GB2554398A

GB2554398A - Bumper component attachment feature

Info

Publication number: GB2554398A
Application number: GB1616263.8A
Authority: GB
Inventors: Andrew Edge James; Harwin Neil; Woolcock Tim
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2016-09-26
Filing date: 2016-09-26
Publication date: 2018-04-04
Anticipated expiration: 2036-09-26
Also published as: GB2554398B; GB201616263D0; WO2018055154A1

Abstract

An extruded component 200 for mounting a bumper component of a bumper assembly to a vehicle (Fig 1, 100), wherein the extruded component 200 is securable to the vehicle and comprises an elongate portion extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and defining an internal channel portion 210 of the extruded component, and at least two extruded attachment features 202 to which fixings for the bumper component are attached to secure the bumper component to the extruded component.

Description

(54) Title of the Invention: Bumper component attachment feature

Abstract Title: An extruded component for mounting a bumper component of a bumper assembly (57) An extruded component 200 for mounting a bumper component of a bumper assembly to a vehicle (Fig 1, 100), wherein the extruded component 200 is securable to the vehicle and comprises an elongate portion extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and defining an internal channel portion 210 of the extruded component, and at least two extruded attachment features 202 to which fixings for the bumper component are attached to secure the bumper component to the extruded component.

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Bumper Component Attachment Feature

TECHNICAL FIELD

The present disclosure relates to a bumper component attachment feature and particularly, but not exclusively to an extruded component of a bumper assembly for a bumper component attachment feature in a vehicle. Aspects of the invention also relate to a bumper assembly comprising an extruded component for bumper component attachment, and additionally to a vehicle comprising a bumper assembly, which comprises an extruded component for bumper component attachment.

BACKGROUND

Typically, a rear side of a vehicle equipped for bumper component attachment, such as for a tow bar or rear bumper armature, comprises a casting which provides attachment points to the vehicle bumper assembly. The casting includes inserts for bolting the bumper component to the vehicle bumper assembly. A casting for bumper component attachment may also need to have a bar protruding outwardly as a manufacturing aid.

Current bumper component attachment castings present a number of shortcomings which it would be advantageous to address. In the first place, bumper component attachment castings are manufactured such that the wall thickness is not typically constant over a given area. Furthermore, castings are generally constrained by casting die angles which often lead to flared rear longitudinals that are difficult to press. Unless the wall thickness is carefully considered at each rivet point, this feature of castings results in the requirement of multiple rivet guns being developed specifically for each material thickness combination.

In addition, it is necessary for castings to include ribs to counter large moment arms arising from heavy loads applied to the casting. However, this often adds significant weight to the casting. Furthermore, it can be difficult to increase the towing load capabilities of a casting without in turn increasing casting size or complicating the casting design, resulting in additional parts, material or production equipment being required.

Due to these and similar considerations, the design of the casting may constrain and intrude on other elements of the rear of the vehicle, such as exhaust movement envelopes, and therefore often these other elements may need to be redesigned and changed to cater for the casting.

The present invention has been devised to mitigate or overcome at least some of the above-mentioned problems.

SUMMARY OF THE INVENTION

According to an aspect of the present invention there is provided an extruded component for mounting a bumper component of a bumper assembly to a vehicle, wherein the extruded component is securable to the vehicle and comprises an elongate portion extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and defining an internal channel portion of the extruded component, and at least two extruded attachment features to which fixings for the bumper component are attached to secure the bumper component to the extruded component.

In addition, the rearward end of the internal channel portion may define an opening provided with a plurality of extruded attachment features provided in at least two opposed corners of the opening. Optionally, the extruded two attachment features are provided in horizontally aligned corners of the opening.

In addition, the opening may be provided with at least four extruded attachment features, each attachment feature being provided in a corner of the opening.

Furthermore, the internal channel of the extruded component may comprise at least one further attachment feature on the underside of the extruded component to which a fixing of the bumper component is attached to secure the bumper component to the extruded component. Advantageously, this allows the bumper component to be attached to a longitudinal member of the vehicle.

Optionally, each extruded attachment feature is defined by a cylinder extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and into the internal channel portion of the extruded component.

Additionally, the internal channel portion of the extruded component may be provided with at least one recessed area immediately behind each of the extruded attachment features, such that unnecessary extruded material is removed, reducing the weight of the extrusion.

Optionally, the internal channel portion of the extruded component comprises side walls of substantially uniform thickness.

