WO2016074101A1

WO2016074101A1 - Wheel flare with energy absorbing component

Info

Publication number: WO2016074101A1
Application number: PCT/CA2015/051189
Authority: WO
Inventors: David Flajnik; Jamie WELLS; Michael Kurt PROFYT; John Sudak; Kent SALVILLA; Kulbir Singh Dhillon; Sunny MOTWANI; Scott COLMAN
Original assignee: Salflex Polymers Limited
Priority date: 2014-11-16
Filing date: 2015-11-13
Publication date: 2016-05-19

Abstract

An energy absorbing wheel flare assembly comprising an energy absorbing component and a fascia for attachment to the energy absorbing component. The energy absorbing component presents a plurality of absorption lobes for dissipating energy upon a collision event.

Description

WHEEL FLARE WITH ENERGY ABSORBING COMPONENT

Inventors: David Flajnik, James Wells, Michael Kurt Profyt, John Sudak, Kent Salvilla,

Kulbir Singh Dhillon, Sunny Motwani, Scott Colman

FIELD OF THE INVENTION

[0001] The present invention generally relates to an automotive wheel flare and, in particular, to an automotive wheel flare incorporating an energy absorbing component.

BACKGROUND

[0002] The World Health Organization reports that more than 270,000 pedestrians lose their lives each year in pedestrian collision events. This accounts for nearly a quarter of all road traffic deaths reported. Automotive manufacturers have traditionally focused safety systems upon occupants of the passenger compartment, with little regard to exterior protection systems.

[0003] Pedestrian-protection requirements have placed new pressures on automotive manufacturers to develop ways to impart safety outside the traditional passenger cabin envelope. For example, additional clearance between the underside of the engine hood and the engine is now provided to reduce the likelihood of pedestrian impact upon the engine in the event of a pedestrian collision. Deeper bumper profiles and air dam structures under the bumper have also been shown to reduce lower limb injury.

[0004] For certain vehicles, in particular sport utility vehicles, body-side structures such as wheel flares sit pronounced from the vehicle side surface. Wheel flares can therefore present an impact surface in the event of a pedestrian collision. Accordingly, there exists a need to revisit the traditional design of wheel flare assemblies in the search for pedestrian-protection solutions.

SUMMARY OF THE INVENTION [0005] According to an aspect of an embodiment, provided is an energy absorbing wheel flare assembly comprising an energy absorbing component and a fascia for attachment to the energy absorbing component. The energy absorbing component presents a plurality of absorption lobes for dissipating energy upon a collision event.

[0006] According to another aspect of an embodiment, provided is an energy absorbing wheel flare assembly comprising an energy absorbing component and a fascia for attachment to the energy absorbing component. The energy absorbing component presents at least one energy absorption element for dissipating energy upon a collision event.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. The drawings are not to scale.

[0008] Fig. 1 is an exemplary sport utility vehicle having an energy absorbing wheel flare over each front wheel assembly.

[0009] Fig. 2 is a schematic sectional representation of a prior art wheel flare assembly.

[0010] Figs. 3 A and 3B show a perspective view and exploded perspective view, respectively, of an energy absorbing wheel flare assembly according to a first embodiment.

[0011] Fig. 4A is a schematic sectional representation of an energy absorbing wheel flare assembly according to the embodiment of Figs. 3 A and 3B, taken along line A-A of Fig. 3 A.

[0012] Fig. 4B is a close up of an energy absorption lobe according to an exemplary embodiment.

[0013] Figs. 5 A to 5F show a variety of absorption lobes for use in the energy absorbing wheel flare assembly of Figs. 3 A and 3B.

[0014] Fig. 5G is a sectional view of the embodiment shown in Fig. 5F. [0015] Fig. 6 is an alternate embodiment of an energy absorbing wheel flare assembly.

DETAILED DESCRIPTION OF EMBODIMENTS

[0016] Specific embodiments of the present invention will now be described with reference to the Figures, wherein like reference numbers indicate identical or functionally similar elements. The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the invention. Although the description and drawings of the embodiments hereof exemplify the technology as applied to automotive front wheel flares, the invention may be applied in other automotive applications, including but not limited to rear wheel flares and other body-side applications. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, brief summary or the following detailed description.

[0017] Turning now to Fig. 1, shown is an exemplary vehicle 10 that typically employs wheel flares 20 over each of the front wheel assemblies 22. In a sport utility vehicle, such as that exemplified by vehicle 10, wheel flare 20 is dimensioned to present a substantial outward extension to the side of vehicle 10, sufficient to substantially cover wheel assembly 22. The extent of outward extension contributes to both aesthetic quality and the protection of vehicle 10 from debris. It will be appreciated that in this configuration, front wheel flare 20 presents a potential impact surface in the event of a pedestrian collision.

