Vehicle front bumper system

Abstract

The present invention relates to a vehicle front bumper system including a bumper beam disposed at a front end of a vehicle and having a plurality of openings to a cooling assembly disposed within a front compartment of the vehicle. The bumper beam has a plurality of ribs defining the plurality of openings, and each rib has an aerodynamic cross-section with a thickness that gradually decreases from the front of the vehicle toward the rear of the vehicle.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and benefit to Korean Patent Application No. 10-2020-0128299, filed on October 5, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to a front bumper system for vehicles. Background Technology

[0004] The statements in this section are provided only as background information relating to the invention and do not constitute prior art.

[0005] As is known in the art, a vehicle includes a front compartment that houses a powertrain comprising an internal combustion engine and / or an electric motor and a transmission. A cooling assembly, including multiple heat exchangers (radiators, condensers, and intercoolers) and cooling fans, may be located in the front compartment and may be mounted on a front-end module (FEM) carrier.

[0006] The front grille can be positioned in front of the cooling components. When the vehicle is in motion, ambient air flows into the cooling components through the front grille, thus cooling them. Additionally, the front bumper crossbeam can be positioned in front of the cooling components, allowing it to absorb impact energy and prevent damage to the cooling components in the event of a vehicle collision.

[0007] The front bumper crossbeam can be configured to at least partially cover the cooling components and be formed by a closed wall. We have found that ambient air flowing into the cooling components during vehicle operation is blocked by the front bumper crossbeam, thereby reducing the cooling performance of the cooling components.

[0008] The information described above in this background section is provided to help understand the background of the inventive concept and may include any technical concept that is not considered prior art known to those skilled in the art. Summary of the Invention

[0009] One aspect of the present invention provides a vehicle front bumper system that allows ambient air to flow into a cooling assembly located at the front of the vehicle, thereby improving the cooling performance of the cooling assembly.

[0010] According to one aspect of the invention, a vehicle front bumper system may include a bumper beam disposed at the front end of the vehicle, and the bumper beam may have multiple openings.

[0011] The bumper beam can have multiple ribs.

[0012] Each rib can have a streamlined cross-section with a thickness gradually decreasing from a front of the vehicle toward a rear of the vehicle.

[0013] The vehicle front bumper system can further include a reinforcing member attached to the bumper beam, and the reinforcing member can extend in a longitudinal direction of the bumper beam.

[0014] The reinforcing member can have a streamlined cross-section with a thickness gradually decreasing from a front of the vehicle toward a rear of the vehicle.

[0015] The reinforcing member can be at least partially embedded in the bumper beam such that the reinforcing member and the bumper beam can form an integrated whole structure.

[0016] The reinforcing member can be made of a fiber-reinforced composite material.

[0017] The reinforcing member can have an intermediate portion and two end portions made of different types of fiber-reinforced composite materials.

[0018] The vehicle front bumper system can further include a pair of first mounting plates respectively connected to the two end portions of the reinforcing member, and a pair of second mounting plates respectively connected to the pair of first mounting plates.

[0019] Each first mounting plate can have a recess accommodating each end portion of the reinforcing member, and the end portion of the reinforcing member and the recess of the first mounting plate can be joined by a structural adhesive.

[0020] Each first mounting plate can have a pair of flanges, and each second mounting plate can be connected to the pair of flanges of the corresponding first mounting plate.

[0021] The bumper beam can be made of an aluminum material.

[0022] The bumper beam can be made of a plastic material.

[0023] The bumper beam can include an intermediate portion overlapping the cooling assembly and a pair of closed walls located on both sides of the intermediate portion.

[0024] Other applications will become apparent to those skilled in the art from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0025] In order that the application can be well understood, various embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings in which:

[0026] Figure 1A perspective view showing a vehicle front bumper system according to an example embodiment of the present application;

[0027] Figure 2 A perspective view showing Figure 1 A front view showing the vehicle front bumper system shown;

[0028] Figure 3 A perspective view showing Figure 1 An exploded perspective view showing a bumper beam, a plurality of reinforcing members, a pair of first mounting plate members, and a pair of second mounting plate members in the vehicle front bumper system shown;

[0029] Figure 4 A structure in which the plurality of reinforcing members are mounted on the first mounting plate member in the vehicle front bumper system according to an example embodiment of the present application is shown;

