Front body structure

Abstract

The present invention relates to a front vehicle body structure, comprising: a pair of front side members, each front side member being arranged on both sides of the front vehicle body in the longitudinal direction of the vehicle; a pair of mounting brackets, each mounting bracket engaging with a corresponding front side member of the pair of front side members and arranged to protrude from the inner panel of the corresponding front side member in the width direction of the vehicle to face each other; a crossbar having an upper surface, a front surface and a rear surface, the crossbar having an open bottom side and an open side end, and the crossbar engaging with the mounting bracket in the height direction of the vehicle; and a joining unit engaging the crossbar to the pair of mounting brackets, a predetermined gap being between the pair of front side members and the side end of the crossbar.

Description

[0001] Citations of relevant applications

[0002] This application claims priority to Korean Patent Application No. 10-2020-0101494, filed on August 13, 2020, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] This invention relates to a vehicle body structure. Background Technology

[0004] Typically, electric vehicles have various structures mounted on the front body, such as the front trunk structure and high-voltage electrical units. These electric vehicles also have a front crossbar installed on the front body to enhance collision stability and to accommodate various other structures.

[0005] The front crossbar connects to the inside of the front side member in the width direction of the vehicle. For example, the front crossbar is made of extruded aluminum material with a circular or rectangular closed cross section and is directly joined to the front side member.

[0006] Here, when a front crossbar with a circular closed cross section is used, the end of the crossbar is compressed and the compressed portion is directly joined to the front member by bolts. When a front crossbar with a rectangular closed cross section is used, the end of the crossbar is directly joined to the front member by bolts.

[0007] Typically, the front crossbar is assembled to the front side member before the various assembly components are assembled to the front body. This is because interference may occur between the assembly components and the fastening tools when the front crossbar is assembled to the front side member after the assembly components are assembled to the front body.

[0008] However, if the front crossbar is assembled to the front side component before the assembly parts are assembled to the front body, the front crossbar may cause inconvenience to the worker's movement line and working posture.

[0009] On the other hand, it is generally disadvantageous in terms of cost when aluminum extrusion material with a circular or rectangular closed cross section is used as the front crossbar.

[0010] The information included in this background section of the present invention is intended only to enhance the understanding of the general background of the invention and should not be construed as an endorsement of prior art known to those skilled in the art or any form of implication. Summary of the Invention

[0011] Various aspects of the present invention aim to provide a front body structure that may include a pair of front side members, each front side member being arranged on both sides of the front body in the longitudinal direction of the vehicle; a pair of mounting brackets, each mounting bracket engaging with a corresponding front side member of the pair of front side members and arranged to protrude from the interior panel of the corresponding front side member in the width direction of the vehicle to face each other; a crossbar having an upper surface, a front surface and a rear surface, the crossbar having an open bottom side and an open side end in cross section, and the crossbar engaging with the mounting bracket in the height direction of the vehicle; and a joining unit engaging the crossbar to the pair of mounting brackets, with a predetermined gap between the pair of front side members and the side end of the crossbar.

[0012] An exemplary front body structure may also include a guide pillar that is fixed to the upper surface of a pair of mounting brackets in the vehicle height direction and configured to couple to a guide hole disposed on the upper surface of a crossbar in the vehicle height direction.

[0013] Each of a pair of mounting brackets may include a top surface, a front surface, a rear surface, a bottom surface, and a side surface, wherein the side surfaces of the mounting brackets face each other; the mounting brackets may be coupled to the inner top surface and inner side surface of the front member.

[0014] The mounting bracket may include: an upper surface portion; a first curved surface portion that bends downward from the front and rear sides of the upper surface portion; a side surface portion that bends downward from a first side of the upper surface portion; a lower surface portion formed by bending the side surface portion in the width direction of the vehicle; and a second curved surface portion formed by bending upward at the front and rear sides of the lower surface portion and partially overlapping the first curved surface portion.

[0015] The mounting bracket may include: a first engagement flange extending forward and backward from a second side of the upper surface portion and engaging with the inner upper surface of the front member; a second engagement flange bending forward and backward from a second curved surface portion and engaging with the inner surface of the front member; and a third engagement flange bending downward from a lower surface portion and engaging with the inner surface of the front member.

[0016] The first joining flange can be spot welded to the inner upper surface of the front component.

[0017] The second and third joint flanges can be spot welded to the inner surface of the front component.

[0018] The first curved surface portion and the second curved surface portion can partially overlap each other and can form the front and rear surfaces of the mounting bracket.

[0019] The side surface portion may include a reinforcing rib, which can be formed by bending the front and rear sides of the side surface portion toward the first curved surface portion along the width direction of the vehicle and overlapping the first curved surface portion.

[0020] The mounting bracket can form a closed section whose cross-section gradually decreases from one front member toward the opposite front member.

[0021] The crossbar can be formed with a cross-sectional shape having an open bottom side.

[0022] The crossbar can be formed into a circular portion that bends outward at the bottom of the front and rear surfaces.

[0023] The engagement unit may include: an engagement hole formed on the upper surface of the mounting bracket; and a welding nut engaged from the inside of the mounting bracket to the edge of the engagement hole.