According to another aspect of the invention there is provided a bumper assembly comprising at least one extruded component as described above, and the bumper component.

According to yet another aspect of the invention there is provided a vehicle comprising a bumper assembly as described above.

Additionally, a vehicle may also be provided having a bumper assembly, wherein the bumper assembly comprises a first extruded component on one side of the rear face of the vehicle and a second extruded component located on an opposing side of the rear face of the vehicle.

Furthermore, the bumper component may extend across the width of the vehicle rearward of the extruded component, wherein the bumper component is mounted to the first and second extruded components.

Optionally, the bumper component is a tow bar comprising a tow bar attachment for a trailer to be towed by the vehicle.

Alternatively, the bumper component may be a rear bumper armature comprising an element extending across the width of the vehicle mounted to the first and second extruded components. However, optionally the rear bumper armature may also comprise a first element extending across the width of the vehicle coupled to two secondary elements mounted to the first and second extruded components.

Within the scope of this application it is expressly intended 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. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

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 drawings, in which:

Figure 1 illustrates a vehicle comprising first and second extruded components for bumper component attachment, according to an embodiment of the invention;

Figure 2 illustrates bumper component attachment points of an extruded component, according to an embodiment of the invention;

Figure 3 is a rear-facing view of a tow bar attachment mounted to an extruded component as in Figure 2;

Figure 4 is an underside-view of the tow bar attachment mounted to the extruded component as in Figures 2 and 3;

Figure 5 is a rear-facing view of a vehicle with a tow bar mounted to an extruded component as in Figures 3 and 4;

Figure 6 is a rear-facing view of rear bumper armature mounted to an extruded component according to an embodiment of the invention;

Figure 7 is an underside-view of a rear bumper armature mounted to an extruded component as in Figure 6;

Figure 8 is a rear-facing view of the rear side of a vehicle with rear bumper armature mounted to an extruded component as in Figures 6 and 7.

DETAILED DESCRIPTION

For the purpose of the following description, reference to the front and rear of the vehicle, and forwardmost and rearmost, shall be taken in the context of a vehicle facing in the normal direction of travel moving forwards.

Figure 1 illustrates a vehicle 100 having a vehicle bumper assembly 101 mounted at the rear of the vehicle to provide an impact absorber for the vehicle in the event of a collision with another object or vehicle. The vehicle bumper assembly comprises first and second extruded components (not visible in Figure 1), hereinafter referred to as “extrusions” of the vehicle bumper assembly, which are provided to enable components of the vehicle bumper assembly to be mounted to the vehicle. Typically, the bumper component may take the form of what is commonly referred to as “bumper armature”, which is a bumper component which extends across the width of the vehicle to provide strength and resistance to impact forces. Alternatively, the bumper component may refer to a tow bar, when the rear bumper armature is replaced with a tow bar. As such, the term bumper component as used herein refers to either rear bumper armature or a tow bar, and the alternative embodiments of the invention comprising either rear bumper armature or a tow bar are discussed in more detail below.

The vehicle bumper assembly further includes a bumper skin 102 which provides a cover for various other features of the vehicle bumper assembly so as to ensure the vehicle maintains an aesthetically pleasing appearance even when the vehicle bumper assembly is attached thereto. The extrusions are located under the bumper assembly skin 102, in positions indicated by the circled areas 104 and 106. The extrusions may be made of robust material, adverse to warping and bowing, such as tapped aluminium.

Figure 2 shows an extrusion 200 of the vehicle bumper assembly located on the rear left-hand side of a vehicle. The extrusion defines a rear-facing opening 204 provided with four extruded attachment features or points 202 to which fixings for a bumper component, such as nuts and bolts or rivets, are attached in order to secure the bumper component to the extrusion 200. One attachment point is provided in each corner of the opening 204. For the purpose of the following description only one extrusion will be described, although it will be appreciated that a similar extrusion is provided on the right-hand side of the vehicle, albeit with any relevant adjustment for being on the right side of the vehicle as opposed to the left. In other embodiments of the invention it is envisaged that the vehicle may comprise a greater number than two extrusions, depending on the requirements of the bumper component to be secured to the vehicle.

Likewise, the number of attachment points should not be considered limiting, and it is possible to provide a greater or lesser number of attachment points 202. For example, in one embodiment of the invention, two of the four extruded attachment points 202 may not be required for attachment of the rear bumper armature, as will be described in further detail below. In the embodiment of the invention where there are at least two extruded attachment points 202 provided, the extruded attachment points 202 are present in either horizontally or diagonally opposing corners of the opening 204.