[0030] Figure 5 A structure in which the second mounting plate member is mounted on the first mounting plate member in the vehicle front bumper system according to an example embodiment of the present application is shown;

[0031] Figure 6 An enlarged view of part A shown; Figure 1

[0032] Figure 7 A partial cross-sectional perspective view showing a bumper beam in a vehicle front bumper system according to an example embodiment of the present application is shown;

[0033] Figure 8 A partial cross-sectional perspective view showing a reinforcing member in a vehicle front bumper system according to an example embodiment of the present application is shown;

[0034] Figure 9 A perspective view showing a reinforcing member in a vehicle front bumper system according to an example embodiment of the present application is shown;

[0035] Figure 10 A cross-sectional view showing a vehicle front bumper system according to an example embodiment of the present application is shown; and

[0036] Figure 11 A front view showing a vehicle front bumper system according to another example embodiment of the present application is shown.

[0037] The accompanying drawings described herein are for purposes of illustration only and are not intended to limit the scope of the present application in any way.

[0038] Explanation of Reference Numerals:

[0039] 3, 4: Front grille

[0040] 5: Cooling assembly

[0041] 11: Bumper beam​

[0042] 12: reinforcing member

[0043] 13: first mounting plate member

[0044] 14: second mounting plate member

[0045] 21: first wall

[0046] 22: second wall

[0047] 23: third wall

[0048] 24: fourth wall

[0049] 31: first rib portion

[0050] 32: second rib portion

[0051] 33: third rib portion

[0052] 34: fourth rib portion

[0053] 35: opening DETAILED DESCRIPTION

[0054] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0055] Hereinafter, exemplary embodiments of the present application will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals will be used throughout the different drawings and repetitive descriptions of which will be omitted. In addition, detailed descriptions of known technologies related to the present application will be omitted so as not to unnecessarily obscure the present application.

[0056] Terms such as first, second, A, B, (a) and (b) can be used to describe elements in the exemplary embodiments of the present application. These terms are used only to distinguish one element from another element, and the intrinsic characteristics, order or sequence of the corresponding elements are not limited by these terms. Unless otherwise defined, all terms used herein, including technical terms or scientific terms, have the same meanings as those generally understood by those skilled in the art to which the present application pertains. The terms should be interpreted as having a same meaning as commonly used in the relevant technical fields, and should not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.

[0057] A vehicle front bumper system according to exemplary embodiments of the present application can include a bumper beam 11 disposed at a front end of a vehicle.

[0058] Reference Figure 1The bumper cross beam 11 can extend in a width direction of the vehicle, and the bumper cross beam 11 can be adjacent to the cooling assembly 5. In particular, the bumper cross beam 11 can be positioned in front of the cooling assembly 5, and the bumper cross beam 11 can be disposed to partially cover the cooling assembly 5. The bumper cross beam 11 can be a long beam having a length greater than a height and a width of the bumper cross beam. The bumper cross beam 11 can include a plurality of openings 35 that open to the cooling assembly 5.

[0059] The cooling assembly 5 can be mounted on a front end module (FEM) carrier 6. Both ends of the bumper cross beam 11 can be connected to the FEM carrier 6 through a pair of crash boxes 15 and a pair of mounting brackets 16.

[0060] Referring to Figure 10 The cooling assembly 5 can be disposed within a front compartment 2 of the vehicle, and the front compartment 2 can house an internal combustion engine and / or an electric motor, a transmission, and other components. One or more front grilles 3 and 4 can be positioned in front of the front compartment 2, and the cooling assembly 5 can be disposed to face the front grilles 3 and 4.

[0061] According to Figure 10 According to an exemplary embodiment shown in FIG. 1, the front upper grille 3 can be disposed above the bumper cross beam 11, and the front lower grille 4 can be disposed below the bumper cross beam 11.

[0062] According to another exemplary embodiment, the front upper grille 3 can be disposed above the bumper cross beam 11, and a lower closure wall can be disposed below the bumper cross beam 11.

[0063] According to another exemplary embodiment, an upper closure wall can be disposed above the bumper cross beam 11, and the front lower grille 4 can be disposed below the bumper cross beam 11.

