BUMPER ARRANGEMENT FOR A MOTOR VEHICLE

Abstract

A bumper arrangement for a motor vehicle has a crossmember and crash boxes which are arranged in each case at the end of the crossmember, and also outer end modules. Each end module has a shell body and a shield which covers the front side of the shell body at least in certain regions, wherein the shell body is joined to a crash box, and an end of the crossmember is joined to a respective shell body. The bumper arrangement has a functionally high energy absorption capacity with a modularized design.

Claims

1-18. (canceled)

19. A bumper arrangement for a vehicle, the bumper arrangement comprising: a crossmember; a crash box arranged at an end of the crossmember; and an end module arranged at an outer portion of the crash box, wherein the end module has a shell body, the shell body is joined to the crash box, and the end of the crossmember is joined to the shell body.

20. The bumper arrangement according to claim 19, wherein the end module further comprises a shield, and a front side of the shell body is covered by the shield at least in certain regions.

21. The bumper arrangement according to claim 19, wherein the crossmember has a strut profile that is U-shaped or hat-shaped, and a closing panel on a front side of the crossmember.

22. The bumper arrangement according to claim 21, wherein the closing panel arranged on the front side of the crossmember is shorter than the front side of the crossmember.

23. The bumper arrangement according to claim 21, wherein the end module further comprises a shield which covers or overlaps the front side of the crossmember at least in certain regions.

24. The bumper arrangement according to claim 19, wherein the end module has a front portion, a transition portion, and a side portion, the front portion is arranged in front of the crash box, and the end module is laterally adjoined to the crash box, at a height level below the crash box, by the transition portion which transitions from the front portion into the side portion.

25. The bumper arrangement according to claim 24, wherein the transition portion extends in an arcuate or curved manner downward and in a longitudinal direction of the vehicle.

26. The bumper arrangement according to claim 19, wherein the shell body of the end module has a bottom wall, and the shell body is supported on the crash box by the bottom wall.

27. The bumper arrangement according to claim 19, wherein the shell body has a connection contour to which the end of the crossmember is connected.

28. The bumper arrangement according to claim 27, wherein the end of the crossmember at least partially engages in a form-fitting manner into the connection contour and is joined to the shell body.

29. The bumper arrangement according to claim 19, wherein the shell body has a base region arranged at a front of the crash box, and a skirt portion adjoining the base region, and the skirt portion extends outward at a height level below the crash box.

30. The bumper arrangement according to claim 19, wherein the end of the crossmember extends within the shell body at least in certain regions up to a front of the crash box.

31. The bumper arrangement according to claim 19, wherein an end side of the crash box has a stepped support contour which interacts with a counterpart support contour on the shell body.

32. The bumper arrangement according to claim 20, wherein the shell body is a hot-formed and press-hardened member, and the shield is a cold-formed member.

33. The bumper arrangement according to claim 19, wherein the shell body has a bead, a fold, or a turned-over portion in an edge-side wall portion of the shell body.

34. The bumper arrangement according to claim 23, wherein the crossmember, the strut profile, the closing panel, the shell body, and the shield are joined together by a combination of material-bond elements and form-fit elements.

35. The bumper arrangement according to claim 29, wherein a ratio of a mean vertical cross-sectional area of the shell body in the base region to a mean vertical cross-sectional area of the crash box is between 2:1 and 4:1, in each case +/−25%.

36. The bumper arrangement according to claim 29, wherein a ratio of a height, measured along a vertical axis, of the shell body in the base region between an upper side wall and a lower side wall of the shell body to a height, measured along the vertical axis, of the crossmember is between 2:1 and 4:1, in each case +/−25%.

37. The bumper arrangement according to claim 19, wherein the shell body has a tensile strength Rm greater than or equal to 1,350 MPa.

38. The bumper arrangement according to claim 29, wherein a ratio of a mean vertical cross-sectional area of the shell body in the base region to a mean vertical cross-sectional area of the crash box is 3:1+/−25%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The disclosure is described in more detail below on the basis of exemplary embodiments which are illustrated in the drawings. In the figures:

[0045] FIG. 1 shows a front view of a motor vehicle bumper arrangement according to the disclosure;

[0046] FIG. 2 shows the bumper arrangement in a rear view from the motor vehicle according to the disclosure;

[0047] FIG. 3 shows a section through the illustration of FIG. 1 along line A-A according to the disclosure;

[0048] FIG. 4 shows a section through the illustration of FIG. 1 along line B-B according to the disclosure;