[0024] The two ends of the crossbar are respectively formed with bolt engagement holes, which are aligned with the welding nuts through the engagement holes.

[0025] The front body structure can be configured to mount vehicle components for electric vehicles to the crossbar, wherein the vehicle components for electric vehicles include wiring harnesses, high-voltage electrical units, and a front luggage compartment structure.

[0026] Another exemplary front body structure may include: a pair of front side members, each front side member being arranged on both sides of the front body in the vehicle length direction; a pair of first mounting brackets, each first mounting bracket engaging with a corresponding front side member of the pair of front side members and arranged to protrude from the interior panel of the corresponding front side member in the vehicle width direction to face each other; a crossbar having an upper surface, a front surface, and a rear surface, the crossbar having an open bottom side and an open side end in its cross section, and the crossbar engaging with the first mounting bracket in the vehicle height direction; and a first engagement unit disposed on the upper surface of the first mounting bracket and configured to... A crossbar is joined to a pair of first mounting brackets, and a predetermined gap exists between a pair of front side members and the side ends of the crossbar; a second joining unit is disposed on the first mounting brackets to mount a vehicle component to the crossbar by engaging with a vehicle component; a second mounting bracket engages with the front side member, the second mounting bracket having a predetermined gap relative to the first mounting brackets in the vehicle length direction, and the second mounting bracket protruding from the inner panel of the front side member in the vehicle width direction; and a third joining unit is disposed on the second mounting brackets to mount the vehicle component to the crossbar by engaging with a vehicle component.

[0027] Vehicle components may include a battery assembly comprising a battery bracket and an auxiliary battery. The battery assembly may be mounted to the crossbar via a second and a third engagement unit.

[0028] The first engagement unit may include: a first engagement hole formed on the upper surface of the first mounting bracket; and a first welding nut engaged from the inside of the first mounting bracket to the edge of the first engagement hole, and aligned with a bolt engagement hole provided in the crossbar through the first engagement hole.

[0029] The second engagement unit may include: a second engagement hole formed on the upper surface of the first mounting bracket; and a second welding nut engaged from the inside of the first mounting bracket to the edge of the second engagement hole, and configured to align with a bolt engagement hole provided in a vehicle component through the second engagement hole.

[0030] The third engagement unit may include: a third engagement hole formed on the upper surface of the second mounting bracket; and a third welding nut engaged from the inside of the second mounting bracket to the edge of the third engagement hole, and aligned with a bolt engagement hole provided in the vehicle component through the third engagement hole.

[0031] The exemplary front body structure also includes a fourth engagement unit disposed in the front side member to mount vehicle components to the crossbar and configured to engage with the vehicle components.

[0032] The fourth engagement unit may include: a fourth engagement hole formed on the inner upper surface of the front member; and a fourth welding nut engaged from the inside of the front member to the edge of the fourth engagement hole, and configured to align with a bolt engagement hole provided in the vehicle component through the fourth engagement hole.

[0033] In the detailed description of the present invention, other effects that can be obtained or predicted through exemplary embodiments will be described, either explicitly or implicitly. That is, various effects predicted in accordance with exemplary embodiments will be described in the following detailed description.

[0034] The methods and apparatus of the present invention have other features and advantages that will be apparent or set forth in more detail from the accompanying drawings and the following detailed description, which are incorporated herein and used together with the following detailed description to explain the particular principles of the invention. Attached Figure Description

[0035] The accompanying drawings are intended as a reference for describing exemplary embodiments of the invention and should not be construed as limiting the technical spirit of the invention.

[0036] Figure 1 This is a perspective view of the front vehicle body structure according to an exemplary embodiment of the present invention.

[0037] Figure 2 This is a partially exploded perspective view of the front vehicle body structure according to an exemplary embodiment of the present invention.

[0038] Figure 3 The mounting structure of the mounting bracket and crossbar applied to the front body structure according to an exemplary embodiment of the present invention is shown.

[0039] Figure 4 , Figure 5 , Figure 6 and Figure 7 Mounting brackets applied to the front vehicle body structure according to an exemplary embodiment of the present invention are shown respectively.

[0040] Figure 8 The mounting structure of the crossbar in the front body structure according to an exemplary embodiment of the present invention is shown.

[0041] Figure 9 A cross-sectional view of a crossbar according to an exemplary embodiment of the present invention is shown.

[0042] Figure 10 , Figure 11 and Figure 12 The diagram illustrates the engagement structure of the mounting bracket and crossbar applied to the front body structure according to an exemplary embodiment of the present invention.

[0043] Figure 13 Figures (a), (b), (c) and (d) illustrate the mounting structure of vehicle components of the front body structure according to an exemplary embodiment of the present invention.

[0044] Figure 14 A front body structure according to another exemplary embodiment of the present invention is shown.

[0045] Figure 15 This illustration shows the mounting structure of a vehicle component in the front body structure according to another exemplary embodiment of the present invention.

[0046] It is understood that the accompanying drawings are not necessarily to scale and present slightly simplified representations of various features illustrating the basic principles of the invention. Specific design features of the invention included herein, such as, for example, specific dimensions, orientations, positions, and shapes, will be determined in part by the particular purpose of the application and the environment of use.