[0018] A sectional view of an exemplary prior art wheel flare assembly 30 is illustrated in Fig. 2. Wheel flare assembly 30 is a 2-piece injection molded system, generally comprising a base support structure 32 and a fascia component 34. Fascia component 34 and base support structure 32 are generally preassembled and mounted as a unit to vehicle 10 using suitable fasteners. For example, attachment to the vehicle body 36 is achieved by way of one or more barbed automotive fasteners 38, while attachment to the vehicle frame 40 is achieved by way of one or more threaded fasteners 42. Base support structure 32 will generally incorporate various structural elements to provide rigidity and durability to wheel flare assembly 30. For example, base support structure 32 will incorporate a plurality of ribs 44, channels or other integral features that impart torsional rigidity. It will be appreciated that wheel flares of this design, while strong and functional, do not exhibit a predictable or consistent energy absorption behavior.

[0019] Turning now to Figs. 3A and 3B, shown is an energy absorbing wheel flare assembly 100. Wheel flare assembly 100 will generally include an energy absorbing component 102 and a fascia 104. Energy absorbing component 102 is injection molded of a suitable polymeric material, for example a thermoplastic poly olefin (TPO). Energy absorbing component 102 provides the base structure of wheel flare assembly 100, providing the required structural integrity to achieve desired form/function performance characteristics. Depending on the design of wheel flare assembly 100, energy absorbing component 102 may present as part of the outwardly visible wheel flare structure, such as in the wheel flare exemplified here. Accordingly, energy absorbing component 102 will be manufactured and/or finished to present exposed surfaces 106 having an automotive Class A surface.

[0020] Energy absorbing component 102 incorporates a plurality of mounting points to permit secure attachment to corresponding mount locations on vehicle 10. For example, as shown in Fig. 4A, energy absorbing component 102 may be provided with side mounts 108 and flange mounts 110, designed to work with barbed fasteners 38 and threaded fasteners 42, respectively. In this arrangement, barbed fasteners 38 serve to securely attach side mounts 108 to vehicle body 36, while threaded fasteners 42 are employed to secure flange mount 110 to the vehicle frame 40. It will be appreciated, however, that a range of mounting methodologies may be used depending on the vehicle in question. Such mounting methodologies are generally known in the automotive arts. [0021] Energy absorbing component 102 also presents a plurality of absorption lobes 112, configured with dimensions that permit predictable deformation during a pedestrian collision event. For example, absorption lobes 112 may be configured as shown, that is in the form of deformable stepped cones having a wall thickness in the region of 1 to 5 mm. As shown more closely in Fig. 4B, absorption lobe 112 provides an annular recess 114 at step 116. Annular recess 114 promotes an inward collapse of absorption lobe 112 upon receiving sufficient downward force. While one annular recess 114 is shown, absorption lobe 112 may provide multiple annular recesses, in particular on configurations having multiple steps. It will be appreciated that other shapes, for example a variety of other truncated 3D rectilinear shapes may be used, including but not limited to frusto-pyramidal shapes. For example, Figs. 5A to 5F present various forms of absorption lobes suitable for use in wheel flare assembly 100. In Fig. 5A, absorption lobe 112a is presented in the form of a stepped truncated cone having 4 deformable wall segments 118 separated by cut-outs 120, wall segments 118 being arranged to interconnect at a dimpled apex 122. Absorption lobe 112b presented in Fig. 5B is similar to the stepped truncated cone shown in Fig. 5 A, with smaller cut-outs 124 provided on the stepped wall portion 126. Similarly, the apex 128 is presented as dimpled. In Fig. 5C, absorption lobe 112c is presented as a truncated rectangular-based prism with stepped walls 130 and cut-outs 132 provided as shown. Absorption lobe 112d presented in Fig. 5D incorporates similar features as absorption lobe 112a of Fig. 5A, with the addition of recess 134 provided on step 136, and a domed apex. Fig. 5E presents an absorption lobe 112e similar to absorption lobe 112b of Fig. 5B, with the addition of recesses 138 on steps 140, 142, and a domed apex. Fig. 5F presents an absorption lobe 112f having a reclined step 160 and domed apex 162. Surrounding absorption lobe 112f is a recess 164 provided on energy absorption component 102. It will be appreciated that a similar recess 164 may be provided in respect of any of the preceding embodiments of absorption lobes. For additional clarity, Fig. 5G provides a sectional view of the embodiment shown in Fig. 5F. [0022] Factors considered in establishing a desired arrangement of absorption lobes will include, but are not limited to lobe shape, lobe width, lobe height, absorption lobe wall thickness, spacing between absorption lobes, and material selection. It will be appreciated that absorption lobe wall thickness may be adjusted to engineer into the structure a predetermined deformation response. For example, as shown in Fig. 5G, the wall thickness of absorption lobe 112f is reduced in comparison to the surrounding energy absorption component 102, to promote collapse of absorption lobe 112f during a collision event. It is also possible to dimension only certain portions of the absorption lobe with increased or decreased wall thickness, again to achieve a predetermined deformation response.

