clearly show.
The total expression of Reference numeral 10 (Fig. 1-4) is used for the bumper assembly of vehicle according to the present invention.In the example shown, bumper assembly 10 comprises first parts 12 and second polymer elements 14.The first parts mouth has the length (Fig. 6) and relative both ends 18 of the chassis frame 28 that is suitable for being connected to vehicle.First parts 12 are made by steel plate, and the most of broad ways along length 16 has thickness 20 in the vehicle installation site.Second polymer elements 14 engages the face 22 of first parts 12 and is connected to first parts 12 rigidly to form structural beams with first parts 12 at least some positions along length.Second polymer elements 14 has enough structures to form the integral part of structural beams, and the interconnective wall 24 that has broad ways to extend is configured as flattening and endergonic energy absorption units 26 when vehicle collision.Therefore moment of inertia and strength balance and optimization that geometric configuration by considering each parts and strength of material make system, have developed the mixed system of real single skin type.Bonded assembly intensity and impregnability are preferably enough transmitted load by the interface effectively between two parts, and under height distortion situation, keep the globality of structure.This allows the energy management functionality that new mixed system is carried out needed two or more parts that separate to carry out in the past.
In an illustrated embodiment, first parts 12 stamp out from having single thickness of material plate.Preferably, first parts 12 are formed from steel.For example, first parts 12 can be made by the ultra-high-tensile steel of two-phase 980MPa.But, expect that first parts 12 can be by the material manufacture of the performance that is similar to steel.In addition, first parts 12 preferably have the yield strength greater than 80KSI, and the yield strength greater than 170KSI is most preferably arranged.In addition, the height of first parts 12 and length dimension are bigger than depth dimensions.First parts 12 comprise the opposed end 18 of the chassis frame 28 that is suitable for being connected to carriage frame.First parts 12 also comprise the stage casing 30 that extends between the opposed end 18.First parts 12 also comprise extend along the length 16 of first parts 12, top flange 32 that apical pore 34 passes and the bottom flange 36 that has bottom outlet 38 to pass arranged.
There is the cross-sectional plane that is roughly C shape in opposed end 18 extensions of first parts 12 in the stage casing 30 of the first shown parts 12, and is connected to second polymer elements 14.Stage casing 30 comprise a top surface 40, a basal surface 42 and in the rear surface 44 of longitudinal slot 46 is arranged.Top surface 40 is connected to top flange 32 and extends downwards from pushing up protruding level 32 rearward face 44.The two ends of top surface 40 also comprise leg-of-mutton oblique angle part 48.Basic and the top surface 40 minute surface symmetries of basal surface 42, and be connected with bottom flange 36, and at both ends respectively comprises leg-of-mutton oblique angle part 50.The rear surface 44 of first parts 12 comprise a stage casing 52 and from the stage casing 52 with the extended pair of end portions section 54 of low-angle.Longitudinal slot 46 is arranged in stage casing 52 and end segments 54, longitudinal slot 46 has substantially parallel with the stage casing 52 of rear surface 44 the darkest regional 56 and be arranged in the end segments 54 of rear surface 44 and reach the opposed end 18 of first parts 12 and the pair of end portions zone 58 that narrows down gradually with groove 46.
Shown in example in, the opposed end 18 of first parts 12 is suitable for being connected with the chassis frame 28 of vehicle frame.End 18 is C shapes, and comprises and the top surface 40 bonded assembly top surfaces 60 in stage casing 30, and the basal surface 42 bonded assembly basal surfaces 62 in stage casing 30 and at the top surface 60 of end 18 and the back joint face 64 between the basal surface 62.Back joint face 64 comprises a plurality of holes of passing 66, be used to receive fastener with will back joint face 64 and therefore bumper assembly be connected to chassis frame 28.Back joint face 64 also comprises the recess 68 along its end edge.In an illustrated embodiment, end 18 is included in that three of inserting top surface 60 and joint face 64 places, back go up groove 70 and at three following grooves 72 that insert basal surface 62 and joint face 64 places, back.