[0047] In the figures, reference numerals throughout the figures refer to the same or equivalent parts of the invention. Detailed Implementation

[0048] Reference will now be made in detail to various embodiments of the invention, examples of which are illustrated in the accompanying drawings and described below. Although the invention (multiple inventions) will be described in conjunction with exemplary embodiments thereof, it will be understood that this specification is not intended to limit the invention (multiple inventions) to those exemplary embodiments. On the contrary, the invention (multiple inventions) is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents, and other embodiments that may be included within the spirit and scope of the invention as defined by the appended claims.

[0049] In the following description, various exemplary embodiments of the present invention will be described more fully with reference to the accompanying drawings, which illustrate exemplary embodiments of the invention. As those skilled in the art will recognize, the described embodiments can be modified in various different ways without departing from the spirit or scope of the invention.

[0050] To clarify the invention, parts irrelevant to the description will be omitted, and the same elements or equivalents will be indicated by the same reference numerals throughout the specification.

[0051] Similarly, the dimensions and thicknesses of each element are shown arbitrarily in the accompanying drawings, but the invention is not limited thereto, and the thicknesses of layers, films, panels, regions, etc., may be enlarged for clarity in the accompanying drawings.

[0052] Furthermore, in the following description, because the names of the components are the same as each other, the names of the components are divided into first, second, etc. to distinguish the names, and their order is not particularly restricted.

[0053] Furthermore, unless explicitly contrary to the description, the words “including” and variations such as “contains” or “comprising” will be understood to imply the inclusion of the stated elements, but not to exclude any other elements.

[0054] Furthermore, each of the terms described in the specification (such as "...unit", "...device", "...part" and "...component") refers to a unit of a complex element that performs at least one function or operation.

[0055] Figure 1 This is a perspective view of the front vehicle body structure according to an exemplary embodiment of the present invention. Figure 2 This is a partially exploded perspective view of the front vehicle body structure according to an exemplary embodiment of the present invention.

[0056] refer to Figure 1 and Figure 2 The front body structure 100 according to an exemplary embodiment of the present invention is applied to the front body structure of a passenger car, and can also be applied to the front body structure of an electric vehicle having a luggage compartment (commonly referred to as the front luggage compartment) at the front.

[0057] In various exemplary embodiments of the present invention, the front vehicle body structure 100 may mount various parts of the drive motor for driving the electric vehicle, such as wiring harnesses and high-voltage electrical units, and may also mount structures such as the front luggage compartment.

[0058] In this disclosure, exemplary embodiments of the invention are described with reference to the width direction, length direction, and height direction of the vehicle.

[0059] Furthermore, in the following text, "end (one end, another end, etc.)" may be defined as any end or as the portion including that end (one end, another end, etc.).

[0060] A front vehicle body structure 100 according to various exemplary embodiments of the present invention includes: a front side member 10 mounted on the left and right sides of the vehicle body along its vehicle length direction; a fender 1 mounted on the front side member 10; and a fender upper member 3 mounted on the upper end of the fender 1 and connected to the front side member 10.

[0061] This basic scheme for the front body structure is known in the art and will not be described in further detail.

[0062] Here, the front member 10 includes an inner panel 11 and an outer panel 12, wherein the term "inner" refers to the inner side between the front members 10 along the width direction of the vehicle.

[0063] The front vehicle body structure 100 according to an exemplary embodiment of the present invention is configured to reduce cost and weight, ensure the support strength of vehicle components mounted on the front vehicle body, and increase assembly freedom.

[0064] Figure 3 The mounting structure of the mounting bracket and crossbar applied to the front body structure according to an exemplary embodiment of the present invention is shown.

[0065] refer to Figures 1 to 3 According to various exemplary embodiments of the present invention, the front vehicle body structure 100 includes a mounting bracket 20, a crossbar 40, and a connecting unit 60.

[0066] In various exemplary embodiments of the present invention, the mounting bracket 20 is used to mount the crossbar 40 between the front side members 10 in the width direction of the vehicle.

[0067] Mounting bracket 20 engages with front member 10 and is arranged to protrude from interior panel 11 of front member 10 in the width direction of the vehicle so as to face each other.

[0068] Figure 4 , Figure 5 , Figure 6 and Figure 7 Mounting brackets applied to the front vehicle body structure according to an exemplary embodiment of the present invention are shown respectively.

[0069] refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7 Each of a pair of mounting brackets 20 according to various exemplary embodiments of the present invention includes an upper surface 21, a front surface 22, a rear surface 23, a lower surface 24, and a side surface 25, wherein the side surfaces 25 of the mounting brackets 20 face each other. The mounting brackets 20 are coupled to the inner upper surface 13 and the inner side surface 15 of the front member 10.

[0070] More specifically, the mounting bracket 20 includes an upper surface portion 31, a first curved surface portion 32, a side surface portion 33, a lower surface portion 34, a second curved surface portion 35, a reinforcing rib 36, a first engaging flange 37, a second engaging flange 38, and a third engaging flange 39.