[0049] FIG. 5 shows a section through the illustration of FIG. 1 along line C-C according to the disclosure;

[0050] FIG. 6 shows a view of a shell body according to the disclosure;

[0051] FIG. 7 shows a detail from the lateral region of a bumper arrangement with the illustration of the shell body of an end module and the schematically indicated connection of a crossmember according to the disclosure;

[0052] FIG. 8 shows a view of an end module with the technically schematic illustration of the covering contour of a shield and the illustration of the crash box contour according to the disclosure;

[0053] FIG. 9 shows the illustration of a possible modification in the arrangement of the crossmember and the connection thereof to an end module according to the disclosure;

[0054] FIG. 10 shows a technically schematic illustration of a further modification of the bumper arrangement according to the disclosure;

[0055] FIG. 11 shows a further modification of the bumper arrangement with the illustration of the shell body of an end module and the end-module-side end of a crossmember according to the disclosure, and

[0056] FIG. 12 shows a perspective illustration of a detail from the connection region between a crash box and a shell body according to the disclosure.

DETAILED DESCRIPTION

[0057] Where expedient, the same reference designations are used for identical or similar components or component elements in FIG. 1-FIG. 11, even if a repeated description is omitted for reasons of simplification.

[0058] A first exemplary embodiment of a bumper arrangement 1 according to the disclosure for a motor vehicle is described with reference to FIG. 1-FIG. 5. The bumper arrangement 1 is used in the front or rear region, for example, in the front region of the body of a motor vehicle.

[0059] The bumper arrangement 1 has a crossmember 2 which is arranged transversely with respect to the longitudinal members (not illustrated here) of a motor vehicle. The bumper arrangement 1 is supported on the longitudinal members via crash boxes 3, which are provided at the end of the crossmember 2. The crash boxes 3, in addition to the crossmember 2, are intended to absorb the energy resulting from an impact by converting said energy into deformation work.

[0060] The crossmember 2 extends between the inner side walls of the crash boxes 3. The crossmember 2 has a U-shaped or hat-shaped strut profile 4 which is formed in one part from a sheet metal, for example, sheet steel. The strut profile 4 has a rear wall 5 with two limbs 6 which are each adjoined at the end by an outwardly directed longitudinal flange 7,8. A closing panel 9 is provided on the front side of the strut profile 4. The closing panel 9 extends in the y direction over virtually the entire length of the front side 10 of the crossmember 2. In the middle length portion 11 of the crossmember 2 (see FIG. 3), the upper longitudinal flange 8 is adjoined by a turned-over portion 12 which is directed rearward in the x direction toward the vehicle. In the middle length portion 11, the closing panel 9 also has a rearwardly directed turned-over portion 13 which overlaps the turned-over portion 12 on the upper longitudinal flange 8 of the strut profile 4. The closing panel 9 bears against the strut profile 4 on the lower longitudinal flange 7 of the strut profile 4 in the middle length region 11 of the crossmember 2.

[0061] The bumper arrangement 1 has an end module 14 at each end. Each end module 14 has a shell body 15 and a shield 16 which covers the front side of the shell body 15. The shell body 15 is joined to the crash box 3. An end 17 of the crossmember 2 is joined to the shell body 15. The join between the component elements is effected in a materially bonded manner by means of welding.

[0062] FIG. 6 shows a view of a shell body 15.

[0063] An end module 14 has a front portion 18 which is arranged in front of the crash box 3 and which is laterally adjoined, at a height level below the crash box 3, by a transition portion 19 which transitions into a side portion 20.

[0064] The transition portion 19 is of arcuate configuration or runs in a curved manner downward and in the direction toward the vehicle longitudinal side or toward the wheel arch.

[0065] The shell body 15 has a bottom wall 21. A crash box 3 is supported in each case on the outer side or on the outer surface of the bottom wall 21 of the shell body 15, said outer surface being directed toward the vehicle. Toward the end portions 22 of the crossmember 2, a shell body 15 has, in its side wall 23 which is directed forward from the bottom wall 21 and which is adjacent to the end 17 of the crossmember 2, a connection contour 24 to which the end of the crossmember 2 is connected.

[0066] The shell body 15 has a base region 25 arranged in front of a crash box 3, and a skirt portion 26 adjoining the base region 25. The skirt portion 26 extends outward at a height level below the crash box 3 in the direction toward the vehicle longitudinal sides.

