HEADLAMP ASSEMBLY FOR A VEHICLE BODY

Abstract

The invention relates to a component group for a vehicle body, having a headlamp housing, which has at least one connecting portion integrally formed in one piece for connection to an adjoining body part, and a predetermined breaking point for separation of the connecting portion from a neighboring portion. To minimize both the repair costs in the event of a collision at low speed in the region of the headlamp and also the costs for production and assembly, it is provided according to the invention that the neighboring portion has connecting structures for connection to a joining part with which the connecting portion is replaceable after its separation.

Claims

1. A component group for a vehicle body comprising: a headlamp housing including at least one first connecting structure integrally formed in one piece for connection to an adjoining body part, each first connecting structure having a connecting portion and a neighboring portion joined together by a joint having a predetermined breaking point for separating the connecting portion from the neighboring portion in an impact; and a joining part attached to one of the neighboring portions that is connected to the adjoining body part after the connecting portion is separated from the neighboring portion in the impact for replacing the connecting portion after separation.

2. The component group as claimed in claim 1, wherein the at least one first connecting structure is designed for form-fitting connection.

3. The component group as claimed in claim 1, wherein the at least one first connecting structure has at least one through-opening for a screw.

4. The component group as claimed in claim 1, further comprising: a joining part connected to the at least one first connecting structure and to the adjoining body part.

5. The component group as claimed in claim 1, further comprising: at least one web is formed in the neighboring portion for reinforcing purposes.

6. The component group as claimed in claim 1, wherein the headlamp housing includes a plurality of connecting structures.

7. The component group as claimed in claim 1, further comprising: a fender, wherein at least one connecting portion is designed for connection to the fender.

8. The component group as claimed in claim 7, wherein the fender has an attaching structure for connection to a vehicle body, wherein the attaching structure is designed to yield as planned under an application of a force on the part of the headlamp housing.

9. The component group as claimed in claim 8, wherein the attaching structure has a through-opening for a screw, wherein an extent of the through-opening in a Y direction is greater than an extent of a head of the screw and the through-opening is delimited on the inside in the Y direction by a web whereof the extent in the Y direction is, at most, 50% of the extent of the through-opening.

10. The component group as claimed in claim 8, wherein the fender has, in front of and behind a through-opening extending in an X direction, two slots extending in a Y direction.

11. A headlamp assembly comprising: a housing; a plurality of connectors including a first portion connected to the housing and a second portion connected to a vehicle; a joint connecting the first and second portions, the joint being predisposed to separate the second portion from the first portion upon application of an impact force to the housing; and a joining portion assembled to the first portion and the vehicle after separating the first and second portions.

12. The headlamp assembly of claim 11, wherein the joint is predisposed to separate the second portion from the first portion when the impact force applied to the housing exceeds a predetermined level of force.

13. The headlamp assembly of claim 11, wherein the joining portion includes a re-attachment portion that is attached to the first portion and a replication portion corresponding in shape to the second portion that is attached to the vehicle.

14. The headlamp assembly of claim 13, wherein the re-attaching portion is secured by fasteners to through-holes defined by the first portion.

15. The headlamp assembly of claim 11 wherein the first and second portions of the connectors and the joining portion are integral with the housing prior to application of the impact force to the headlamp assembly.

16. The headlamp assembly of claim 11 wherein the second portion includes an elastic pin that is adapted to be received in an opening defined by the vehicle.

17. A method of repairing a vehicle having headlamp assembly including a housing having a plurality of connectors including a first portion connected to the housing and a second portion connected to the vehicle, and a joint connecting the first and second portions that is predisposed to separate the second portion from the first portion when an impact force applied to the housing exceeds a predetermined level of force, the second portion being separated from the first portion, the method comprising: providing a joining portion including a re-attachment portion and a replication portion corresponding at least partially in structure to the second portion; and assembling the re-attachment portion to the first portion and the replication portion to the vehicle.