[0071] The upper surface portion 31 forms the upper surface 21 of the mounting bracket 20, such that the upper surface 21 is substantially parallel to the inner upper surface 13 of the front member 10. In the following text, the term "first side" refers to the side away from the inner surface 15 of the front member 10 in the width direction of the vehicle, and the term "second side" refers to the side facing the inner surface 15.

[0072] The first curved surface portion 32 is formed by bending the front and rear sides of the upper surface portion 31 downwards. The side surface portion 33 is formed by bending the first side of the upper surface portion 31 downwards, and forms the side surface 25 of the mounting bracket 20.

[0073] The lower surface portion 34 is formed by bending the side surface portion 33 in the width direction of the vehicle to correspond to the upper surface portion 31, and forms the lower surface 24 of the mounting bracket 20. Furthermore, the second curved surface portion 35 is formed by bending upwards on the front and rear sides of the lower surface portion 34, and partially overlaps with the first curved surface portion 32. At this time, the second curved surface portion 35 partially overlaps with the first curved surface portion 32, which is located internally.

[0074] Here, the first curved surface portion 32 and the second curved surface portion 35 partially overlap each other and form the front surface 22 and the rear surface 23 of the mounting bracket 20. Moreover, the overlapping portions of the first curved surface portion 32 and the second curved surface portion 35 can be bonded, for example, by structural adhesive or by welding.

[0075] The reinforcing rib 36 is configured to reinforce the first curved surface portion 32 and the second curved surface portion 35 that overlap each other. The reinforcing rib 36 is formed by bending the front and rear sides of the side surface portion 33 toward the first curved surface portion 32 along the width direction of the vehicle and overlapping with the first curved surface portion 32.

[0076] The mounting bracket 20 forms a closed section 40a, the cross-section of which gradually decreases from one front member 10 toward the other (i.e., opposite) front member 10. By forming the closed section 40a, the load applied to the mounting bracket 20 can be easily distributed to the front members 10.

[0077] The first joining flange 37 extends forward and backward from the second side of the upper surface portion 31 and is joined to the inner upper surface 13 of the front member 10. The first joining flange 37 is spot welded to the inner upper surface 13 of the front member 10. Thus, a first spot weld portion 45 is formed in the first joining flange 37.

[0078] The second joining flange 38 is formed by bending the second curved surface portion 35 forward and backward, and is joined to the inner surface 15 of the front member 10. The second joining flange 38 is spot welded to the inner surface 15 of the front member 10. Thus, a second spot weld portion 46 is formed in the second joining flange 38.

[0079] Furthermore, the third joining flange 39 is formed by bending the lower surface portion 34 downward and is joined to the inner surface 15 of the front member 10. The third joining flange 39 is spot-welded to the inner surface 15 of the front member 10 below the second joining flange 38. Thus, a third spot weld portion 47 is formed in the third joining flange 39.

[0080] Here, the third engagement flange 39 bends downward at the end of the lower surface portion 34, its width corresponding to the width of the lower surface portion 34, and a curved protrusion 49 is formed at the center. Thus, the curved protrusion 49 is located between the third spot weld portions 47, which are formed on both sides of the curved protrusion 49. The curved protrusion 49 can easily distribute the load applied to the upper surface portion 31 to the inner surface 15 of the front member 10, and furthermore, the curved protrusion 49 can be configured to reinforce the lower surface portion 34 of the mounting bracket 20.

[0081] refer to Figures 1 to 3 In various exemplary embodiments of the invention, the crossbar 40 is configured to mount various components (such as wiring harnesses, high-voltage electrical units, and front trunk structures) to the front vehicle body and coupled to the mounting bracket 20. The crossbar 40 may be made of steel and is attached to the mounting bracket 20 in a top-down manner along its height direction within the vehicle.

[0082] Figure 8The mounting structure of the crossbar in the front body structure according to an exemplary embodiment of the present invention is shown. Figure 9 A cross-sectional view of a crossbar according to an exemplary embodiment of the present invention is shown.

[0083] refer to Figure 8 and Figure 9 According to various exemplary embodiments of the present invention, the crossbar 40 includes an upper surface 41, a front surface 42 and a rear surface 43, and may have a cross-sectional shape with an open bottom side and open side ends.

[0084] The crossbar 40 has a circular portion 40R formed at the bottom of the front surface 42 and the rear surface 43, which is curved in an outward direction (i.e., from the front surface forward and from the rear surface backward). In various exemplary embodiments of the invention, the cross section of the crossbar 40 can be maximized by the circular portion 40R.

[0085] In addition, the crossbar 40 includes at least one welded stud bolt 48a and at least one welded stud nut 48b for mounting various components.

[0086] A double-ended bolt 48a is welded to the upper surface 41 of the crossbar 40 in the height direction of the vehicle. Furthermore, a double-ended nut 48b is welded from the inside between the front surface 42 and the rear surface 43 of the crossbar 40 to the edge of a hole provided on the upper surface 41.

[0087] Meanwhile, the end of the crossbar 40 is coupled to a predetermined position of the mounting bracket 20 in the vehicle height direction. For this purpose, in various exemplary embodiments of the present invention, the crossbar 40 further includes a guide post 29, which is fixed to the upper surface 21 of the mounting bracket 20 in the vehicle height direction.

