Bumper system for a motor vehicle

Abstract

The present invention relates to a motor vehicle including a distal end, at least one collision bar, and a bumper system provided at the distal end, wherein the bumper system is configured to limit damage to the motor vehicle by absorbing collision energy in a low-speed collision with an object at the distal end, wherein the bumper system includes a bumper beam and at least one impact box, wherein the bumper beam is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in an RCAR low-speed structural crash test, and wherein the at least one impact box is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in the RCAR low-speed structural crash test to limit the maximum intrusion distance of the object.

Description

Technical Field

[0001] The present invention relates to a bumper system for a motor vehicle and a motor vehicle including said bumper system.

[0002] The project upon which this application is based has been funded by the EU Horizon 2020 research and innovation program, grant agreement number 848620. Background Technology

[0003] When a motor vehicle comes into contact with an external object, such as another motor vehicle, the external object and / or the motor vehicle will be damaged. Generally, the motor vehicle will be damaged. To limit damage, motor vehicles typically include a bumper system at their distal ends (i.e., the front and / or rear).

[0004] In automotive collisions, a distinction is made between low-speed and high-speed collisions. In this context, a collision at 15 km / h is considered a low-speed collision, while a collision at speeds exceeding 15 km / h is considered a high-speed collision. During a low-speed collision, the primary concern is minimizing damage to the vehicle, while for a high-speed collision, the primary concern is the safety of the occupants.

[0005] The object of this invention is to reduce damage to motor vehicles in low-speed collisions. This object is particularly relevant to expensive motor vehicles, as repair costs are often also high. Expensive motor vehicles are, for example, those that include solar panels.

[0006] Vehicles that are at least partially charged by solar energy include solar panels provided on the upper surface of the vehicle and used to charge one or more battery packs. The battery packs provide at least a portion of the energy required to power the vehicle. To maximize solar charging capacity, the area of ​​the solar panels on the upper surface of the vehicle needs to be maximized. The area of ​​the solar panels is related to the number of kilometers driven solely by the sun per year, where a larger solar panel area means more annual solar kilometers. Because solar panels are expensive components, damage to them in low-speed collisions should be prevented. Summary of the Invention

[0007] Purpose of the invention

[0008] One object of the present invention is to provide a motor vehicle that suffers less damage in a low-speed collision.

[0009] Another object of the present invention is to provide a motor vehicle capable of traveling for more years of solar-powered kilometers.

[0010] Invention Summary

[0011] To achieve at least one objective, a motor vehicle is provided, comprising:

[0012] remote,

[0013] At least one collision bar extends toward the distal end in the longitudinal direction of the vehicle, the collision bar including a free end.

[0014] A bumper system is provided at the distal end, wherein the bumper system is configured to limit damage to the motor vehicle by absorbing collision energy in a low-speed collision with an object at the distal end, wherein the bumper system includes

[0015] The bumper beam extends substantially perpendicular to the longitudinal axis of the vehicle.

[0016] At least one collision box extending generally parallel to the longitudinal axis of the motor vehicle, the at least one collision box including a first end and an opposing second end, wherein the first end is connected to the bumper crossbeam, and wherein the second end is connected to the free end of the at least one collision bar of the motor vehicle.

[0017] The bumper beam is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in a low-speed structural crash test (RCAR), and the at least one impact box is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in the RCAR low-speed structural crash test to limit the maximum intrusion distance of the object.

[0018] RCAR stands for the Automotive Repair Research Committee, hereinafter referred to as RCAR. The RCAR low-speed structural crash test is a widely used test to determine the extent of damage to motor vehicles.

[0019] Motor vehicle bumper systems are configured to limit the maximum intrusion distance of objects. By limiting the maximum intrusion distance, a larger portion of the vehicle remains undamaged during low-speed collisions. This reduces damage costs and increases usable space, such as in the trunk, and, in cases where the vehicle includes solar panels, increases the usable area of ​​those panels. This is advantageous for expensive motor vehicles because a limited intrusion distance results in less damage compared to a greater intrusion distance.