The second shown polymer elements 14 is connected with first parts 12.Preferably, second polymer elements 14 is by the polymeric material manufacturing of injection molding engineering level.For example, second polymer elements 14 can be by the injected-formative plastic manufacturing.In addition, second polymer elements 14 can be by the compound manufacturing of the thermoplastic plastic of for example polycarbonate (PC) and polyester (for example PBT and PET).But, can expect that second polymer elements 12 can and can comprise non-polymer part (for example to small part be aggregated the molded carbon fiber that the thing material is wrapping) by any polymeric material manufacturing.In addition, the yield strength of first parts 12 is preferably greater than 80KSI, and is most preferably greater than 170KSI.
In an illustrated embodiment, second polymer elements 14 comprises roof 80, antetheca 82 and diapire 84.In an illustrated embodiment, roof 80 and diapire 84 are substantially parallel.Roof 80 is along the limit of contiguous first parts 12 and the flange 86 that two opposed side edges have setting.Roof 80 also comprise from roof 80 extend upward and with a plurality of big ribs of erectting 88 of flange 86 bonded assemblys, a plurality of size rib 90 and a plurality of riblet 92.Similarly, diapire 84 has edge and two flanges 94 that opposed side edges hangs along contiguous first parts 18 downwards.Diapire 84 comprise from diapire 84 extend downwards and with a plurality of big ribs 96 of flange 94 bonded assemblys of downward suspension, a plurality of size rib 98 and a plurality of small size rib 100.In an illustrated embodiment, the flange 94 of the flange 86 of setting and suspension downwards is connected respectively to the top flange 32 and the bottom flange 36 of first parts 12.In a preferred embodiment, the flange 86 of setting and the flange 94 that hangs downwards respectively comprise a plurality of perpendicular firmware 102 of the bottom outlet 38 of the apical pore of the top flange 32 of extend through first parts respectively and bottom flange 36.In an illustrated embodiment, a plurality of fasteners 102 comprise that wherein projection comprises heat staked heads from flange of erectting 86 and the flange 94 extended integrally formed projections that hang downwards.Alternately, or except that projection, available adhesive agent is connected to the 3rd parts 14 with first parts 12.In addition, fastener 102 can comprise rivet.Yet, can expect that first parts 12 can be connected by any way with second parts 14.For example, first parts 12 or second parts 14 can comprise a pair of U-shaped flange of facing, and on another the slided into band U-shaped vibrating part in first parts 12 and second parts 14.
The antetheca 82 of the second shown polymer elements 14 comprises first side channel 110 and second side channel 112.First side channel 110 and second side channel 112 respectively have the cross-sectional plane of the basic C shape that has each five parallel walls 114 of extending between the top of first side channel 110 and second side channel 112 and bottom.In addition, first side channel 110 and second side channel 112 respectively are included in the grill-shaped wall section 116 of extending between the top of two walls 114 and groove 110,112 and the bottom.Shown in Fig. 4 and 8, first side channel 110 and second side channel 112 two holes 118 that both comprise when first parts 12 are connected with second polymer elements 14 and 66 pairs in the hole of the back joint face of first parts 12 has.In addition, first side channel 110 and second side channel, 112 boths comprise that the permission instrument inserts first side channel 110 and second side channel 112 and is used for being connected and penetrates hole 118 and hole 66 inverted draw cut 120 and the kerve 122 with fastener that bumper assembly 10 and chassis frame 28 are coupled together.
In an illustrated embodiment, the wall 24 that forms energy absorption units 26 extends between the top of the following of roof 80 and first and second side channels 110,112 and between the bottom of the top of diapire 84 and first and second side channels 110,112.Therefore, shown in example in, the energy absorption units of organizing above 26 is limited by the part of the antetheca of two walls 24, second polymer elements 14 and the top of first side channel 110 or the top of second side channel 112.In addition, the energy absorption units of organizing below 26 is limited by the part of the antetheca of two walls 24, second polymer elements 14 and the bottom of first side channel 110 or the bottom of second side channel 112.Energy absorption units 26 is configured as and is crushed when Vehicular impact and absorbs energy.The second shown polymer elements 14 also is included in a plurality of energy absorption units 26 in the stage casing of second polymer elements.When observing from the rear portion in Fig. 8, the stage casing is included in the wall 24 that extends between the top of the top of first side channel 110 and second side channel one than the top.And the stage casing is included in the wall 24 that extends between the bottom of the bottom of first side channel 110 and second side channel one than the below.And in the wall 24 four extend between the top of the downside of roof 80 and diapire 84, to form nine energy absorption units 26 of grid form.