[0088] The guide post 29 is used to mount the crossbar 40 at a predetermined position between the front members 10 via the mounting bracket 20, and the guide post 29 is configured to adjust the position of the crossbar 40.

[0089] The guide post 29 is welded to the upper surface 31 of the mounting bracket 20 in the vehicle height direction. The guide post 29 is coupled to the guide hole 44 provided on the upper surface 41 of the crossbar 40 in the vehicle height direction.

[0090] Therefore, in various exemplary embodiments of the present invention, the crossbar 40 is coupled to the mounting bracket 20 from above in a downward direction, and when the guide post 29 is inserted into the guide hole 44 of the crossbar 40, both ends of the crossbar 40 can be coupled to predetermined positions of the mounting bracket 20.

[0091] Here, the predetermined position between the front members 10 refers to a position in which the crossbar 40 is coupled to the mounting bracket 20 and has a predetermined gap between the two ends of the crossbar 40 and the inner surface 15 of the front member 10.

[0092] refer to Figures 1 to 3 In various exemplary embodiments of the present invention, the engagement unit 60 is used to engage the crossbar 40 to the mounting bracket 20 by bolts 51, wherein a predetermined gap is formed between the two ends of the crossbar 40 and the inner surface 15 of the front member 10. The engagement unit 60 is disposed on the mounting bracket 20.

[0093] Figure 10 , Figure 11 and Figure 12 The diagram illustrates the engagement structure of the mounting bracket and crossbar applied to the front body structure according to an exemplary embodiment of the present invention.

[0094] refer to Figure 10 , Figure 11 and Figure 12 According to various exemplary embodiments of the present invention, the engagement unit 60 includes an engagement hole 61 formed on the upper surface portion 31 of the mounting bracket 20 and a welding nut 63 that engages with the edge portion of the engagement hole 61 from the inside of the mounting bracket 20.

[0095] Bolt 51 engages with weld nut 63 through upper surface 41 of crossbar 40 and engagement hole 61, thereby allowing both ends of crossbar 40 to engage with mounting bracket 20. Bolt engagement holes 65 are formed at both ends of crossbar 40, which are aligned with weld nut 63 through engagement holes 61.

[0096] The assembly process and operation of the front vehicle body structure according to an exemplary embodiment of the present invention are described in detail below with reference to the accompanying drawings.

[0097] First, in various exemplary embodiments of the present invention, the vehicle body is transferred to an assembly position on the assembly line, and the mounting brackets 20 are mounted (attached) to the front member 10 in a direction facing each other along the width direction of the vehicle. Here, the mounting brackets 20 protrude from the inner panel 11 of the front member 10 toward the opposing mounting bracket 20 in the width direction of the vehicle.

[0098] In this state, in various exemplary embodiments of the present invention, various assembly components are installed onto the front member 10, the mudguard 1, and the upper mudguard member 3. During this process, since there is no obstruction to the movement of the worker in the space between the front members 10, the various assembly components can be installed on the front member 10, the upper mudguard member 1, and the upper mudguard member 3 in a convenient working posture.

[0099] Subsequently, in various exemplary embodiments of the invention, the two ends of a crossbar 40 having an open bottom cross-section are coupled to the mounting bracket 20 from above in a downward direction. At this time, in various exemplary embodiments of the invention, guide holes 44 at the two ends of the crossbar 40 are fitted to guide posts 29 of the mounting bracket 20, and thus, the crossbar 40 is coupled to a predetermined position on the mounting bracket 20.

[0100] Therefore, in various exemplary embodiments of the present invention, the crossbar 40 is coupled to the mounting bracket 20, and there is a predetermined gap between the two ends of the crossbar 40 and the inner surface 15 of the front member 10.

[0101] Therefore, the crossbar 40 is positioned above the mounting bracket 20 at both ends, and the bolt engagement holes 65 at both ends of the crossbar 40 coincide with the welding nuts 63 through the engagement holes 61 of the mounting bracket 20.

[0102] Subsequently, in various exemplary embodiments of the invention, the bolt 51 is engaged with the weld nut 63 through the bolt engagement hole 65 and the engagement hole 61. Thus, both ends of the crossbar 40 are engaged with the mounting bracket 20 by the bolt 51.

[0103] Therefore, in various exemplary embodiments of the invention, the crossbar 40 engages with the mounting bracket 20, wherein a predetermined gap exists between the two ends of the crossbar 40 and the inner surface 15 of the front member 10. Thus, in various exemplary embodiments of the invention, even when the crossbar 40 is assembled after the assembly components are assembled to the front vehicle body, there may be less interference between the assembly components and the fastening tools.

[0104] Therefore, in various embodiments of the present invention, since it is not necessary to assemble the crossbar 40 before assembling the assembly components to avoid interference between the assembly components and the fastening tools, interference in the worker's movement line and inconvenience in working posture caused by the prior assembly of the crossbar 40 can be prevented.

[0105] When the crossbar 40 is pre-engaged with the mounting bracket 20, in various exemplary embodiments of the present invention, such as Figure 13 As shown in Figures (a), (b), (c) and (d), various vehicle components 101 (such as wiring harness 102, high-voltage electrical unit 103, and front trunk structure 104) are mounted to the crossbar 40.