The extrusion 200 extends from the opening 204 along a longitudinal direction of the vehicle, defining an internal substantially hollow area. The hollow area of the extrusion defines an internal channel 210 of the extrusion 200 which provides accommodation space to allow for elements of the bumper component to extend into the extrusion 200. The floor of the extrusion 200 aligns with a lower wall of a rear longitudinal (not shown) of the vehicle, where the rear longitudinal comprises a longitudinal element extending forwards in the vehicle, which defines a channel for receiving the extruded component. The floor of the extrusion 200 and the corresponding lower wall of a rear longitudinal are provided with one or more additional attachment features 218 to allow any elements of the bumper component which extend into the channel 210 to be attached to the extrusion 200, allowing a secure fixing to the vehicle via the additional attachment features 218 in addition to attachment via the extruded attachment points 202. This allows the bumper component to be secured more fixedly to the extrusion 200, and to the vehicle, where the additional attachment features 218 contribute to the load-bearing potential of the bumper assembly and aid load transfer from the extrusion 200 to the main vehicle structure, such that rear recovery load or tow load requirements may be met without necessitating an increase in the size and area of the extrusion 200. As such, the additional attachment features 218 thus also reduce the moment arm applied to the extrusion 200 by any load disposed by a bumper component.

Furthermore, the channel 210 being substantially hollow reduces the weight and material required for the extrusion. The configuration of the cross-sectional area of the extrusion 200 of the embodiment of Figure 2 is shown as a right-angled trapezoid. However, in other embodiments of the invention, other cross-sectional areas may be envisaged.

The extruded attachment features 202 are defined by longitudinally extending cylinders 206, comprising openings 208, for insertion of fixings, such as bolts, which secure the bumper component to the extrusion and the vehicle. In one embodiment of the invention the openings 208 of the attachment points 202 are internally threaded for interlocking with an externally threaded bolt for bumper component attachment. This avoids any requirement for additional steel fixings and also allows for the offset distance 222 to the side walls of the rear longitudinals to be minimised. In minimising the offset distance 222, the moment applied to the extrusion 200 and thus to the vehicle is reduced, in turn reducing high stress forces being applied to the extrusion 200, which may potentially weaken the extrusion material.

In the embodiment of the invention illustrated in Figure 2, the longitudinally extending cylinders 206 which define the extruded attachment points 202 do not extend along the full longitudinal length of the extrusion 200, such that each cylinder is located just at the rearmost end of the channel 210, that being the end towards the rear of the vehicle. Typically, the longitudinally extending cylinders 206 may be cut away at a longitudinal distance from the opening 204 of approximately 2-3 times the prescribed bolt diameter. However, this is not limiting and the length of the longitudinally extending cylinders 206 may be dependent on a number of design or load-bearing constraints. The internal threading of the extruded attachment points 202 may be present through the whole length of the longitudinally extending cylinders 206, or may only extend through part of the length of the longitudinally extending cylinders 206.

At the forwardmost end of each cylinder (immediately behind each cylinder in the orientation shown in Figure 2), the cylinder is cut away to define a recessed area 220 which opens into and communicates with the channel 210 of the extrusion, with the recessed areas 220 extending in a longitudinally parallel direction to the cylinders 210. By recessing the areas 220 immediately behind each of the extruded attachment features 202, the weight of the extrusion is reduced and the amount of material required when forming the extrusion 200 is also reduced.

The side walls of the extrusion 200 may be coupled to the bumper assembly. In the embodiment of the invention shown in Figure 2, the extrusion 200 is coupled to the inner longitudinal side walls of rear longitudinals (not identified) of the vehicle via a plurality of couplings 212. Typically the couplings 212 may be rivets. The longitudinals thus act to transfer loads from the extrusion 200 into the vehicle, and additionally to absorb energy during high-speed impacts. By virtue of the extrusion process, the side walls of the extrusion 200 are of constant thickness, where the appropriate thickness for the extrusion 200 can be selected during the manufacturing process. Having walls of the extrusion 200 of constant thickness, and thus a simple extruded shape, aids the stamping feasibility of the rear longitudinals as the extrusion 200 is placed adjacently to the rear longitudinals and coupled via the rivets. It is not necessary for the longitudinal length of the extrusion 200 to be the same as that of the rear longitudinals of the vehicle, and the longitudinal length of the extrusion 200 may be dependent on the load-bearing requirements of the bumper components to be fitted thereto.