[0067] The shell contour of the shell body 15 runs over from the base region 25 into the skirt portion 26, which has a channel-like profile, in a hollowed manner. The transition 37 between base region 25 and skirt portion 26 runs in an arcuate and curved manner downward and in the direction toward the vehicle longitudinal side, that is to say toward the outer side of a vehicle. In vertical cross section, the skirt portion 26 has a channel form 38 recessed in a U-shaped manner with the shell contour formed by the bottom wall 21 and the side walls 23. The channel form 38 runs out in an open manner at the end of the skirt portion 26.

[0068] The shield 16 is arranged in each case on the front side in front of the shell bodies 15 and is of curved configuration in an arcuate portion 27. The shield 16 is able to overlap the front side of the crossmember 2 in certain regions. FIG. 8 shows such a configuration. The end 17 of the crossmember 2 lies in the connection contour 24 of the shell body 15. The shield 16 covers the front side of the arrangement. Here, the shield 16 bears against parallel surfaces of the shell body 15 in an areal manner and overlaps the end 17 and the closing panel 9 of the crossmember 2 in an overlap region 28.

[0069] In one embodiment of a bumper arrangement 1, as explained with reference to FIG. 10, the closing panel 9 is embodied to be shorter than the front side 10 of the crossmember 2 so that short portions 29 on the front side 10 of the crossmember 2 are not covered by the closing panel 9. These front-side portions 29 are covered by the shield 16, the closing panel 9 and the shield 16 bearing against one another in an approximately flush manner in an abutment region.

[0070] FIG. 7 shows, in a schematically indicated manner, that the end 17 of the crossmember 2 at least partially engages in a form-fitting manner into the connection contour 24. The end 17 is joined to the shell body 15 in the region of the connection contour 24. The end 17 of the crossmember 2 or the end 30 of the strut profile 4 is of trapezoidal configuration. A form-fitting join is effected, which is optionally supplemented by material-bond elements.

[0071] In principle, a combined joining technique of parts to be joined is also possible, in the case of which for example the strut profile 4 and the shell body 15 are joined by means of material-bond elements and form-fit elements.

[0072] The shell body 15 is formed from a steel sheet, for example, from a manganese-boron-steel sheet. A shell body 15 is hot-formed and press-hardened and has a tensile strength Rm of greater than or equal to (≥) 1,350 MPa.

[0073] The shields 16 is able to be hot-formed and press-hardened with comparable material properties. The shields 16 are able to be cold-formed and be composed of ultra-high-strength cold-formed steels.

[0074] The strut profile 4 of the crossmember 2 also has a tensile strength Rm of greater than or equal to (≥) 1,350 MPa. The strut profile 4 is hot-formed and press-hardened.

[0075] The end 17 of the crossmember 2 and an end-side length portion or the end portion 22 of the crossmember 2 is able to extend into the shell body 15, specifically into a region which lies in front of the crash box 3. FIG. 8 shows such a configuration. The crash box contour is indicated by the dashed line C. The dashed line S illustrates the contour of the closing panel 9. The front side of the end module 14, just like the end-side length portion 22, which projects into the shell body 15, and the end 17 of the crossmember 2, is covered by the shield 16.

[0076] The crash box contour, illustrated by the dashed line C, is able to be seen in the illustration of FIG. 9. The contour of the end 17 of the crossmember 2 is indicated by the dashed line E. The crossmember 2 or that the end 17 of the crossmember 2 does not extend as far as the crash box contour C. The end 17 of the crossmember 2 is connected to the shell body 15, but ends at a spacing in the y direction in front of a crash box 3.

[0077] In the modification illustrated in FIG. 10, the end 30 of the strut profile 4 of the crossmember 2 extends within the shell body 15 in front of the crash box 3 and goes beyond the total crash box contour C. The closing panel 9 of the crossmember 2 ends in front of the shield 16. However, the closing panel 9 is also able to extend over the end 30 of the strut profile 4, which lies in front of the crash box 3. The bottom wall 21 of the shell body 15 is located on the vehicle side, between the crossmember 2 and the end 17. The front side of the end module 14 or of the shell body 15 is covered by the shield 16.

[0078] A crash box 3 has, on the front side, for example, in the front-side vertical end sides 31 oriented in the z axis, a stepped support contour 32 which interacts with a counterpart support contour 33 on the shell body 15. This is illustrated in an indicative manner in the illustration of FIG. 4, and is able to be seen with reference to FIG. 11. The shell body 15 (see FIG. 4 and FIG. 6) has hollow-like embossed portions 34 in its bottom wall 21. The embossed portions 34 are formed in the direction toward the outer side or in the direction toward the shield 16. FIG. 5 also shows such an embossed portion 34 or hollow. The counterpart support contour 33 is formed by the transitions to the embossed portions 34, the support contour 32 being supported on said counterpart support contour.