Shown in bumper assembly of the present invention 10 in, energy absorption units 26 is configured as and is crushed when vehicle collision and absorbs energy, therefore, needing to avoid energy absorber separately substantially on the face of bumper assembly 10.According to shown in Figure 1, bumper assembly 10 and the face 200 that covers energy system 10 form and do not comprise that energy absorber separately is located at the vehicle front parts on the face of second polymer elements 14.Face 200 and their vehicle to be connected those skilled in the art be known.In addition, first parts are formed by plate of material and length is enough and be suitable for extending between the chassis frame of separating 28 of vehicle.Because the geometric configuration that first parts 12 are more flat, therefore as the parts of independent usefulness, first parts 12 along forwards to characteristics be not have good bending strength.But, the polymer elements length of second polymer elements 14 approximate first parts length and a plurality of stationkeeping be connected to the center beam of bumper of the enhancing of the rigid construction of supporting certainly that first parts 12 form bending resistances.
Can understand under the situation that does not deviate from notion of the present invention, can make and change and remodeling said structure.For example, by the main portion of at first molded second polymer elements, in the second molded stage second polymer elements 14 is molded on first parts 12 then second polymer elements 14 is connected to first parts 12.Additionally, but the flange crimping of expecting first parts 12 on the flange of second polymer elements 14 and first parts 12 are connected to second polymer elements 14.In addition, the expection elastomeric material can insert one or more energy absorption units 26 to regulate the energy absorbing characteristics of bumper assembly 10.At last, expect that second polymer elements 14 can be molded as difformity and protect, makes gas channel to pass, make being connected folder, having the connection of single-piece panel, permission draw gear and hauling hook to be connected to vehicle frame and can having the plastics flattening awl on chassis frame to be used for improving airbag actuating adjustment of single-piece lampshade, live wire bundle with corner impact with the style that satisfies the bight.
Fig. 9-9F is the sectional elevation that multiple center beam of bumper embodiment is shown, and comprises that the various overlap joints that are used for first parts 12 and second polymer elements 14 are connected layout.Fig. 9 discloses the section of bumper assembly 10, and wherein the top flange connector of being close to 32,86 of first and second polymer elements and end flange connector 36,94 such difference as discussed above are vertically extended.Fig. 9 A-9C illustrates alternative method of attachment.
Fig. 9 A illustrates the layout that wherein first parts 12 and second polymer elements 14 do not comprise flange connector 32,36,86 and 94.Replace it, the roof 80 of second polymer elements 14 and diapire 84 overlap the top surface 40 and the basal surface 42 of first parts 12 respectively, and as are fixed together with mechanical device (owing to different metals and plastics are worked well) or with any other device that is suitable for real material (for example chemical bond or adhesive method).It should be noted that shown in Fig. 9 A be arranged in vehicle collision the time connecting device added shearing.But this is not a problem, because the too early crooked and flattening of first parts of bumper assembly 10 is avoided by 14 protections of second polymer elements in the surface 40 of first parts 12 and 42 therefore.In addition, second polymer elements 14 comprises energy absorption units and extends into recess, the interconnective strengthening rib group of first parts 12, this has reduced shearing (when energy absorption units and strengthening rib group engage with the interior rear wall of metal parts), and also helps to stablize the top surface 40 and the basal surface 42 of first parts 12.Fig. 9 B illustrates the different layout with Fig. 9 A, but the roof 80 of second parts 14 and diapire 84 be in the top surface 40 and basal surface 42 of first parts 12, and is fixed together.Note, owing to the same reason of beam shown in Fig. 9 A, this structure also enough forms a structural beams.