As can be seen in Figure 2, the extrusion 200 is fitted within an opening of a back panel 214 of the bumper assembly, where the extrusion 200 has a raised profile in comparison to that of the back panel 214, such that the extrusion 200 projects through the opening of the back panel 214, around its perimeter defining a lip of the extrusion 200. As such, a bumper component attachment (not shown) may clamp directly to the extrusion material which is resistant to local deformation and hence an appropriate material for use in bolted joints. Furthermore, the shape of the extrusion 200 allows for the back panel 214 to be shaped such that space for the exhaust envelope is provided conveniently by the recess 216. The back panel 214 may be made of an aluminium sheet.

As mentioned previously, a second extrusion for attaching a right-hand side component of the bumper assembly to the vehicle may be located on the rear righthand side of the vehicle, the second extrusion having a symmetrically mirrored configuration to that of the extrusion 200 shown in Figure 2.

Figure 3 illustrates an alternative embodiment of the invention, in a view from the rear, of a bumper component in the form of a tow bar 300 mounted onto the extrusion 300. The tow bar 300 is an elongate component which extends across the width of the vehicle and is provided with a tow hitch for allowing a trailer for the vehicle to be coupled thereto. The tow bar 300 is coupled to the extrusion 300 via extruded attachment points 302, as discussed for the previous embodiment. The attachment points 302 are located one above the other in Figure 3, with two other attachment points 302 not being visible. The two attachment features 302 which are not shown are located substantially horizontally parallel to those that are visible, and are located behind a horizontally extending element 304 of the tow bar 300. The tow bar attachment points 306 on an end plate 308 of the tow bar comprise bolts interlocked with the extruded attachment points of the extrusion 302.

As described previously for the bumper armature, the tow bar 300 is coupled to the extrusion 302 via additional attachment points (not shown in Figure 3) located in the lower wall of the channel defined in the extrusion 300 to allow coupling to the rear longitudinal of the vehicle, which cannot be seen in Figure 3.

Figure 4 is an underside-view of the tow bar 300 when coupled to the extrusion 302 where additional attachment points 400 on the rear longitudinal can be seen. The tow bar attachment points 400 on the lower wall 402 of the rear longitudinal 404 are aligned with the corresponding attachment points (not identified in Figure 4) such that a bolt may be secured through the points to couple the extrusion 400 to the tow bar 300. This additional attachment feature is provided via threaded bolts interlocked with weld nuts in the tow bar assembly.

Figure 5 shows a view from the rear of a vehicle 500 according to an embodiment of the invention, the vehicle comprising extrusions, as in Figures 3 and 4, on both the right-hand and left-hand side of the vehicle for attachment of a tow bar 502. The tow bar extends across the width of the vehicle and is mounted to first and second extrusions on the right-hand and left-hand side of the vehicle, respectively. The tow bar comprises a tow bar attachment 506 for a trailer to be towed by the vehicle, which as can be seen in Figure 5 is located in the middle of the width of the tow bar 502, equidistant from the first and second extrusions. Equal force from a tow load is therefore applied to the first and second extrusions, thus supporting the stability of both the vehicle and the trailer towed by the vehicle.

Figure 6 illustrates an alternative embodiment of the invention, in a view from the rear, of a bumper armature 600 mounted to an extrusion 602. The rear bumper armature 600 is coupled to the extrusion via extruded first and second attachment points 604, but with two further attachment points 606 of the extrusion (located substantially vertically parallel to the other two) not in use. The extruded attachment point which cannot be seen in Figure 6, and which is not in use by the rear bumper armature 600, is located in Figure 6 behind a horizontally extending element 608 of the rear bumper armature 600. The rear bumper armature 600 needs only to be coupled via the extrusion and does not need to be coupled to the back panel 608 of the bumper assembly.

The rear bumper armature 600 is coupled via externally threaded bolts, which are interlocked with the internally threaded openings of the extruded attachment points of the extrusion 602, where the extruded attachment points are projected forward through the opening of the back panel 610 such that they have a raised profile with respect to that of the back panel 610, as is described for previous embodiments.