[0023] Returning to Fig. 4A, energy absorbing component 102 may incorporate additional structural features, including but not limited to structural ribs 144. It will be appreciated, however, that the use and placement of structural ribs 144 is limited to impart minimal counter-effect to the energy absorption qualities achieved by the absorption lobes, as will be discussed in greater detail below.

[0024] Fascia 104 is generally injection molded of TPO, finished to an aesthetically-acceptable surface, for example the automotive Class A surface. In some embodiments, fascia 104 is colour matched to the vehicle in question. Mounting of fascia 104 to energy absorbing component 102 is generally achieved by way of snap-fit assembly. As shown, at distal end 146, energy absorbing component 102 is configured with an aperture 148 sized to receive a barbed extension 150 from fascia 104. Proximal end 152 of energy absorbing component 102 and fascia 104 may be similarly configured (not shown). In some embodiments, fascia 104 is formed with integral clip mounts (not shown) to permit attachment of fascia to energy absorbing component 102, similar to arrangements known in the automotive arts. It will be appreciated that the manner by which fascia 104 is attached to energy absorbing component 102 may be achieved in a variety of different ways, and is not intended to be limited to the examples detailed above. [0025] As noted in Fig. 4A, fascia 104 is positioned in adjacent relationship to energy absorbing component 102, in particular to absorption lobes 112 provided thereon. Under normal usage, the absorption lobes 112 will provide support to fascia 104, presenting a firm surface, while energy absorbing component 102 provides an overall torsional stability to wheel flare assembly 100. In some embodiments, additional features such as tuning ribs, stand-offs, foam pads and adhesive compounds/strips are incorporated to present additional support and/or suppress audible noise/vibration between the structures.

[0026] In the event of a collision with a pedestrian, the energy of impact upon wheel flare assembly 100 will be at least partially dissipated by way of generally downwardly and/or rearwardly deformation/buckling of absorption lobes 112. In this way, kinetic energy from the impacting force, the pedestrian is absorbed in a controlled and predictable manner. Wheel flare assembly 100, and in particular energy absorbing component 102 may be engineered to exhibit desired energy absorption characteristics, depending on applicable regulatory requirements, such as head impact criteria. As indicated earlier, factors affecting performance will include, but are not limited to lobe shape, lobe width, lobe height, absorption lobe wall thickness, spacing between absorption lobes, and material selection.

[0027] While the energy absorbing characteristic in the aforementioned wheel flare assembly 100 is provided by way of deformable absorption lobes 112, other methodologies for energy absorption in a wheel flare structure are possible. For example, wheel flare assembly 200 presented in Fig. 6 presents an assembly of similar structure to that shown in Fig. 4A, with the exception of the absorption lobes. In this alternate embodiment, the absorption lobes are replaced with absorption elements 212 situated between energy absorbing base 202 and fascia 204. The remaining construction is much like that described for wheel flare assembly 200, and thus will not be further detailed. With this arrangement, during a collision event, energy absorption is provided by way of a cushioning effect provided by way of absorption elements 212. Suitable materials for absorption elements 212 may include, but are not limited to a range of open and closed-cell foams. While illustrated as pad-like elements, absorption elements 212 may be provided in the form of strips. In some embodiments, energy absorbing base 202 is at least partially covered by absorption elements 212. In other embodiments, energy absorbing base 202 is substantially covered with absorption element 212.

[0028] It will be appreciated that the energy absorbing component and fascia as presented herein are exemplary in design, and may be provided in alternate form, but in keeping with the described energy absorbing functionality. For example, one or both of the energy absorbing component and fascia may be provided in multi-part form. While described as being formed using TPO, other suitable materials may find application in forming the energy absorbing component and/or fascia.

[0029] It will also be appreciated that the absorption lobes described, in particular the type, form and size of absorption lobes selected may be intermixed. In other words, an energy absorption component may include absorption lobes of varying size, and/or possibly at least two different types of absorption lobes, for example being selected from the various forms detailed in Figs 5a to 5c.