[0020] This is particularly advantageous for motor vehicles with solar panels on their upper surfaces. By limiting the maximum intrusion distance, the larger upper surface area of ​​a motor vehicle can be used to provide solar panels without damaging them in low-speed collisions. Consequently, providing more solar panels will increase the annual solar kilometers.

[0021] The maximum intrusion distance is reduced by having the bumper beam absorb at least 35%, preferably at least 40%, and more preferably at least 45% of the collision energy. In known bumper systems including a bumper beam and at least one impact box, the bumper beam is configured to absorb less than 35% of the collision energy, wherein at least one impact box is configured to absorb at least 65% of the collision energy in a 15 km / h collision.

[0022] Because the bumper beam absorbs a greater amount of collision energy, the crash box can absorb less. Therefore, the crash box can be shorter. A shorter crash box provides a shorter bumper system in the longitudinal direction. A shorter bumper system can provide more space, for example, in the trunk of a motor vehicle.

[0023] In one embodiment, the motor vehicle includes a chassis, wherein an outer body is provided on the chassis, the outer body including an upper surface including at least one solar panel.

[0024] In one embodiment of the motor vehicle, in a low-speed collision, the maximum intrusion distance along the distal end is defined as a maximum intrusion line extending substantially parallel to the distal end at that distance, wherein, in a top view, at least one solar panel extends from the maximum intrusion line away from the distal end.

[0025] In one embodiment of the motor vehicle, at least one collision bar is connected at its free end to a second end of at least one collision box and at its opposite end to the chassis, wherein, in a top view, at least one solar panel extends from the free end of at least one collision bar away from the distal end.

[0026] In one embodiment of the motor vehicle, the bumper system includes two impact boxes positioned a distance apart from each other in a direction generally perpendicular to the longitudinal axis of the motor vehicle.

[0027] In an embodiment of a motor vehicle, at least one collision box includes a hollow beam, wherein the internal volume of the hollow beam includes aluminum foam filler.

[0028] Aluminum foam filler increases the energy that can be absorbed by the impact box, thus reducing the intrusion distance. One advantage of the foam filler is that it reduces the length of the impact box, as the same amount of energy can be absorbed by a shorter impact box. This frees up more usable space for applications such as the trunk or solar panels.

[0029] In one embodiment of the motor vehicle, the hollow beam has a wall thickness between 1 and 3 mm. This relatively large thickness increases the energy that can be absorbed by the impact box while maintaining a simple structure.

[0030] In one embodiment of the motor vehicle, the bumper beam and / or at least one collision box are made of a material including aluminum.

[0031] In one embodiment of the motor vehicle, the bumper beam has a fill ratio of at least 25% in a cross-sectional view.

[0032] In one embodiment of a motor vehicle, the bumper beam has a wall thickness between 3 and 5 mm. This relatively high thickness increases the energy that can be absorbed by the bumper beam while maintaining a simple structure.

[0033] In one embodiment of the motor vehicle, the bumper beam is curved in a top view.

[0034] In one embodiment of the motor vehicle, the bumper beam has a length that is equal to or greater than the distance between two collision boxes and at least less than or equal to the far-end width of the motor vehicle.

[0035] In one embodiment of the motor vehicle, the bumper beam and at least one impact box are configured to absorb impact energy through their plastic deformation.

[0036] The present invention further relates to a bumper system configured to be provided at the distal end of a motor vehicle, wherein the bumper system is configured to limit damage to the motor vehicle by absorbing collision energy in a low-speed collision with an object at the distal end, wherein the bumper system includes

[0037] Bumper crossbeam

[0038] At least one collision box extends substantially perpendicular to the bumper crossbeam, the at least one collision box including a first end and an opposing second end, wherein the first end is connected to the bumper crossbeam, and wherein the second end is configured to connect to the collision bar of the motor vehicle.