The rear bumper armature attachment 600 is also coupled to the extrusion via additional attachment features located in the internal channel portion (not shown) of the extrusion 602, and positioned in the floor of the extrusion and the corresponding lower wall of the rear longitudinal. An element of the rear bumper armature 600 extends into the internal channel portion of the extrusion 602, and is fixed adjacently to the lower wall of the extrusion. This is shown in Figure 7, and described in more detail below.

Figure 7 is an underside-view of rear bumper armature 600 mounted to an extrusion 602 of a vehicle bumper assembly. The rear bumper armature is mounted via two extruded attachment points 604, which define an opening of the extrusion, and is also mounted via additional attachment features 700 which are located on, and extend through, the lower wall of the internal channel portion of the extrusion and correspondingly on the lower wall of the rear longitudinal 702, such that an element of a bumper component may be attached to the extrusion 602. The additional attachment features 700 provide coupling via clearance holes in the lower wall of the rear longitudinal 702 and extrusion 602, into weld nuts in the bumper assembly.

Figure 8 shows a rear-facing view of a vehicle 800 according to an embodiment of the invention, the vehicle comprising extrusions 802, as in Figures 6 and 7, on both the right-hand and left-hand side of the vehicle for attachment of rear bumper armature 804. The rear bumper armature extends across the width of the vehicle and is mounted to first and second extrusions on the right-hand and left-hand side of the vehicle, respectively. The rear bumper armature is therefore secured to the vehicle bumper assembly 806.

As described by the above embodiments of the invention, bumper components for attachment to the extrusion are coupled to an extruded component having extruded attachment points, and to the additional attachment points located within the internal channel portion of the extrusion. Thus the extrusion provides a reduced clamping area in comparison to traditional casting designs, where the clamping area of the extrusion is sufficient to support a load which would have required a much larger clamping area necessary for a casting design. Embodiments of the invention described above present a compactly-packaged extrusion providing both extruded and internal attachment points for a bumper component, which also may reduce torque applied to the vehicle during towing. A manufacturing benefit is also achieved due to the convenience of the extrusion process.

Many modifications may be made to the above examples without departing from the scope of the present invention as defined in the accompanying claims.

Claims

1. An extruded component for mounting a bumper component of a bumper assembly to a vehicle , wherein the extruded component is securable to the vehicle and comprises an elongate portion extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and defining an internal channel portion of the extruded component, and at least two extruded attachment features to which fixings for the bumper component are attached to secure the bumper component to the extruded component.

2. The extruded component of Claim 1, wherein a rearward end of the internal channel portion defines an opening provided with a plurality of extruded attachment features provided in at least two opposed corners of the opening.

3. The extruded component of Claim 2, wherein two extruded attachment features are provided in horizontally aligned corners of the opening.

4. The extruded component of Claim 2 or Claim 3, wherein the opening is provided with at least four extruded attachment features, each attachment feature being provided in a corner of the opening.

5. The extruded component of any preceding claim, wherein the internal channel portion comprises at least one further attachment feature on the underside of the extruded component to which a fixing of the bumper component is attached to secure the bumper component to the extruded component.

6. The extruded component according to any previous claim, wherein each extruded attachment feature is defined by a cylinder extending along a longitudinal direction of the vehicle forward of the bumper assembly, in use, and into the internal channel portion of the extruded component.

7. The extruded component according to any previous claim, wherein the internal channel portion of the extruded component is provided with at least one recessed area immediately behind each of the extruded attachment features.

5

8. The extruded component of any preceding claim, wherein the internal channel portion of the extruded component comprises side walls of substantially uniform thickness.

9. A bumper assembly comprising at least one extruded component as claimed in any

10 of Claims 1 to 8, and a bumper component.

10. A vehicle comprising a bumper assembly as claimed in Claim 9.

11. The vehicle of Claim 10, wherein the bumper assembly comprises a first extruded

15 component on one side of the rear face of the vehicle and a second extruded component located on an opposing side of the rear face of the vehicle.

12. The vehicle of Claim 11, wherein the bumper component extends across the width of the vehicle rearward of the extruded component, and wherein the bumper

20 component is mounted to the first and second extruded components.

13. The vehicle of Claim 12, wherein the bumper component is a tow bar comprising a tow bar attachment for a trailer to be towed by the vehicle.

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14. The vehicle of Claim 12, wherein the bumper component is a rear bumper armature comprising an element extending across the width of the vehicle mounted to the first and second extruded components.

Intellectual

Property

Office

Application No: GB1616263.8 Examiner: Mr Charles Ellwood