[0030] While traditional injection molding technology may be used to manufacture energy absorption component 102, one exemplary technique to achieve the desired Class A surface is the injection molding process disclosed in U.S. Patent No. 7,846,533, the contents of which are herein incorporated by reference. Although not discussed in detail herein, United States Patent No. 7,846,533 teaches a process for injection molding plastic articles using a molten thermoplastic plastic, a blowing agent and a pressurizable mold cavity. In the process, gas cells form within the molten plastic and through the control of venting of the pressurizing gas during the molding process, a finished molded plastic article can be achieved having a Class "A" skin surface and a foamed core, regardless of the positioning of projections on the inside surface of the molded plastic article. For example, with some thermoplastic materials and traditional injection molding, a sink mark will form in the surface of the article when the thickness of the projection is 40% or greater than the thickness of the structure. In contrast, with the process detailed in U.S. Patent No. 7,846,533, the thickness of any projections may be up to and/or greater than 100% of the thickness of the structure.

[0031] While various embodiments according to the present invention have been described above, it should be understood that they have been presented by way of illustration and example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other combination. All patents and publications discussed herein are incorporated by reference herein in their entirety.

Claims

CLAIMS What is claimed is:

1. An energy absorbing wheel flare comprising:

an energy absorbing component; and

a fascia for attachment to the energy absorbing component,

wherein the energy absorbing component presents a plurality of absorption lobes for dissipating energy upon a collision event.

2. The energy absorbing wheel flare assembly according to claim 1, wherein the energy absorbing component is injection molded of thermoplastic material.

3. The energy absorbing wheel flare assembly according to claim 2, wherein the thermoplastic material is thermoplastic polyolefin.

4. The energy absorbing wheel flare assembly according to claim 1, wherein the energy absorbing component forms part of the outwardly visible wheel flare structure.

5. The energy absorbing wheel flare assembly according to claim 4, wherein the energy absorbing component is formed with an automotive Class A surface on outwardly visible surfaces.

6. The energy absorbing wheel flare assembly according to claim 1, wherein the energy absorbing component incorporates a plurality of mounting points to permit secure attachment of the wheel flare assembly to corresponding mount locations on a vehicle.

7. The energy absorbing wheel flare assembly according to claim 6, wherein the plurality of mounting points includes side mounts for attachment to the vehicle body, and flange mounts for attachment to the vehicle frame.

8. The energy absorbing wheel flare assembly according to claim 1, wherein the absorption lobes are provided as deformable stepped cones having a wall thickness of about 1 mm to about 5 mm.

9. The energy absorbing wheel flare assembly according to claim 8, wherein the absorption lobes provides a plurality of steps defining the deformable stepped cones.

10. The energy absorbing wheel flare assembly according to claim 9, wherein an annular recess is provided at each step defining the deformable stepped cones.

11. The energy absorbing wheel flare assembly according to claim 10, wherein the deformable stepped cone is defined as having a plurality of deformable wall segments separated by cutouts.

12. The energy absorbing wheel flare assembly according to claim 1, wherein the absorption lobes are provided as a 3-D rectilinear shape

13. The energy absorbing wheel flare assembly according to claim 12, wherein the 3-D rectilinear shape is a truncated frusto-pyramidal shape.

14. The energy absorbing wheel flare assembly according to claims 1, wherein the absorption lobes are provided with a wall thickness that is reduced in comparison to the surrounding wall structure of the energy absorbing component.

15. The energy absorbing wheel flare assembly according to claim 1, wherein the energy absorbing component further comprises one or more structural features.

16. The energy absorbing wheel flare assembly according to claim 15, wherein the structural features includes structural ribs.

17. The energy absorbing wheel flare assembly according to claim 1, wherein the fascia is attached to the energy absorbing component by way of snap-fit assembly.

18. The energy absorbing wheel flare assembly according to claim 1, wherein the absorption lobes provide support to the fascia.

19. The energy absorbing wheel flare assembly according to claim 1, wherein the absorption lobes are provided in a variety of shapes and sizes.

20. An energy absorbing wheel flare comprising:

an energy absorbing component; and

a fascia for attachment to the energy absorbing component,

wherein the energy absorbing component presents at least one energy absorption element for dissipating energy upon a collision event.

21. The energy absorbing wheel flare assembly according to claim 20, wherein the energy absorption element is provided as a pad-like element.

22. The energy absorbing wheel flare assembly according to claim 21, wherein the pad-like elements is an open or closed cell foam.