[0039] The bumper beam is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in a low-speed structural crash test (RCAR), and the at least one impact box is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in the RCAR low-speed structural crash test to limit the maximum intrusion distance of the object. Attached Figure Description

[0040] Referring to the accompanying schematic diagrams, embodiments of the system and method are described by way of example only. In the drawings, corresponding reference numerals denote corresponding components.

[0041] Figure 1 A top view schematically illustrates an embodiment of a motor vehicle according to the invention, the motor vehicle including an embodiment of a bumper system according to the invention.

[0042] Figure 2A A schematic top view of the RCAR low-speed structural crash test apparatus is shown.

[0043] Figure 2B A schematic side view of the RCAR low-speed structural crash test apparatus is shown.

[0044] Figures 3A to 3C The diagram schematically shows a top view of different stages of the RCAR low-speed structural crash test process.

[0045] Figure 4 A schematic top cross-sectional view of the distal end of a motor vehicle including an embodiment of the bumper system according to the invention is shown, with particular emphasis on the maximum intrusion distance.

[0046] Figure 5 A perspective view schematically illustrating an embodiment of the bumper system according to the present invention is shown.

[0047] Figure 6 Schematic illustration of the connection to the collision bar. Figure 5 A perspective view of the bumper system.

[0048] Figure 7 A cross-section of an embodiment of the bumper beam of the bumper system according to the present invention is shown schematically.

[0049] Figure 8 A cross-section of an embodiment of the collision box of the bumper system according to the present invention is shown schematically. Detailed Implementation

[0050] Turning Figure 1 The diagram illustrates a motor vehicle 1, particularly a motor vehicle for transporting at least one person. The motor vehicle 1 includes a distal end 2. In the diagram shown, the rear end 2A of the motor vehicle 1 is the distal end 2. The front end 2B of the motor vehicle 1 may also be the distal end 2.

[0051] At least one collision bar 3, here two collision bars 3, extends toward the distal end 2 in the longitudinal direction 4 of the vehicle 1. The collision bar 3 includes a free end 5. The collision bar 3 is connected to the chassis (not shown) of the motor vehicle 1 at its opposite end 23.

[0052] A bumper system 6 is provided at the distal end 2. The bumper system 6 is configured to limit damage to the motor vehicle 1 by absorbing collision energy in a low-speed collision 7 with an object 8 at the distal end 2.

[0053] The bumper system 6 includes a bumper beam 10 extending substantially perpendicular to the longitudinal axis 11 of the vehicle 1. The bumper system 6 further includes at least one collision box 12, here two collision boxes 12, which extend substantially parallel to the longitudinal axis 11 of the vehicle 1. See also... Figure 3C The collision box 12 includes a first end 13 and an opposing second end 14. The first end 13 is connected to the bumper beam 10. The second end 14 is connected to the free end 5 of at least one collision rod 3 of the motor vehicle 1.

[0054] See Figure 4 The two collision boxes 12 are positioned at a distance 24 from each other in a direction that is approximately perpendicular to the longitudinal axis 11 of the motor vehicle 1.

[0055] The bumper beam 10 is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in an RCAR low-speed structural crash test. At least one impact box 12 is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy in an RCAR low-speed structural crash test 15 to limit the maximum intrusion distance 16 of the object 8.

[0056] An external body 18 is provided on a chassis. The external body 18 includes an upper surface 19, which includes at least one solar panel 20. In the illustrated embodiment, the front upper surface 19A, the middle upper surface 19B, and the rear upper surface 19C include solar panels 20.

[0057] like Figure 1 As can be seen from the top view, the bumper system 6 is located within a volume surrounded by the outer body 18.

[0058] Turning Figures 2A to 3C The diagram illustrates the RCAR low-speed structural crash test 15. Figure 2A-2B and Figures 3A-3C Taken from RCAR Low-Speed ​​Structural Crash Test Protocol, Appendix 2, July 2011, Issue 2.2.

[0059] Figure 2A and Figure 2B The diagram shows a top view and a side view of a motor vehicle 1 undergoing an RCAR low-speed structural crash test 15 before the collision. The motor vehicle 1 will collide with an external object 8 at a speed of 15 km / h. This is considered a low speed, and the collision bar 3 is configured to remain intact.