[0106] Here, vehicle component 101 can be mounted to crossbar 40 by means of welded double-ended bolts 48a and welded double-ended nuts 48b provided on crossbar 40.

[0107] Therefore, in various exemplary embodiments of the present invention, the cross section of the crossbar 40 can be maximized by the circular portion 40R, the strength of the mounting bracket 20 can be strengthened by the closed section 40a, reinforcing ribs 36, bending protrusions 49, etc. of the mounting bracket 20, and the load applied to the mounting bracket 20 can be distributed to the front member 10.

[0108] Therefore, in various exemplary embodiments of the present invention, the crossbar 40 can be ensured to have sufficient strength to stably support various vehicle components 101, the crossbar 40 can absorb and distribute the impact during a vehicle collision, and the vehicle behavior in the vehicle width direction during minor overlap collisions can be improved.

[0109] According to various exemplary embodiments of the present invention, the front vehicle body structure 100 allows for the installation of crossbars 40 regardless of the assembly sequence of the assembly components assembled to the front vehicle body, thus increasing the degree of freedom in setting the packaging layout for assembling vehicle components.

[0110] Furthermore, in various exemplary embodiments of the invention, cost and weight can be reduced by using a crossbar 40 made of steel with an open bottom side cross section instead of the relatively expensive extruded aluminum material.

[0111] Figure 14 A front body structure according to another exemplary embodiment of the present invention is shown. Figure 15 The accompanying drawings illustrate the mounting structure of a vehicle component in the front body structure according to another exemplary embodiment of the present invention. In the drawings, the same elements as in the previous exemplary embodiments of the invention are assigned the same reference numerals.

[0112] refer to Figure 14 and Figure 15 A front vehicle structure 200 according to another exemplary embodiment of the present invention is constructed, which is based on the structure of a previous exemplary embodiment of the present invention, such that the battery assembly 202, which is a vehicle component 201, can be installed to the front vehicle while being supported by the crossbar 40.

[0113] Here, the battery assembly 202 includes a battery bracket 203 fixed to the front vehicle body and a 12V auxiliary battery 205 fixed to the battery bracket 203.

[0114] According to another embodiment, the front vehicle body structure 200 includes a crossbar 40 as in a previous embodiment of the invention, and further includes a first mounting bracket 220, a first engagement unit 260, a second engagement unit 270, a second mounting bracket 310, a third engagement unit 330, and a fourth engagement unit 340.

[0115] In various exemplary embodiments of the present invention, the first mounting bracket 220 is a bracket structure having the same shape and cross-section as the mounting bracket 20 of a previous exemplary embodiment of the present invention, and is coupled to the front member 10.

[0116] In various exemplary embodiments of the present invention, a first engagement unit 260 is used to engage the two ends of the crossbar 40 with a first mounting bracket 220, and a predetermined gap is formed between the front member 10 and the side ends of the crossbar 40. The first engagement unit is disposed on the upper surface 231 of the first mounting bracket 220. The first engagement unit 260 includes a first engagement hole 261 and a first welding nut 263, which are formed in the same manner as in the engagement unit 60 of a previous exemplary embodiment of the present invention.

[0117] Here, when the bolt 51 engages with the first welding nut 263 through the first engagement hole 261 and bolt engagement hole 65 provided at both ends of the crossbar 40, the two ends of the crossbar 40 can engage with the first mounting bracket 220.

[0118] The first joining unit 260 is formed in the same manner as the joining unit in the previous exemplary embodiments of the present invention, and will not be described in further detail.

[0119] In various exemplary embodiments of the present invention, the second engagement unit 270 is disposed together with the first engagement unit 260 on the first mounting bracket 220, so that the battery bracket 203 of the battery assembly 202 can be mounted on the crossbar 40.

[0120] The second engagement unit 270 is disposed separately from the first engagement unit 260 on the upper surface 231 of the first mounting bracket 220, and is located between the end of the crossbar 40 and the inner side surface 15 of the front member 10, and is engaged with the battery bracket 203 by bolts 51. The second engagement unit 270 includes a second engagement hole 271 and a second welding nut 273 to engage the battery bracket 203 with the first mounting bracket 220.

[0121] The second engagement hole 271 is formed on the upper surface 231 of the first mounting bracket 220. The second welding nut 273 engages with the edge of the second engagement hole 271 from the inside of the first mounting bracket 220, and is aligned with the bolt engagement hole 207 provided in the battery bracket 203 through the second engagement hole 271.

[0122] Here, when the bolt 51 engages with the second welding nut 273 through the second engagement hole 271 and bolt engagement hole 207 of the battery bracket 203, the battery bracket 203 can engage with the first mounting bracket 220.

[0123] In various exemplary embodiments of the present invention, the second mounting bracket 310 is used to mount the battery bracket 203 of the battery assembly 202 on the crossbar 40 and engage with the front member 10, and the second mounting bracket 310 has a predetermined gap relative to the first mounting bracket 220 in the vehicle length direction.