18. The method of claim 17 wherein the replication portion includes attachment features that are adapted to be secured to the vehicle in place of the second portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 part of a motor vehicle and an obstacle;

[0030] FIG. 2 a detailed illustration of the motor vehicle of FIG. 1;

[0031] FIG. 3 a perspective illustration of a headlamp housing of the motor vehicle of FIG. 1;

[0032] FIG. 4 a perspective illustration of part of the headlamp housing with a first connecting portion;

[0033] FIG. 5 a perspective illustration of part of the headlamp housing with a second connecting portion;

[0034] FIG. 6 a perspective illustration of part of the headlamp housing with a third connecting portion;

[0035] FIG. 7A a perspective illustration of part of the headlamp housing with the first connecting portion;

[0036] FIG. 7B a perspective illustration of part of the headlamp housing with a separated first connecting portion;

[0037] FIG. 7C a perspective illustration of part of the headlamp housing with a first joining part;

[0038] FIG. 8A a perspective illustration of part of the headlamp housing with the second connecting portion;

[0039] FIG. 8B a perspective illustration of part of the headlamp housing with a separated second connecting portion;

[0040] FIG. 8C a perspective illustration of part of the headlamp housing with a second joining part;

[0041] FIG. 9A a detailed view of FIG. 1 with an attaching structure of a fender;

[0042] FIG. 9B an illustration of the attaching structure following a collision at low speed; and

[0043] FIG. 10 part of the vehicle and the obstacle following a collision at low speed.

DETAILED DESCRIPTION

[0044] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. In the different figures, the same parts are always denoted by the same reference signs, which is why they are generally also described only once.

[0045] FIGS. 1 and 2 each show, in a plan view, part of a motor vehicle 1more precisely, an automobile. This has, in a front region, a headlamp housing 10 which is adjoined by a fender 40 to the rear, as seen in the direction of the X axis. A door 50 is in turn arranged adjacent to the fender 40. A hood 60 adjoins the headlamp housing 10 and the fender 40 on the upper side and to the center of the vehicle. As can be seen in FIG. 2, in which the hood 60 has been removed, the fender 40 is connected to a frame part 70 of a vehicle body 2 via connecting structures 41. The headlamp housing 10 is connected both to the frame part 70 and to the fender 41 via a first connecting portion 12.

[0046] FIG. 3 is a perspective illustration of the headlamp housing 10, which can be made from plastics material in a known manner. A multiplicity of openings 11 for light units (not illustrated) such as low beam, high beam, turn signals etc. can be seen. In addition to the first connecting portion 12, a further second connecting portion 18 arranged further to the front and a third connecting portion 26 arranged toward the underside are arranged on the headlamp housing 10. The second and third connecting portion 18, 26 can serve for connecting the headlamp housing to other body parts or to the vehicle body 2.

[0047] FIG. 4 is a detailed view in which the first connecting portion 12 adjoins a first neighboring portion 13, wherein a first predetermined breaking point 14 is formed between these portions 12, 13. This is formed substantially by lateral notches and a linearly extending groove. The connecting portion 12 has a first through-opening 15 (visible in FIG. 7A) through which a first screw 71 is guided in order to connect the first connecting portion 12 to the frame part 70. The first neighboring portion 13 has three second through-openings 16, which are not used in normal operation of the motor vehicle 1. To stabilize the first neighboring portion 13, this has a series of first reinforcing webs 17.

[0048] FIG. 5 is a detailed view which shows that the second connecting portion 18 adjoins a second neighboring portion 19, wherein a second predetermined breaking point 20, like the first predetermined breaking point 14, is formed between these portions 18, 19. The second connecting portion 18 has a third through-opening 24, through which a second screw 72 is guided in order to connect the second connecting portion 18 to the vehicle body 2. A pin element 23 is furthermore provided, which can serve for example for form-fitting connection to the vehicle body 2. The first connecting portion 12 can have, on an underside which is not visible in FIG. 4, a corresponding pin element 23 which serves for form-fitting connection to the fender 40. The second neighboring portion 19 has three fourth through-openings 22, which are not used in normal operation of the motor vehicle 1. In this case, the through-openings 22 are formed inside sleeve portions 21 of the second neighboring portion 19. A series of second reinforcing webs 25 are provided for stabilizing the second neighboring portion 19.

[0049] FIG. 6 is a detailed view with the third connecting portion 26. This has an elastic latching element 73, which is latched in a correspondingly formed opening in the vehicle body 2.