[0079] In edge-side wall portions 35, a shell body 15 has a turned-over portion 36 which has a stiffening function in the edge-side wall portions 35.

[0080] Openings 39 or apertures 39 are able to be present both in the shell body 15 and in the shield 16 (see for example FIG. 4 or FIG. 7). The openings 39 are able to be embodied as passages.

[0081] In the modification of the bumper arrangement 1 or of the connection and joining of the end 17 of the crossmember 2 or of the end 30 of the strut profile 4, as illustrated in FIG. 11, a clamp-like or hook-like joining element 40 is provided at the end 30. This engages through an abutment element 41 in the shell body 15. The abutment element 41 is able to be an aperture in the bottom wall 21 of the shell body 15. The abutment element 41 is able to be designed in a slot-like manner as well as in the form of an outwardly or inwardly embossed abutment element 41 with a form-fitting action.

[0082] In the shell body 15, there is a form-fit element 42 within the connection contour (see FIG. 6). Here, this is able to be a recess or elevation. The form-fit element 42 interacts with a form-fit element 43 of correspondingly complementary design at the end 30 of the strut profile 4 of the crossmember 2. In the form-fit elements 43 is illustrated in FIG. 7, the form-fit elements 43 is provided in the rear wall 5 of the strut profile 4.

[0083] FIG. 12 again illustrates the connection and support of a crash box 3 to/on the rear side of the bottom wall 21 of a shell body 15. The end side of the crash box 3 has a stepped support contour 32 having a step 45 formed on a side wall 44 of the crash box 3. The support contour 32 interacts with a counterpart support contour 33 on the shell body 15. The counterpart support contour 33 is formed on an arcuate portion of a hollow or embossed portion 34 of the counterpart support contour 33. Corresponding support contours 32 and counterpart support contours 33 are formed on both sides, that is to say also on the opposite side of the crash box 3 and the side wall 46 provided there.

[0084] In this way, the crash box 3 is retained and stabilized on the shell body 15 in the z axis and in the y axis.

[0085] An end module 14 has, in the base region 25 of the shell body 15, a vertical cross-sectional area which is at least twice as great, for example, is a multiple of, the vertical cross-sectional area of a crash box 3. The ratio of the cross-sectional areas of the base region 25 of shell body 15 and crash box 3 to one another is crucial, the vertical cross-sectional ratio of the base region 25 and the vertical cross-sectional ratio of the crash box 3 being at least 2:1, 3:1. The cross-sectional ratio is able to be from 2:1 to 4:1, to 3.5:1, in each case +/−25%.

[0086] To ascertain the cross-sectional ratio, account is able to in each case be taken of a mean vertical cross-sectional ratio. Here, the area is able to be ascertained in the region of the bottom wall 21 of the shell body 15, in the center of the base region 25 and on the open outer side. The same applies to a crash box 3. There, the cross-sectional ratio is able to be ascertained at the start, in the center and at the end of the crash box 3, and a mean value is able to be formed from the respective cross-sectional ratios.

[0087] In the case of an impact, force or energy is distributed in a large-area manner over the base region 25 of the shell body 15 of an end module 14, said base region being considerably larger in terms of cross section.

[0088] The ratio of the height h1, measured along the z axis, of the shell body 15 in the base region 25 between its upper side wall 23′ and its lower side wall 23″ to the height h2, measured along the z axis, of the crossmember 2 is between 2:1 and 4:1, in each case with a tolerance or a variation in the scope of the overall design of +/−25%.

[0089] As seen in reference to FIG. 4, the shield 16 also is able to have a hollow-like or channel-like recess 47. In the region of the hollow-like recess, the shield 16 bears against the bottom wall 21 of the shell body 15 and is supported against the latter. In the contact region, the bottom wall 21 and the shield 16 is able to be joined, for example is able to be joined in a materially bonded manner. This is able to be effected by way of an adhesive bond.

[0090] In principle, a transverse beam which extends in the y direction is able to be provided below the crossmember 2.

[0091] The foregoing description of some embodiments of the disclosure has been presented for purposes of illustration and description. The description is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings. The specifically described embodiments explain the principles and practical applications to enable one ordinarily skilled in the art to utilize various embodiments and with various modifications as are suited to the particular use contemplated. Various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the disclosure.