Fig. 9 C illustrates another bridging arrangement, wherein the roof 80 of second polymer elements 14 and diapire 84 respectively with the top surface 40 of first parts 12 and basal surface 42 overlap joints (as the embodiment of Fig. 9 B), and extend through in the top surface 40 of first parts 12 and the corresponding hole 302 in the basal surface 42 with 84 one-tenth single-pieces of roof 80 and diapire of second polymer elements 14, the projection 300 of at least one polymeric material.Fig. 9 D illustrates the enlarged drawing of the connection structure of Fig. 9 C, projection 300 wherein integrally formed, polymeric material is forced through the hole 302 in the surface 40,42 of first parts 12, and 304 being located on the projection 300 to form the such permanent connection of riveted joint of enlarging.Can expect that this layout can be obtained by diverse ways (for example using hot riveting).In addition, when using injection moulding, be that material can flow through hole 302 under fusing and the flowable situation at polymeric material.Can expect that also the edge of polymeric material can heat (or keeping enough heat) and make polymeric material to be pressed to reach in the hot hole 302 of flowing through so that second polymer elements 14 is bonded to first parts 12.
Fig. 9 E and 9F illustrate a bumper assembly 10 ', wherein energy absorption units 350 (for example one group of interconnective strengthening rib) selectively extend into first parts 12 ' inside face contact (Fig. 9 E), and selectively extend not with first parts 12 ' inside face contact (Fig. 9 F).For example, the layout of Fig. 9 F provides when impacting forwardly, the impact absorption profile of the order of step, and the layout of Fig. 9 E provides the high increase at once (just when impacting, energy absorption units begins to absorb energy immediately) of energy absorbing.In one embodiment, bumper assembly 10 ' can be configured to wherein laying out on the present installation surface of Fig. 9 E, and the middle part that lays out present metal and plastic components of Fig. 9 F.In addition, vertically the district is bigger at some for the gap shown in Fig. 9 F, and vertically distinguishes less (for example, when the energy absorbing that requires special order) at some.Expect that also special rib can be positioned at the layout at special interval (for example Figure 10 A) and maybe can be provided with special shape (for example Figure 10 B), will discuss as following.The gauge that Figure 10 B illustrates rib can change (thicker or thinner) or uneven (for example, tapered along length, it is shorter or inhomogeneous etc. to make length).Can expect bumper assembly 10 ' parts can connect with above-mentioned any method in conjunction with Fig. 9-9D.
Figure 10 illustrates back metal parts 12 with punching press ' and the transparent view of injection molding polymeric front component 14 bumper assembly 10 of remodeling " ".Polymeric front component 14 " has a plurality of difform strengthening rib group 400 with energy absorbing section 402 of adjusting energy absorbing characteristics of formation shown in Figure 10 A and 10B.Figure 10 A illustrates rib and is positioned at specific interval layout, as has the intermediate rib 404 of many (or few), or regular (or irregular) intermediate rib 404 at interval.In addition, rib also can be provided with special " customised " shape, shown in Figure 10 B.For example, rib 402a (thicker) and 402b (thin) can be made into vicissitudinous gauge, or rib 402c makes uneven (becoming the tapering of different angle along their length), or make length shorter (or inhomogeneous).In addition, rib 404 can extend (shown in Figure 10 A) or only extend (shown in Figure 10 B) in the part in this zone in the whole zone between rib 402.Note, can change rib 402 quickly by revising injection mold, make bumper assembly 10 " the specific region can adjust to specific desired impact absorption characteristics easily; even in the later stage of bumper/spoiler development project, polymeric material can change over more easily than metallic material has special energy absorbing characteristics.This reason is to add filler (as glass fibre or similar) in the polymers material.Perhaps, be used for the different metal sheet ratio of metal parts, buy polymeric material itself as long as the shorter delivery time of usefulness with purchase.
Figure 11 is a lateral plan of making the signal of the forming method at the middle part of bumper assembly among Figure 10, and wherein metal parts 12 " is located in the forming panel 500 of injection mould 502 and is located between the template 500.Method comprises that with on the plastic components 14 " folder thing be molded in metal parts 12 " part (as forming the box in projection 504 and hole) that melt polymer material flows to metal parts 12 " and surrounding metal parts 12 " forms and metal parts 12 with integral body " be connected.In addition, molded the making between plastics and metallic material of folder thing bonds.
", can avoid basic additional processing by stamped metal parts 12 with installation surface 600 with coplane.Particularly, can avoid the installation bracket of auxiliary joint vehicle frame is soldered to the needs of the rear wall of beams of metal.In addition, by means of injecting forming plastic parts 14 ", can avoid basic additional processing.Particularly,, can be at plastic components 14 as the part of shaping operation " go up and wholely form a plurality of additional parts, as be used for the part of hookup wire and lamp and at plastic components 14 " on licence plate.In addition, all (or to small part) connection characteristics can be integrally formed in plastic components 14 " on.