[0064] The bumper cross beam 11 can include a first wall 21 facing a top of the vehicle, a second wall 22 facing a bottom of the vehicle, a third wall 23 facing a right side of the vehicle, and a fourth wall 24 facing a left side of the vehicle. The bumper cross beam 11 can include a plurality of ribs 31, 32, 33, and 34 extending within an area defined by the first wall 21, the second wall 22, the third wall 23, and the fourth wall 24, and the plurality of ribs 31, 32, 33, and 34 can define a plurality of openings 35. Ambient air can flow into the cooling assembly 5 through the plurality of openings 35. As the air flows through the openings 35 of the bumper cross beam 11, air resistance is reduced, and thus cooling performance of the cooling assembly 5 can be significantly improved.

[0065] The plurality of ribs 31, 32, 33, and 34 can include a plurality of first ribs 31, a plurality of second ribs 32, a plurality of third ribs 33, and a plurality of fourth ribs 34. Each first rib 31 can extend vertically between the first wall 21 and the second wall 22, and the plurality of first ribs 31 can be spaced apart from each other in the longitudinal direction of the bumper beam 11. Each second rib 32 can extend horizontally in the longitudinal direction of the bumper beam 11, and the plurality of second ribs 32 can extend between the third wall 23 and the fourth wall 24. Each third rib 33 can extend obliquely between the first wall 21 and the second wall 22, and the plurality of third ribs 33 can be spaced apart from each other in the longitudinal direction of the bumper beam 11. Each fourth rib 34 can extend obliquely between the first wall 21 and the second wall 22, and the plurality of fourth ribs 34 can be spaced apart from each other in the longitudinal direction of the bumper beam 11. The oblique direction of each third rib 33 can be symmetrical to the oblique direction of each fourth rib 34, and the third ribs 33 can intersect the fourth ribs 34. The weight of the bumper beam 11 can be reduced by the plurality of openings 35, and the stiffness and / or strength of the bumper beam 11 can be increased by the plurality of ribs 31, 32, 33, and 34.

[0066] Each of the ribs 31, 32, 33, and 34 can have a streamlined cross-section whose thickness gradually decreases from the front of the vehicle toward the rear of the vehicle. As shown in Figure 7 At least some of the ribs 32, 33, and 34 can have a streamlined cross-section, such as a teardrop shape, as shown in FIG. 4. In particular, the teardrop-shaped cross-section of some of the ribs 32, 33, and 34 can be easily formed using a draft angle with respect to a mold parting line. Thus, the bumper beam 11 can obtain significantly improved stiffness as well as reduced weight. Meanwhile, the drag coefficient of an object having a circular cross-section is 0.47, and the drag coefficient of an object having a teardrop-shaped cross-section is 0.04. Thus, the bumper beam 11 having a teardrop-shaped cross-section can maximize the air flow by minimization of drag.

[0067] The vehicle front bumper system 10 according to exemplary embodiments of the present application can further include a plurality of reinforcing members 12 attached to the bumper beam 11. Thus, the stiffness and / or strength of the bumper beam 11 can be increased by the plurality of reinforcing members 12.

[0068] Each reinforcing member 12 can extend in the longitudinal direction of the bumper beam 11, and the plurality of reinforcing members 12 can be spaced apart from each other in the height direction of the bumper beam 11. The plurality of reinforcing members 12 can be attached to both ends of the bumper beam 11 by a pair of first mounting plates 13, and the plurality of reinforcing members 12 can be attached to a pair of crash boxes 15 by a pair of second mounting plates 14.

[0069] Referring toFigure 8 Each of the reinforcing members 12 can have a streamlined cross-section whose thickness gradually decreases from the front of the vehicle toward the rear of the vehicle. In particular, the reinforcing members 12 can have a streamlined cross-section, such as a teardrop shape. In particular, the teardrop-shaped cross-section of the reinforcing members 12 can be easily formed using a draft angle with respect to a mold parting line. Accordingly, the reinforcing members 12 can achieve a significantly improved rigidity as well as a reduced weight. Meanwhile, the drag coefficient of an object having a circular cross-section is 0.47, and the drag coefficient of an object having a teardrop-shaped cross-section is 0.04. Accordingly, the reinforcing members 12 having the teardrop-shaped cross-section can increase or maximize the air flow by reducing or minimizing the drag.