[0124] The second mounting bracket 310 protrudes from the inner panel 11 of the front member 10 toward the opposing second mounting bracket 310 in the width direction of the vehicle. In a bracket structure having the same shape and cross-section as the first mounting bracket 220, the second mounting bracket 310 may be formed as the same as the mounting bracket 20 of the previous exemplary embodiments of the present invention and be combined with the front member 10.

[0125] In various exemplary embodiments of the present invention, a third engagement unit 330 is disposed on the upper surface of the second mounting bracket 310 to mount the battery bracket 203 of the battery assembly 202 onto the crossbar 40.

[0126] The third engagement unit 330 is engaged with the battery bracket 203 by bolts 51 and includes a third engagement hole 331 and a third welding nut 333 to engage the battery bracket 203 with the second mounting bracket 310.

[0127] The third engagement hole 331 is formed on the upper surface of the second mounting bracket 310. The third welding nut 333 engages with the edge of the third engagement hole 331 from the inside of the second mounting bracket 310, and is aligned with the bolt engagement hole 208 provided in the battery bracket 203 through the third engagement hole 331.

[0128] Here, when the bolt 51 engages with the third welding nut 333 through the third engagement hole 331 and the bolt engagement hole 208 of the battery bracket 203, the battery bracket 203 can engage with the second mounting bracket 310.

[0129] In several exemplary embodiments of the present invention, a fourth engagement unit 340 is disposed in the front member 10 to mount the battery bracket 203 of the battery assembly 202 onto the crossbar 40.

[0130] The fourth engagement unit 340 is disposed on the inner upper surface 13 of the front member 10 and is engaged with the battery bracket 203 by bolts 51. The fourth engagement unit 340 includes a fourth engagement hole 341 and a fourth welding nut 343 to engage the battery bracket 203 with the inner upper surface 13 of the front member 10.

[0131] A fourth engagement hole 341 is formed on the inner upper surface 13 of the front member 10. A fourth welding nut 343 engages with the edge of the fourth engagement hole 341 from the inside of the front member 10, and is aligned with the bolt engagement hole 209 provided in the battery bracket 203 through the fourth engagement hole 341.

[0132] Here, when the bolt 51 engages with the fourth welding nut 343 through the fourth engagement hole 341 and bolt engagement hole 209 of the battery bracket 203, the battery bracket 203 can engage with the inner upper surface 13 of the front member 10.

[0133] Therefore, according to another exemplary embodiment of the present invention, the front vehicle structure 200 can ensure sufficient strength for supporting the battery assembly 202 mounted on the first mounting bracket 220, the second mounting bracket 310 and the front side member 10 by means of the crossbar 40.

[0134] The remaining configuration, operation, and effects of the front body structure 200 according to another exemplary embodiment of the present invention are the same as those of the previous exemplary embodiments of the present invention, and will not be described in further detail.

[0135] For ease of explanation and precise definition in the appended claims, the terms “upper,” “lower,” “inner,” “outer,” “upward,” “downward,” “upward,” “downward,” “front,” “back,” “rear,” “inside,” “outside,” “inward,” “outer,” “inner,” “external,” “inner,” “outer,” “forward,” and “backward” are used to describe the positions of the features shown in the figures to describe these features of the exemplary embodiments. It will be further understood that the term “connection” or its derivatives refer to both direct and indirect connections between the two.

[0136] The above description of specific exemplary embodiments of the invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and it will be apparent that many modifications and variations can be made in accordance with the above teachings. The exemplary embodiments were chosen and described to explain certain principles of the invention and its practical application, enabling others skilled in the art to make and utilize various exemplary embodiments of the invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the appended claims and their equivalents.

Claims

1. A front vehicle body structure, comprising: A pair of front side members, each of the front side members being arranged on both sides of the front body in the longitudinal direction of the vehicle; A pair of mounting brackets, each of the mounting brackets engaging with a corresponding front member of the pair of front members and arranged to protrude from the interior panel of the corresponding front member in the width direction of the vehicle, so as to face each other; A crossbar having an upper surface, a front surface, and a rear surface, the crossbar having an open bottom side and an open side end, and the crossbar engaging with a pair of mounting brackets in the height direction of the vehicle; as well as A coupling unit engages the crossbar with a pair of mounting brackets, and a predetermined gap exists between the pair of front members and the open side ends of the crossbar. The pair of mounting brackets forms a closed section, the cross-section of which decreases from one of the pair of front members toward the opposite front member of the pair of front members.

2. The front vehicle body structure according to claim 1, further comprising a guide post fixed to the upper surface of a pair of mounting brackets in the height direction of the vehicle, and the guide post being configured to be coupled to a guide hole provided on the upper surface of the crossbar in the height direction of the vehicle.

3. The front vehicle body structure according to claim 1, in, Each of the pair of mounting brackets includes a top surface, a front surface, a rear surface, a bottom surface, and a side surface, wherein the side surfaces of the mounting brackets face each other; and The pair of mounting brackets are coupled to the inner upper surface and inner surface of the pair of front members.

4. The front vehicle body structure according to claim 3, wherein, Each of the pair of mounting brackets includes: upper surface; The first curved surface portion bends downward from the front and rear sides of the upper surface portion; The side surface portion bends downward from the first side of the upper surface portion; The lower surface portion is formed by bending the side surface portion in the width direction of the vehicle to correspond to the upper surface portion; and The second curved surface portion is formed by bending upward at the front and rear sides of the lower surface portion and partially overlaps with the first curved surface portion.