Figure 12 be metal parts 12 with engaged with vehicle " and being connected to metal parts 12 " ' on form the outer metal parts 14 bumper assembly 10 of replacement " ' " of bumper assembly ' the top view of signal, wherein plastic components 14 " ' have form the group of interconnective rib 700 that the middle part is flattened unit 702, center crush unit 704 and formed the flattening unit 706 in bight, these flatten unit and respectively are designed to along bumper assembly 10 " ' middle part, installation portion and bight position separately have special flattening feature.
Should understand that these above-mentioned notions plans are covered by following claims, are not like this unless claims clearly show.

Claims (29)

1. bumper assembly that is used for vehicle, described vehicle have the vehicle frame of band chassis frame, and described bumper assembly comprises:
Metal parts, it has the opposed end and the length of the chassis frame that can be connected to described vehicle frame; With
Second parts, it engages with the face of metal parts and is connected to metal parts rigidly in the some positions along the interface continuously or at least along public interface, to form structural beams with metal parts;
Described second parts comprise polymeric material and have enough structures to form the integral part of structural beams, and has an interconnective wall, described wall extends on the transverse width direction, to form energy absorption units, described energy absorption units is configured to be crushed when vehicle collision and absorb energy.
2. according to the bumper assembly of claim 1, it is characterized in that described metal parts is made greater than the material of 80KSI by yield strength.
3. according to the bumper assembly of claim 2, it is characterized in that described metal parts is made greater than the material of 170KSI by yield strength.
4. according to the bumper assembly of claim 1, it is characterized in that described metal parts is made by plate, and have the single thickness of major part on Width along length when time on the installation site at vehicle.
5. according to the bumper assembly of claim 1, it is characterized in that described second parts comprise the top flange and the bottom flange of the binding face that is connected to the coupling on the metal parts.
6. according to the bumper assembly of claim 5, it is characterized in that described second parts comprise a plurality of fasteners, described fastener is connected to described top flange and bottom flange the binding face of the coupling on the metal parts.
7. according to the bumper assembly of claim 6, it is characterized in that described a plurality of fasteners comprise from described top flange and the extended projection of bottom flange.
8. according to the bumper assembly of claim 7, it is characterized in that described projection integrally forms the part of described top flange and bottom flange; And the binding face of the coupling on metal parts comprises the hole, and described projection extends through described hole.
9. according to the bumper assembly of claim 1, it is characterized in that described second parts comprise a plurality of integrally formed projection that extends through the hole of mating in the described metal parts.
10. according to the bumper assembly of claim 9, it is characterized in that described projection comprises heat staked heads, described heat staked heads is retained to described metal parts with described second parts.
11. a vehicle end assembly, it is included in the bumper assembly that limits in the claim 1, and comprises the panel that covers the metal parts and second parts, and wherein said vehicle front parts does not comprise the energy absorber that separates on the face that is located at second parts.
12. the bumper assembly according to claim 1 is characterized in that, described metal parts comprises metal sheet, and described metal sheet punching press forms has the 3D shape of integrally formed attachment face, and described attachment face is configured to and is used to be connected to described chassis frame.
13. the bumper assembly according to claim 1 is characterized in that, the opposed end of described metal parts comprises the attachment face of coplane.
14. the bumper assembly according to claim 1 is characterized in that, described second parts comprise strengthening rib, and described strengthening rib extends upward in front and back when on the installation site at vehicle.
15. the bumper assembly according to claim 1 is characterized in that, described second parts comprise the end segments that forms the bight, and the direction of described end segments outside car extends beyond the opposed end of described metal parts.
16. bumper assembly according to claim 1, it is characterized in that, described second parts also comprise one group of interconnective wall, and described interconnective wall forms collapsed box at the car external position place of the opposed end of described metal parts, and described collapsed box is used to provide corner impact intensity.
17. the bumper assembly according to claim 1 is characterized in that, described second parts also comprise one group of interconnective wall, and described interconnective wall forms structure bight and bumper/spoiler shape at the car external position place of the opposed end of described metal parts.