[0070] Referring to Figure 3 A pair of first mounting plate members 13 can be connected to both ends of the reinforcing members 12, respectively. Referring to Figure 4 Each of the first mounting plate members 13 can have a plurality of grooves 41 that respectively receive the ends of the reinforcing members 12, and the plurality of grooves 41 can be spaced apart from each other in the height direction of the first mounting plate member 13. The first mounting plate member 13 can include a pair of flanges 42 disposed at the top end and the bottom end thereof, respectively. For example, each of the ends of the reinforcing members 12 and the grooves 41 of the first mounting plate member 13 can be joined by a structural adhesive. As another example, each of the ends of the reinforcing members 12 and the grooves 41 of the first mounting plate member 13 can be joined by using fasteners or welding.

[0071] A pair of second mounting plate members 14 can be coupled to the pair of first mounting plate members 13, respectively. Referring to Figure 5 Each of the second mounting plate members 14 can have a central opening portion 14a at the central portion thereof, and thus the weight of the second mounting plate member 14 can be reduced. Each of the second mounting plate members 14 can be connected to the flanges 42 of the corresponding first mounting plate member 13 by using fasteners, welding, adhesive, or the like. For example, the second mounting plate member 14 can be connected to the flanges 42 of the first mounting plate member 13 by a rivet or a self-piercing rivet 17. Each of the second mounting plate members 14 can be installed at the front end of the corresponding crash box 15 by welding, using fasteners, or the like.

[0072] According to an exemplary embodiment, the reinforcing members 12 can be made of a fiber-reinforced composite material including continuous fibers such as carbon fibers, aramid fibers, and glass fibers or hybrid fibers in which two or more different fibers are mixed. For example, the reinforcing members 12 can be made of a fiber-reinforced composite material such as a carbon fiber-reinforced polymer (CFRP) composite material.

[0073] According to another exemplary embodiment, as shown in FIG. 9, the reinforcing member 12 can have a middle portion 12a and two opposite end portions 12b made of different types of fiber-reinforced composites. For example, the middle portion 12a of the reinforcing member 12 can be made of a first composite material containing high-tenacity fibers (e.g., aramid fiber-reinforced polymer composite), and the opposite end portions 12b of the reinforcing member 12 can be made of a second composite material containing high-stiffness and high-strength fibers (e.g., carbon fiber-reinforced polymer composite).

[0074] The bumper beam 11 can be made of a lightweight material that is easy to cast. For example, the bumper beam 11 can be made of a light metal such as aluminum. As another example, the bumper beam 11 can be made of a synthetic resin such as plastic. After the first mounting plate member 13 and the second mounting plate member 14 are mounted at the two ends of the reinforcing member 12, the first mounting plate member 13 and the second mounting plate member 14 and the reinforcing member 12 can be integrally connected to the bumper beam 11 by insert molding, such that the first mounting plate member 13 can be at least partially embedded in the rib portions 31, 32, 33, and 34 of the bumper beam 11 (see 18a in FIG. 18), and the reinforcing member 12 can be at least partially embedded in the rib portions 31, 32, 33, and 34 of the bumper beam 11 (see 18b in FIG. 18). Thus, the bumper beam 11, the reinforcing member 12, the first mounting plate member 13, and the second mounting plate member 14 can form an integrated monolithic structure, so that the stiffness and / or strength of the vehicle front bumper system can be significantly improved. Figure 6 Figure 6

[0075] Referring to Figure 11 According to another exemplary embodiment of the vehicle front bumper system according to the present application, the bumper beam 110 can have a middle portion 250 overlapping the cooling assembly 5, and a pair of closed walls 120 and 130 can be located on both sides of the middle portion 250.

[0076] In one embodiment, the middle portion 250 can directly overlap the cooling assembly 5. The middle portion 250 can include a first wall 210 facing the top of the vehicle and a second wall 220 facing the bottom of the vehicle. In other words, the first wall 210 can be disposed above the second wall 220 in the vertical direction of the vehicle. The first wall 210 and the second wall 220 can be spaced apart from each other. The pair of closed walls 120 and 130 can not directly overlap the cooling assembly 5.

[0077] ​​The middle portion 250 can have a plurality of openings 350 to allow ambient air to flow into the cooling assembly 5 and the plurality of openings 350 can directly face the cooling assembly 5 when the middle portion 250 directly overlaps the cooling assembly 5. The plurality of openings 350 can be defined by the plurality of ribs 310, 320, 330, and 340. The plurality of ribs 310, 320, 330, and 340 can extend within an area defined by the first wall 210, the second wall 220, and the pair of closed walls 120 and 130.