[0050] In the event of a collision at low speed, which is illustrated by way of example in FIG. 10, a force is applied to the headlamp housing 10 in relation to the vehicle body 2. If this exceeds a predetermined threshold value, it is provided that the first predetermined breaking point 14 yields as planned. This can be seen with reference to FIG. 7A, which shows the normal state of the headlamp housing 10, and FIG. 7B, which shows the first connecting portion 12 separated from the first neighboring portion 13. The neighboring portion 13 can remain substantially undamaged owing to the presence of the reinforcing webs 17, amongst other things. If this also applies to other parts of the headlamp housing 10, this does not have to be replaced completely but can instead be repaired. To this end, as illustrated in FIG. 7C, a first joining part 110 is used, which is provided to replace the separated first connecting portion 12. It has a fifth through-opening 111 which corresponds in terms of size and position to the first through-opening 15. All in all, the first joining part 110 is designed for form-fitting engagement with the first neighboring portion 13. In particular, it has three sixth through-openings 112 which are each flush with the second through-openings 16 when positioned appropriately. Therefore, the first joining part 110 can be connected with form fit and force fit to the first neighboring portion 13, in that screws (not illustrated here) are guided through the sixth through-openings 112 and the second through-openings 16.

[0051] In the event of a collision at low speed, the force applied to the headlamp housing 10 also results in the second connecting portion 18 becoming separated as planned, as illustrated with reference to FIG. 8A, which shows the normal state, and FIG. 8B, in which the second connecting portion 18 is separated. In this case, the neighboring portion 19 remains undamaged owing to the presence of the second reinforcing webs 25, amongst other things. Repair is also possible in this case, whereby a second joining part 120 illustrated in FIG. 8C is used. This second joining part replaces the second connecting portion 18 after its separation and therefore has a seventh through-opening 122, corresponding to the third through-opening 24, and a second pin element 121 corresponding to the first pin element 23. Moreover, three eighth through-openings 123 are provided, which are flush with the fourth through-openings 22. A form-fitting and force-fitting connection of the second joining part 120 to the neighboring portion 19 is therefore possible by means of screws.

[0052] The third connecting portion 26 is not provided for separation from the headlamp housing 10. Instead, the elastic latching element 73 detaches from the vehicle body 2 in that it is deformed under the application of a corresponding force. All in all, the headlamp housing 10 therefore detaches from the vehicle body 2 and from the fender 40 as planned, whereby both the force applied to the headlamp housing and also the force reacting upon the obstacle 100 remain limited. It is therefore possible to prevent considerable damage to the essential parts of the headlamp housing 10. If surface scratches occur, these can possibly be removed by polishing.

[0053] Although the headlamp housing 10 also detaches from the fender 40, a certain force can still be applied to the fender 40, which could push this rearward in the direction of the door 50. This could result in damage to the paintwork on the door 50, even in the event of relatively small collisions. To prevent this, it is provided that the fender 40 deforms and deflects laterally outward, as indicated in FIG. 10. To promote this sequence, the attaching structure 41 is provided to yield as planned under the application of a force on the part of the headlamp housing 10. In this case, a ninth through-opening 42 with an approximately rectangular cross-section is incorporated in the sheet metal material of the fender 40. A third screw 74, which is secured by a washer 75, is guided through this ninth through-opening 42. The screw 74 is screwed to the frame part 70 of the vehicle body 2. In this case, an extent of the ninth through-opening 42 in the direction of the Y axis is greater (by ca. 80-100%) than an extent of a head 74.1 of the screw 74. Two slots 43, 44 extending in the Y direction are formed in front of and behind the ninth through-opening 42, as seen in the direction of the X axis. Toward the center of the vehicle in the Y direction, the ninth through-opening 42 is delimited by a first web 45, whereof the extent in the Y direction is approximately a third of the extent of the ninth through-opening. The slots 43, 44 are separated from the ninth through-opening 42 by a second web 46 and a third web 47. Under the application of a sufficiently strong force between the fender 40 and the vehicle body 2 or the screw 74 screwed thereto, the screw 74 is pressed against the first web 45 and the second web 46, which ultimately results in at least partial separation of at least one of the webs 45, 46. This is illustrated in FIG. 9B. As a result of the separation, the fender 40 detaches from the vehicle body 2 in this region and can deflect laterally, as shown in FIG. 10. In this case, deformation of, and damage to, the fender 40 is consciously accepted since a rearward movement of the fender 40 is thus substantially prevented. There is therefore no impact with the door 50 and costly repair for possible damage to the paintwork is thereby avoided.

[0054] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.