18. bumper assembly according to claim 1, it is characterized in that, the described metal parts and second parts are included at least that some position is fixed together to form tubular antetheca, rear wall, roof and diapire, and wherein at least one in the energy absorption units extends in the described tubular inner chamber.
19. a bumper assembly that is used for vehicle, described vehicle have the vehicle frame of band chassis frame, described bumper assembly comprises:
First parts, it has the opposed end and the length of the chassis frame that can be connected to described vehicle frame; And
Second parts, its face with first parts engage and are connected to first parts rigidly, to form structural beams with first parts;
Described second parts are molded into by the material that comprises poly-mer, and have and be configured to when vehicle collision to flatten and endergonic energy absorption units, thereby have avoided the needs to the energy absorber that separates on the face of structural beams substantially.
20. the bumper assembly according to claim 19 is characterized in that, described second parts comprise a plurality of projections, and described projection has the hot formed heat staked heads that described second parts is connected to described first parts.
21. the bumper assembly according to claim 19 is characterized in that, described first parts are made greater than the material of 80KSI by yield strength.
22. the bumper assembly according to claim 21 is characterized in that, described first parts are made greater than the material of 170KSI by yield strength.
23. the bumper assembly according to claim 19 is characterized in that, described first parts are made up of metal, and are formed by plate.
24. the bumper assembly according to claim 19 is characterized in that, the height dimension and the length dimension of described first parts are bigger than depth dimensions.
25. the bumper assembly according to claim 19 is characterized in that, described first parts are connected with described second parts along the position of length in some at least tops and bottom.
26. a bumper assembly that is used for vehicle, described vehicle has isolated chassis frame, and described bumper assembly comprises:
Metal parts, its plate by material forms, and the length of described metal parts is enough to and can extend between the isolated chassis frame of described vehicle, the feature of described metal parts is because the more flat geometric configuration of metal parts, therefore conduct independently makes described metal parts itself can not be used as the bumper/spoiler strength beam forwards to there not being good bending strength in the parts edge; With
Second parts, it comprises polymeric material, the length of polymer elements approximates the length of described metal parts, and be fixedly connected to metal parts continuously or in a plurality of positions, to form the bumper/spoiler strength beam from the supporting rigidity structure of bending resistance, described second parts comprise a plurality of integrally formed energy absorbing sections of extending forward, and described energy absorbing section is configured to be crushed when receiving impact and absorb energy.
27. a method of making bumper assembly, described method comprises
Form first parts of first material;
Form second parts of second material, described first material is different with second material;
The face of described second parts and described first parts is joined together;
In some at least positions described second parts are connected to described first parts rigidly, to form structural beams with described first parts along length;
Provide enough structure forming the integral part of structural beams for described second parts, but also have the interconnective wall that broad ways is extended, to form energy absorption units, described energy absorption units is configured to be crushed when car impact and absorb energy.
28. the method according to claim 27 is characterized in that, described second material comprises poly-mer.
29. the method according to claim 27 is characterized in that, forms first parts and comprises punching press mono-metal sheet.