[0078] Since the pair of closed walls 120 and 130 do not overlap the cooling assembly 5, they can not have the plurality of openings. The two end portions of the reinforcement member 12, the first mounting plate member 13, and the second mounting plate member 14 can be connected to the pair of closed walls 120 and 130.

[0079] According to another exemplary embodiment, the plurality of openings 350 can be formed only in the middle portion of the bumper beam 110 directly facing the cooling assembly 5, and the two end portions of the bumper beam 110 can be closed. Thus, the manufacturing process of the bumper beam 110 can be simplified, and the manufacturing cost thereof can be reduced.

[0080] As described above, according to the exemplary embodiment of the present application, the bumper beam can have a plurality of openings leading to the cooling assembly, and thus the amount of air flowing through the cooling assembly can be increased. Accordingly, the cooling performance of the cooling assembly can be significantly improved.

[0081] According to the exemplary embodiment of the present application, the bumper beam can have a plurality of ribs defining the plurality of openings, and the rigidity and / or the strength of the bumper beam can be improved by the plurality of ribs. Further, a plurality of reinforcement members can be integrally attached to the bumper beam, which significantly improves the impact absorption performance in the case of a low-speed impact / collision of the vehicle.

[0082] According to the exemplary embodiment of the present application, although the materials of the reinforcement members and the bumper beam are relatively expensive, the cooling performance of the cooling assembly can be improved by the openings of the bumper beam, and thus the sizes of the heat exchanger and the cooling fan constituting the cooling assembly can be reduced. Accordingly, the total manufacturing cost of the vehicle can be reduced.

[0083] According to the exemplary embodiment of the present application, since the bumper beam has a plurality of openings, the degree of freedom in the position of the bumper beam can be increased, and thus the degree of freedom in the design of the front bumper system can be improved.

[0084] According to an exemplary embodiment of the present application, the reinforcing member can be made of a fiber-reinforced composite material, and the weight of the bumper beam can be reduced through the plurality of openings, so the weight reduction of the front bumper system can be effectively achieved. The weight reduction of the front bumper system can contribute to uniform weight distribution with respect to the front and rear of the vehicle, improvement in fuel economy, etc.

[0085] In the foregoing, although the present application has been described with reference to the exemplary embodiments and the accompanying drawings, the present application is not limited thereto, but various modifications and changes can be made thereto by those skilled in the art without departing from the spirit and scope of the present application.

Claims

1. A front bumper system for a vehicle, comprising: The bumper beam located at the front of the vehicle; Reinforcing members attached to the bumper crossbeam; A pair of first mounting plates, the pair of first mounting plates being respectively connected to two ends of the reinforcing member; and A pair of second mounting plates, each connected to a pair of first mounting plates. The bumper beam includes multiple openings. The reinforcing member extends in the longitudinal direction of the bumper beam. Each of the pair of first mounting plates has a groove to receive each end of the reinforcing member. The end of the reinforcing member and the groove of the first mounting plate are joined by a structural adhesive. Each of the pair of first mounting plates has a pair of flanges. Each of the pair of second mounting plates is connected to the pair of flanges of the corresponding first mounting plate in the pair of first mounting plates.

2. The front bumper system for a vehicle according to claim 1, wherein, The bumper beam further includes multiple ribs.

3. The front bumper system for a vehicle according to claim 2, wherein, Each of the plurality of ribs has a streamlined cross-section, the thickness of which gradually decreases from the front of the vehicle toward the rear.

4. The front bumper system for a vehicle according to claim 1, wherein, The reinforcing member has a streamlined cross-section, the thickness of which gradually decreases from the front of the vehicle toward the rear.

5. The front bumper system for a vehicle according to claim 1, wherein, The reinforcing member is at least partially embedded in the bumper beam, so that the reinforcing member and the bumper beam form an integral structure.

6. The front bumper system for a vehicle according to claim 1, wherein, The reinforcing member is made of fiber-reinforced composite material.

7. The front bumper system for a vehicle according to claim 1, wherein, The reinforcing member has a middle section and ends made of different fiber-reinforced composite materials.

8. The front bumper system for a vehicle according to claim 1, wherein, The bumper beam is made of aluminum.

9. The front bumper system for a vehicle according to claim 1, wherein, The bumper beam is made of plastic.

10. The front bumper system of a vehicle according to claim 1, wherein, The bumper beam includes: The middle section overlaps with the cooling components; and A pair of closed walls are located on either side of the middle portion.

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