GB2506206A

GB2506206A - Sacrificial bracket and method of supporting a structure for vehicle headlight having sacrificial part

Info

Publication number: GB2506206A
Application number: GB1217111.2A
Authority: GB
Inventors: David Ballinger
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2012-09-25
Filing date: 2012-09-25
Publication date: 2014-03-26
Anticipated expiration: 2032-09-25
Also published as: GB201217111D0; GB2506206B

Abstract

A corner node bracket 140 for supporting a headlamp assembly (120, Figure 1) in a substantially fixed position with respect to a vehicle body structure (130, Figure 1). The bracket 140 comprises means 142 for coupling the bracket 140 to a vehicle body structure (130) and means 144 for coupling the bracket 140 to a vehicle headlamp assembly. The bracket 140 is configured to support the headlamp (120) and bumper (110, Figure 1) in a substantially fixed position relative to the vehicle body structure (130). The bracket 140 has a frangible portion 148 arranged to break upon impact of an object with the headlamp assembly (120) thereby to reduce or prevent damage to the vehicle body structure. A corresponding method is also disclosed. Preferably deflection means in the form of ramps 149 guide the headlight assembly (120) in a manner to reduce damage caused to a body part (130) during a vehicle collision.

Description

SACRIFICIAL BRACKET AND METHOD OF SUPPORTING A STRUCTURE

TECHNICAL FIELD

The present invention relates to motor vehicle mounting brackets. In particular but not exclusively the invention relates to a bracket for supporting a vehicle headlamp assembly.

Aspects of the invention relate to a bracket, to a method and to a vehicle.

BACKGROUND

It is known to provide a bracket for supporting a vehicle headlamp assembly. In one known arrangement, a bracket is provided that couples the headlamp assembly to a front wing (or fender') of the vehicle. Coupling the headlamp assembly to the front wing allows the relative positions of the headlamp assembly and wing to be fixed. This improves an aesthetic appearance of the vehicle and reduces the likelihood that the headlamp assembly and fender become misaligned in service. The front wing is in turn fixed to a body structure of the vehicle. The wing may be fixed to the body structure by welding, threaded fasteners or by other means.

In some other known arrangements, the headlamp assembly is coupled to a grille assembly of the vehicle.

In some vehicle designs it may not be possible or desirable to attach the headlamp assembly to a fender or to a hood. It is therefore desirable to provide an alternative arrangement for supporting a headlamp assembly.

SUMMARY OF THE INVENTION

Embodiments of the invention may be understood with reference to the appended claims.

Aspects of the present invention provide a support bracket, a vehicle and a method.

In one aspect of the invention for which protection is sought there is provided a sacrificial motor vehicle support bracket for supporting a headlamp assembly in a substantially fixed position with respect to a vehicle body structure, the bracket comprising means for coupling the bracket to a vehicle body structure and means for coupling the bracket to a vehicle headlamp assembly, wherein the bracket is configured to support the headlamp and bumper in a substantially fixed position relative to the vehicle body structure, the bracket further comprising a frangible portion arranged to break upon impact of an object with the headlamp assembly thereby to reduce or prevent damage to the vehicle body structure.

The bracket may therefore be or comprise a sacrificial component, the breaking of which reduces a risk of damage to one or more other components of the vehicle that would be more costly to repair or replace.

If, in contrast, the bracket were not frangible, an impact applied to the headlamp assembly would be transmitted directly to the vehicle body structure by the bracket. This could result in damage to the vehicle body structure which may be difficult and/or expensive to repair.

Advantageously the frangible portion may be provided between the means for coupling the bracket to a vehicle headlamp assembly and the means for coupling the bracket to a vehicle body structure whereby the portions are separable when the frangible portion breaks.

The bracket may advantageously comprise deflection means, the bracket being configured wherein in the event of an impact in which the headlamp assembly is urged in a direction towards the means for coupling the bracket to the vehicle body structure such that the frangible portion breaks, a direction of continued movement of the means for coupling the bracket to the headlamp assembly is changed by the deflection means thereby to prevent impact of the headlamp assembly with the vehicle body structure.