5. The front vehicle body structure according to claim 4, wherein, Each of the pair of mounting brackets further includes: A first engagement flange extends forward and backward from the second side of the upper surface portion and engages with the inner upper surfaces of the pair of front members; A second engagement flange bends forward and backward from the second curved surface portion and engages with the inner surfaces of the pair of front members; and The third engagement flange bends downward from the lower surface portion and engages with the inner surfaces of the pair of front members.

6. The front vehicle body structure according to claim 5, wherein, The first engagement flange is spot-welded to the inner upper surface of the pair of front members; and The second and third engagement flanges are spot welded to the inner surfaces of the pair of front members.

7. The front vehicle body structure according to claim 4, wherein, The first curved surface portion and the second curved surface portion partially overlap each other and form the front surface and the rear surface of the mounting bracket.

8. The front vehicle body structure according to claim 4, wherein, The side surface portion includes a reinforcing rib, which is formed by bending the front and rear sides of the side surface portion toward the first curved surface portion along the width direction of the vehicle, and the reinforcing rib overlaps with the first curved surface portion.

9. The front vehicle body structure according to claim 3, wherein, The crossbar is formed with a cross-sectional shape having an open bottom side.

10. The front vehicle body structure according to claim 3, wherein, The crossbar forms a circular portion that bends outward at the bottom of the front and rear surfaces.

11. The front vehicle body structure according to claim 1, wherein, The joining unit includes: A mating hole is formed on the upper surface of the pair of mounting brackets; and Weld nuts are attached from the inside of the pair of mounting brackets to the edge of the engagement hole.

12. The front vehicle body structure according to claim 11, wherein, The first and second ends of the crossbar are respectively formed with bolt engagement holes, and the bolt engagement holes are aligned with the welding nuts through the engagement holes.

13. The front vehicle body structure according to claim 1, wherein, The front body structure is configured to mount vehicle components for an electric vehicle to the crossbar, wherein the vehicle components for the electric vehicle include wiring harnesses, electrical units, and a front luggage compartment structure.

14. A front vehicle body structure, comprising: A pair of front side members, each of the front side members being arranged on both sides of the front body in the longitudinal direction of the vehicle; A pair of first mounting brackets, each first mounting bracket engaging with a corresponding front member of the pair of front members and arranged to protrude from the interior panel of the corresponding front member in the width direction of the vehicle, so as to face each other; A crossbar having an upper surface, a front surface, and a rear surface, the crossbar having an open bottom side and an open side end, and the crossbar engaging with a pair of first mounting brackets in the height direction of the vehicle. A first engagement unit is disposed on the upper surface of the pair of first mounting brackets and configured to engage the crossbar to the pair of first mounting brackets, and a predetermined gap is provided between the pair of front side members and the open side end of the crossbar. A second engagement unit is disposed on at least one of the first mounting brackets of a pair of first mounting brackets to mount the vehicle component to the crossbar by engaging with the vehicle component; A second mounting bracket engages with a pair of the front side members, the second mounting bracket having a predetermined gap relative to the pair of first mounting brackets in the longitudinal direction of the vehicle, and the second mounting bracket protruding from the inner panel of the pair of front side members in the width direction of the vehicle. as well as A third engagement unit is disposed on the second mounting bracket to mount the vehicle component to the crossbar by engaging with the vehicle component.

15. The front vehicle body structure according to claim 14, in, The vehicle components include: a battery assembly, the battery assembly including a battery bracket and an auxiliary battery; and... The battery assembly is mounted to the crossbar via the second bonding unit and the third bonding unit.

16. The front vehicle body structure according to claim 14, wherein, The first joining unit includes: A first engagement hole is formed on the upper surface of the pair of mounting brackets; and A first welding nut is attached from the inside of a pair of first mounting brackets to the edge of the first engagement hole, and is aligned with a bolt engagement hole provided in the crossbar through the first engagement hole.

17. The front vehicle body structure according to claim 14, in, The second joining unit includes: A second mating hole is formed on the upper surface of a pair of first mounting brackets; and The second welding nut is attached from the inside of a pair of first mounting brackets to the edge of the second engagement hole, and is configured to align with a bolt engagement hole provided in the vehicle component through the second engagement hole. The third joining unit includes: A third engagement hole is formed on the upper surface of the second mounting bracket; and A third welding nut is attached from the inside of the second mounting bracket to the edge of the third engagement hole and is configured to align with a bolt engagement hole provided in the vehicle component through the third engagement hole.

18. The front body structure of claim 14, further comprising a fourth engagement unit disposed in a pair of the front side members for mounting the vehicle component to the crossbar, and the fourth engagement unit being configured to engage with the vehicle component.

19. The front vehicle body structure according to claim 18, wherein, The fourth joining unit includes: A fourth engagement hole is formed on the inner upper surface of the pair of front members; and A fourth welding nut engages from the inside of a pair of the front members to the edge of the fourth engagement hole and is configured to align with a bolt engagement hole provided in the vehicle component through the fourth engagement hole.

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