[0060] The motor vehicle 1 will collide with the external object 8 at an angle of 10 degrees relative to the longitudinal axis 11 of the motor vehicle 1.

[0061] Figures 3A to 3C The diagram illustrates different moments in the deformation process. Figure 3A The image shows the situation just before impact with the bumper beam, with the external object 8 located near the bumper beam 10 of the bumper system 6. The external vehicle body 18 is not shown.

[0062] Figure 3BThis shows a section of the bumper beam 10, particularly the outer section, being completely crushed.

[0063] Figure 3C The diagram shows the situation where the bumper beam 10 and the impact box 12 are completely deformed. In this case, the total impact energy of the low-speed impact is absorbed, with the bumper beam 10 absorbing at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy, and the impact box 12 absorbing at least 35%, preferably at least 40%, more preferably at least 45% of the impact energy. Because it is a low-speed structural impact test 15, the impact bar 3 is not damaged.

[0064] like Figure 3C As shown, the bumper beam 10 and at least one impact box 12 are configured to absorb impact energy through their plastic deformation 35.

[0065] Figure 4 A schematic top-view cross-section of the distal end 2 of a motor vehicle 1 is shown, in which a bumper system 6 is shown. A low-speed impact results in a maximum intrusion distance 16 along the distal end 2. The maximum intrusion distance 16 along the distal end 2 is defined at a distance 22 that is approximately parallel to a maximum intrusion line 21 extending from the distal end 2.

[0066] The maximum intrusion line 21 extends at least partially between the free end 5 and the distal end 2 of the collision rod 3.

[0067] In the top view, at least one solar panel 20 (not shown) extends from the maximum intrusion line 21 away from the distal end 2. This allows for an increase in the area of ​​the solar panel 20 compared to extending the solar panel 20 from the free end 5 of the impact rod 3. In a low-speed collision, damage to the solar panel 20 will be prevented or at least limited because the solar panel 20 will not extend beyond the maximum intrusion distance 16.

[0068] At least one solar panel 20 may alternatively extend from the free end 5 of at least one impact rod 3 away from the distal end 2. This configuration still allows for a large solar panel area while further preventing or limiting damage to the solar panel.

[0069] The shorter maximum intrusion distance 16 allows the collision bar 3 to extend further towards the distal end 2. Since the trunk is typically provided from the free end 5 of the collision bar 3 toward the opposite distal end 2, the size of the trunk can be increased.

[0070] The bumper beam 10 has a length of 32. The length 32 is equal to or greater than the distance 24 between the two collision boxes 12, and is at least less than or equal to the width 34 of the far end 2 of the motor vehicle 1.

[0071] When viewed from above, the bumper beam 10 appears curved.

[0072] Turning Figure 5 and Figure 6 An embodiment of the bumper system 6 is shown, wherein in Figure 6 In the middle, the bumper system 6 is connected to the two collision bars 3.

[0073] The bumper beam 10 and / or at least one collision box 12 may be made of materials including aluminum. The bumper beam 10 and / or at least one collision box 12 may be made entirely of aluminum alloy.

[0074] like Figure 7 As shown, in a cross-sectional view, an embodiment of the bumper beam 10 has an infill ratio 30 of at least 25%. The infill ratio 30 is the amount of material within the outer circumference of the cross-section relative to the total cross-sectional area. A higher infill ratio 30 can increase the amount of energy that can be absorbed by the bumper beam 10. Therefore, a higher infill ratio 30 can help limit the intrusion distance during a collision.

[0075] The bumper beam 10 can have a wall thickness 31 between 3 and 5 mm. This embodiment is easy to manufacture because it does not require a complex cross-sectional profile. The fill ratio 30 can also be achieved with a more complex cross-sectional profile.