This feature has the advantage that in the event a front impact is suffered by the vehicle and the headlamp assembly is displaced towards the vehicle body structure (for example in a rearward direction), a trajectory of the headlamp assembly may be managed by the bracket such that a risk of damage to the vehicle body structure is reduced.

It is to be understood that in the event of a low speed front impact in which movement of the headlamp assembly takes place towards a vehicle body structure, movement of the assembly may be managed at least in part by the deflection means such that damage to the vehicle body structure does not occur. This is advantageous in reducing a cost of repair of the vehicle, and therefore a cost of ownership.

Advantageously the deflection means may comprise a buffer member arranged to impact a portion of the vehicle body structure upon fracture of the frangible portion and to be deflected away from said portion of the vehicle body structure.

The bracket may further comprise means for coupling the bracket to a vehicle front bumper.

The means for coupling the bracket to a vehicle body structure and/or the means for coupling the bracket to a vehicle headlamp assembly and/or the means for coupling the bracket to a vehicle bumper may comprise at least one selected from amongst an opening through which a fixing means may be passed, a tapped bore and a portion of a latch arrangement for latching to a corresponding portion provided by the component the bracket is to be attached to.

The fixing means may comprise a bolt, a screw or any other suitable fixing means.

In a further aspect of the invention for which protection is sought there is provided a motor vehicle comprising a bracket according to the preceding aspect, the bracket being coupled to the vehicle headlamp assembly and body structure thereby to support the headlamp assembly in a substantially fixed position with respect to the vehicle body structure.

Advantageously the bracket may be further coupled to the front bumper of the vehicle.

The vehicle may comprise a hood having a clamshell portion defining at least a portion of a front wheel arch, the front bumper extending rearwardly to meet the clamshell portion of the bonnet and defining the side of the vehicle forward of the clamshell portion.

In other words, the bumper and clamshell portion of the hood define the fender from the clamshell portion of the hood forward. Thus in some embodiments any separate fender component is provided rearward of the clamshell portion of the hood defining the portion of the front wheel arch. In some embodiments no separate fender component is provided, whether forward or rearward of the clamshell portion of the hood, the clamshell portion of the hood and the front bumper defining the side of the vehicle that might otherwise be provided by a fender.

In a further aspect of the invention for which protection is sought there is provided a method of supporting a headlamp assembly of a motor vehicle by means of a sacrificial bracket, comprising supporting the headlamp assembly in a substantially fixed position relative to a vehicle body structure by means of the bracket, in the event of a vehicle frontal impact the method comprising inducing yielding or breaking of a frangible portion of the bracket so as to reduce or prevent damage to the vehicle body structure.

Advantageously, in the event of a vehicle front impact the method may comprise deflecting a trajectory of the headlamp assembly thereby to prevent impact of the headlamp assembly with the vehicle body structure.

Within the scope of this application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying figures in which: FIGURE 1 is a perspective view of a vehicle according to an embodiment of the present invention incorporating a three-way corner node bracket; FIGURE 2 is a view of a corner node bracket according to an embodiment of the invention from above; FIGURE 3 is a perspective view of the corner node bracket of FIG. 2 as viewed in a rearward-looking direction with respect to an in-vehicle installed orientation; FIGURE 4 shows an underside of the bracket of FIG. 2; FIGURE 5 is a perspective view of the bracket of FIG. 2 coupled to a headlamp assembly; FIGURE 6 is a close-up view of the bracket as shown in FIG. 2 showing the coupling to the headlamp assembly in more detail; FIGURE 7 shows the bracket of FIG. 2 in an installed condition coupled to a shotgun structural member of a vehicle, a bumper and a headlamp assembly; and FIGURE 8 shows the bracket of FIG. 2 in the installed condition of FIG.7 from below.

DETAILED DESCRIPTION

FIG. 1 shows a vehicle 100 according to an embodiment of the present invention. The vehicle has a front bumper 110, headlamp assemblies 120 at front left and right corners of the vehicle 100 and a hood 130. The hood 130 is of clamshell type having side portions 132 that wrap around longitudinal side edges of the vehicle 100 at a rearward portion thereof to form part of a fender or wing of the vehicle 100. The side portions 132 of the hood 130 also define a portion of a front wheel arch 102 of the vehicle 100.