CNA2006800493356A 2005-12-27 2006-12-26 Vehicle bumper beam constructed of metal and plastic Pending CN101346259A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US75407905P 2005-12-27 2005-12-27
US60/754,079 2005-12-27
US11/614,294 2006-12-21

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101823467A (en) * 2010-04-08 2010-09-08 凌云工业股份有限公司 Front anti-collision beam of small car
CN103328273A (en) * 2010-11-04 2013-09-25 沙特基础创新塑料Ip私人有限责任公司 Energy absorbing device and methods of making and using the same
WO2014083926A1 (en) * 2012-11-30 2014-06-05 アイシン精機株式会社 Crush box
CN104010885A (en) * 2011-12-21 2014-08-27 乐金华奥斯有限公司 Bumper back beam with built-in fiber reinforced composite having hollow section, and bumper comprising same
CN104827996A (en) * 2014-10-22 2015-08-12 北汽福田汽车股份有限公司 Rear bumper energy-absorbing device of vehicle and vehicle
CN105691334A (en) * 2016-03-07 2016-06-22 北京航空航天大学 Bumper device integrally formed by metal/composite material
CN105705383A (en) * 2013-10-11 2016-06-22 沙普公司 Beam with varied bending moment, apparatus, and method
CN106132782A (en) * 2014-03-31 2016-11-16 沙特基础工业全球技术有限公司 Hybrid bumper and production and preparation method thereof
CN103328273B (en) * 2010-11-04 2016-11-30 沙特基础全球技术有限公司 Energy absorbing device and manufacture method thereof and include the automobile of energy absorbing device
CN108136986A (en) * 2015-10-16 2018-06-08 麦格纳国际公司 Crossbeam and the method for manufacturing crossbeam
CN108602481A (en) * 2016-01-20 2018-09-28 蒂森克虏伯钢铁欧洲股份公司 Vehicle bumper
CN111183298A (en) * 2017-10-05 2020-05-19 思锐特有限责任公司 Metallic impact-absorbing element for a motor vehicle and associated production method
US11603142B2 (en) 2014-06-16 2023-03-14 Sabic Global Technologies B.V. Structural body of a vehicle having an energy absorbing device and a method of forming the energy absorbing device

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101823467B (en) * 2010-04-08 2011-11-30 凌云工业股份有限公司 Front anti-collision beam of small car
CN101823467A (en) * 2010-04-08 2010-09-08 凌云工业股份有限公司 Front anti-collision beam of small car
CN103328273A (en) * 2010-11-04 2013-09-25 沙特基础创新塑料Ip私人有限责任公司 Energy absorbing device and methods of making and using the same
CN103328273B (en) * 2010-11-04 2016-11-30 沙特基础全球技术有限公司 Energy absorbing device and manufacture method thereof and include the automobile of energy absorbing device
CN104010885A (en) * 2011-12-21 2014-08-27 乐金华奥斯有限公司 Bumper back beam with built-in fiber reinforced composite having hollow section, and bumper comprising same
CN104010885B (en) * 2011-12-21 2016-06-29 乐金华奥斯有限公司 The bumper back beam of built-in fabric composite reinforcing material and bumper
WO2014083926A1 (en) * 2012-11-30 2014-06-05 アイシン精機株式会社 Crush box
CN105705383B (en) * 2013-10-11 2018-01-19 沙普公司 Beam, device and the method for bending moment with change
CN105705383A (en) * 2013-10-11 2016-06-22 沙普公司 Beam with varied bending moment, apparatus, and method
CN106132782A (en) * 2014-03-31 2016-11-16 沙特基础工业全球技术有限公司 Hybrid bumper and production and preparation method thereof
CN106132782B (en) * 2014-03-31 2018-01-02 沙特基础工业全球技术有限公司 Hybrid energy absorbs crossbeam, bumper module and correlation technique
US11603142B2 (en) 2014-06-16 2023-03-14 Sabic Global Technologies B.V. Structural body of a vehicle having an energy absorbing device and a method of forming the energy absorbing device
CN104827996A (en) * 2014-10-22 2015-08-12 北汽福田汽车股份有限公司 Rear bumper energy-absorbing device of vehicle and vehicle
CN108136986A (en) * 2015-10-16 2018-06-08 麦格纳国际公司 Crossbeam and the method for manufacturing crossbeam
CN108136986B (en) * 2015-10-16 2021-07-06 麦格纳国际公司 Cross member and method for producing a cross member
US11267416B2 (en) 2015-10-16 2022-03-08 Magna International Inc. Crossmember and method for manufacturing a crossmember
CN108602481A (en) * 2016-01-20 2018-09-28 蒂森克虏伯钢铁欧洲股份公司 Vehicle bumper
US10894521B2 (en) 2016-01-20 2021-01-19 Thyssenkrupp Steel Europe Ag Bumper for a vehicle
CN105691334A (en) * 2016-03-07 2016-06-22 北京航空航天大学 Bumper device integrally formed by metal/composite material
CN111183298A (en) * 2017-10-05 2020-05-19 思锐特有限责任公司 Metallic impact-absorbing element for a motor vehicle and associated production method
CN111183298B (en) * 2017-10-05 2022-04-08 思锐特有限责任公司 Metallic impact-absorbing element for a motor vehicle and associated production method
US11691580B2 (en) 2017-10-05 2023-07-04 Srt S.R.L. Metal shock absorption element for a motor vehicle and related production method

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