The left and right headlamp assemblies 120, bumper 110 and hood 130 share a common boundary at nodes 1 DON at respective left and right front corners of the vehicle 100.

FIG. 2 shows a non-limiting example of a corner node bracket 140 according to an embodiment of the invention that is incorporated in the vehicle 100. The bracket is shown as viewed in a forward looking direction, i.e. from behind the bracket with respect to its orientation as installed in the vehicle 100. The bracket 140 is formed from a glass-filled polybutylene terephthalate (PBT) material although other materials are also useful.

The bracket 140 is configured for attachment to a vehicle structural member in the form of an upper front longitudinal side member 150 as shown in FIG. 7. Structural member 150 may also be referred to as a shotgun member in vehicles having upper and lower front side longitudinal members, as in the present embodiment. It is to be understood that embodiments of the present invention are also useful in vehicles having only on front longitudinal side member or no front longitudinal side member provided a suitable structural member is available to which the bracket may be attached.

The bracket 140 has a generally rectangular basal portion 140B having vehicle structure fixing portions 142 provided along one longitudinal edge thereof. The fixing portions 142 include a pair of metal insert elements 142 each having a tapped bore 142B provided therein to facilitate attachment of the bracket 140 to the shotgun member 150.

At a midpoint of an opposite longitudinal edge of the basal portion 140B a headlamp assembly fixing portion 144 is provided. The fixing portion 144 comprises an aperture through which a bolt may be passed as shown in FIG. 2, enabling attachment of the bracket to a tang 122 of the headlamp assembly 120 (FIG. 5). As shown in FIG. 5 the tang 122 extends rearwardly from an upper edge of the headlamp assembly 120. In the embodiment shown the tang 122 is formed from a polypropylene material although other materials are also useful.

It is to be understood that other fixing elements are useful instead of or in addition to bolts.

The bracket 140 is provided with a pair of post elements 144F (FIG. 3) protruding upwardly from the basal portion 140B either side of the fixing portion 144. The post elements 144P are arranged to protrude through corresponding apertures 1 22A in the tang 122 of the headlamp assembly 120 which surrounds the post elements 144P (FIG. 6). The post elements 144P are arranged to limit rotation of the tang 122 about the fixing portion 144, thereby constraining movement of the headlamp assembly 120 with respect to the bracket 140.

In the embodiment illustrated, an arm portion 1 40A extends from a lateral edge of the basal portion 1 40B of the bracket 140. The arm portion 1 40A extends out of the plane of the basal portion 140B and supports a pair of bumper coupling elements 146 for coupling the bracket to the bumper 110. The coupling elements 146 define bores through each of which a fixing element may be passed to enable attachment of the bracket 140 to the bumper 110.

FIG. 3 shows the bracket 140 as viewed in a rearward-looking direction.

An underside of the bracket 140 is provided with an initiator feature 148 as shown in FIG. 4.

The initiator feature 148 is arranged to provide a stress raiser and a known point of buckling or crack initiation if loading exceeds a predetermined limit. The initiator feature 148 is in the form of a groove 148 in the basal portion 14DB. The initiator feature 148 is thus defined by a region of the basal portion 140B of reduced thickness. It is to be understood that in some arrangements the initiator feature 148 may buckle if the loading is between first and second limits, and fracture if the loading exceeds the second limit. Other arrangements are also useful.

The groove 148 defines a boundary between the vehicle structure fixing portions 142 and both the headlamp assembly fixing portion 144 and bumper coupling elements 146. Thus, in the event of an impact, the initiator feature 148 enables separation of the vehicle structure fixing portions 142 from both the headlamp assembly fixing portion 144 and bumper coupling elements 146. It is to be understood that, as a consequence, once the bracket 140 yields along the initiator feature 148 the headlamp assembly 120 is no longer constrained in a substantially fixed orientation with respect to either the shotgun member 150 or the bumper 110. Thus, in the event of an impact in which sufficient force is applied in a rearward direction to the headlamp assembly 120 to fracture the bracket 140 along the initiator feature 148, the headlamp assembly 120 may move rearwardly freely and apply either a reduced amount or substantially no force to the shotgun member 150.

In the embodiment shown, the groove 148 defines a boundary between the vehicle structure fixing portions 142 and the arm portion 1 40A. Other arrangements are also useful.

The basal portion 140B has an elongate, substantially rectangular cut-out portion 140C provided substantially perpendicular to the edge along which the vehicle structure fixing portions 142 are provided, the cut-out portion extending between the fixing portions 142.

The cut-out portion 140C is arranged to reduce an amount of force required to fracture of the crack-initiator feature 148 in the event of a front impact.

The underside of the bracket 140 also has a pair of deflector ramps 149 integrally moulded therein. The deflector ramps protrude downwardly from the basal portion 140B with respect to the in-use orientation shown in FIG. 7. The ramps 149 incline upwardly in a rearward direction to meet the initiator feature 148 such that in the event the bracket fractures at the initiator feature 148 due to rearward pressure on the headlamp assembly 120 and the headlamp assembly 120 moves rearwardly, the portion of the bracket 140 that remains attached to the headlamp assembly 120 will ride upwardly and over the shotgun member 150.

FIG. S shows the bracket 140 attached to a headlamp assembly 120. FIG. 6 is a close-up view showing the bracket 140 and headlamp assembly 120 including tang 122 in more detail.

FIG. 8 shows an underside of the bracket 140 as installed in the vehicle 100, showing the shotgun member 150 and headlamp assembly 120 including a portion of tang 122. The relative positions of the deflector ramps 149 and shotgun member 150 may be clearly seen.

As described above, in the event of a collision in which the headlamp assembly 120 is forced to move in a rearward direction towards the shotgun member 150, the basal portion 140B of the bracket 140 is arranged to yield at the initiator feature 148. This effectively creates a discontinuity in the load path between the headlamp assembly and the shotgun member 150. The relative position of the headlamp assembly fixing portion 144 with respect to the shotgun member 150, and the relative position of the bumper coupling elements 146 with respect to the shotgun member 150 are therefore no longer constrained by the bracket 140. The portion of the bracket 140 that is no longer coupled to the shotgun member 150 therefore continues to move rearwardly. As it does so, the deflector ramps 149 contact the shotgun member 150 (or the portion of the basal portion 140B still attached thereto) and ride upwardly, managing the foice applied to the shotgun member 150.

It is to be understood that because the shotgun member 150 is a structural component of the vehicle, reducing or preventing damage thereto in the event of a low speed impact may reduce a cost of repair of the vehicle 100. The cost of replacement of the bracket 140 would typically be considerably less costly than repair of the shotgun member 150.

Embodiments of the invention have the advantage that the relative positions of a headlamp assembly, bumper and a portion of the body structure of a vehicle may be constrained by means of a single bracket. Alignment of the headlamp assembly and bumper with respect to one another and with respect to the body structure of the vehicle may therefore be perfoimed in ielatively simple, quick and convenient manner Furthermore, relative movement of the headlamp assembly and bumper with respect to each other and with respect to the body structure in service may be prevented, preventing deterioration of an aesthetic appearance of the vehicle due to misalignment of these components.

Some embodiments of the present invention provide a frangible bracket for connecting a headlamp assembly to a vehicle body structure. In the event of a low speed impact the bracket fractures, relieving pressure placed on the body structure by the headlamp assembly as it is displaced rearwardly. This reduces a risk of damage to the vehicle body structure in the event of a low speed impact. The bracket may be shaped so that it rides up and over the vehicle body structure, changing the trajectory of the headlamp assembly following the impact.

The bracket may also connect the bumper to the vehicle body structure enabling the headlamp assembly and bumper to be connected to the vehicle body structure by means of a single component.

In an embodiment, the bumper may be connected to the bracket in such a manner that if the bumper is displaced rearwardly with respect to the vehicle, the bumper 110 may become disconnected from the bracket 140. For example the bumper 110 may be arranged to slide rearwardly with respect to the bracket 140 and so become disconnected therefrom. This feature has the advantage that, in the event the bumper 110 suffers a low speed impact with an object such as a fixed post, an amount of force exerted on the vehicle body structure (such as shotgun member 150) by the bumper 110 may be reduced. That is, the bumper does not remain connected to the bracket 140 and so force the headlamp assembly also to move rearwardly in the event of a front impact.

In some alternative embodiments in which the bumper 110 is fixedly attached to the bracket 140, and not arranged to become detached, rearward movement of the bumper 110 may also cause buckling or fracture at the initiator feature 148, reducing an amount of force associated with a collision that is transmitted to the shotgun member 150.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example comprising" and "comprises", means "including but not limited to", and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

S

Claims

CLAIMS: 1. A bracket for supporting a headlamp assembly in a substantially fixed position with respect to a vehicle body structure, the bracket comprising means for coupling the bracket to the vehicle body structure and means for coupling the bracket to the headlamp assembly, wherein the bracket is configured to support the headlamp and a vehicle bumper in a substantially fixed position relative to the vehicle body structure, the bracket further comprising a frangible portion arranged to yield or break upon impact of an object with the headlamp assembly thereby to reduce or prevent damage to the vehicle body structure.
2. A bracket as claimed in claim 1 wherein the frangible portion is provided between the means for coupling the bracket to a vehicle headlamp assembly and the means for coupling the bracket to a vehicle body structure whereby the portions are separable when the frangible portion breaks.
3. A bracket as claimed in claim 1 or claim 2 comprising deflection means, the bracket being configured wherein in the event of an impact in which the headlamp assembly is urged in a direction towards the means for coupling the bracket to the vehicle body structure such that the frangible portion breaks, a direction of continued movement of the means for coupling the bracket to the headlamp assembly is changed by the deflection means thereby to prevent impact of the headlamp assembly with the vehicle body structure.
4. A bracket as claimed in claim 3 wherein the deflection means comprises a buffer member arranged to impact a portion of the vehicle body structure upon fracture of the frangible portion and to be deflected away from said portion of the vehicle body structure.
5. A bracket as claimed in any preceding claim further comprising means for coupling the bracket to a vehicle front bumper.
6. A bracket as claimed in claim 5 wherein the means for coupling the bracket to a vehicle body structure and/or the means for coupling the bracket to a vehicle headlamp assembly and/or the means for coupling the bracket to a vehicle bumper comprises at least one selected from amongst an opening through which a fixing means may be passed, a tapped bore and a portion of a latch arrangement for latching to a corresponding portion provided by the component the bracket is to be attached to.
7. A motor vehicle comprising a bracket as claimed in any preceding claim, the bracket being coupled to the vehicle headlamp assembly and body structure thereby to support the headlamp assembly in a substantially fixed position with respect to the vehicle body structure.
8. A vehicle as claimed in claim 7 as depending through claim 5 wherein the bracket is further coupled to the front bumper of the vehicle.
9. A vehicle as claimed in claim 7 as claim 8 comprising a hood having a clamshell portion defining at least a portion of a front wheel arch, the front bumper extending rearwardly to meet the clamshell portion of the bonnet and defining the side of the vehicle forward of the clamshell portion.
10. A method of supporting a headlamp assembly of a motor vehicle by means of a sacrificial bracket, comprising supporting the headlamp assembly in a substantially fixed position relative to a vehicle body structure by means of the bracket, in the event of a vehicle front impact the method comprising inducing yielding or breaking of a frangible portion of the bracket so as to reduce or prevent damage to the vehicle body structure.
11. A method as claimed in claim 9, in the event of a vehicle front impact the method comprising the step of deflecting a trajectory of the headlamp assembly thereby to prevent impact of the headlamp assembly with the vehicle body structure.
12. A bracket, a vehicle or a method substantially as hereinbefore described with reference to the accompanying drawings.