[0076] Figure 8 A cross-sectional view of one embodiment of the impact box 12 is shown. The impact box 12 includes a hollow beam 26. The internal volume 27 of the hollow beam 26 includes aluminum foam filler 28. The aluminum foam filler 28 is schematically shown. The aluminum foam filler 28 can reduce the peak force on the impact box 12. The reduced peak force, in turn, allows for a reduction in the weight of the impact rod 3.

[0077] The hollow beam 26 can have a wall thickness between 1 and 3 mm.

[0078] Detailed embodiments of the invention are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely examples of the invention, which may be implemented in various forms. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as the basis for the claims and as a representative basis for teaching those skilled in the art to use the invention differently in any suitable detailed configuration. Furthermore, the terminology and phrases used herein are not intended to be limiting, but rather to provide an understandable description of the invention.

[0079] The term “a” or “an” as used herein is defined as one or more. The term “another” as used herein is defined as at least a second or more. The terms “comprising” and / or “having” as used herein are defined as including (i.e., open-ended language, not excluding other elements or steps). Any reference numerals in the claims should not be construed as limiting the scope of the claims or the invention.

[0080] The fact that certain measures are referenced only in mutually different dependent claims does not mean that a combination of these measures cannot be used advantageously.

Claims

1. A motor vehicle (1), comprising: A chassis, wherein an outer body (18) is provided on the chassis, the outer body including an upper surface (19) including at least one solar panel (20). Distant end (2) At least one collision bar (3) extends toward the distal end in the longitudinal direction (4) of the vehicle, the collision bar including a free end (5). A bumper system (6) is provided at the distal end, wherein the bumper system is configured to limit damage to the motor vehicle in a low-speed collision (7) by absorbing collision energy, wherein the bumper system includes: The bumper beam (10) extends substantially perpendicular to the longitudinal axis (11) of the motor vehicle. At least one collision box (12) extends substantially parallel to the longitudinal axis of the motor vehicle, the at least one collision box including a first end (13) and an opposing second end (14), wherein the first end is connected to the bumper crossbeam, and wherein the second end is connected to the free end of the at least one collision bar of the motor vehicle. The bumper beam is configured to absorb at least 35% of the impact energy in the RCAR low-speed structural crash test (15), and the at least one impact box is configured to absorb at least 35% of the impact energy in the RCAR low-speed structural crash test to limit the maximum intrusion distance of the object (16). In the low-speed collision, the maximum intrusion distance along the distal end is defined at a distance (22) approximately parallel to the maximum intrusion line (21) extending from the distal end, wherein, in a top view, the at least one solar panel extends from the maximum intrusion line away from the distal end. And / or wherein the at least one impact rod is connected at its free end to the second end of the at least one impact box and at its opposite end (23) to the chassis, wherein, in a top view, the at least one solar panel extends from the free end of the at least one impact rod away from the distal end.

2. The motor vehicle of claim 1, wherein the bumper system comprises two impact boxes positioned at a distance (24) from each other in a direction substantially perpendicular to the longitudinal axis of the motor vehicle.

3. The motor vehicle according to claim 1, wherein the at least one collision box includes a hollow beam (26), wherein the internal volume (27) of the hollow beam includes aluminum foam filler (28).

4. The motor vehicle according to claim 3, wherein the hollow beam has a wall thickness between 1 and 3 mm.

5. The motor vehicle of claim 1, wherein the bumper beam and / or the at least one collision box is made of a material including aluminum.

6. The motor vehicle according to claim 1, wherein, in a cross-sectional view, the bumper beam has a fill ratio of at least 25% (30).

7. The motor vehicle according to claim 1, wherein the bumper beam has a wall thickness (31) between 3 and 5 mm.

8. The motor vehicle according to claim 1, wherein the bumper beam is curved in a top view.

9. The motor vehicle according to claim 2, wherein the bumper beam has a length (32), wherein the length is equal to or greater than the distance (24) between the two collision boxes, and is at least less than or equal to the far-end width (34) of the far end of the motor vehicle.

10. The motor vehicle of claim 1, wherein the bumper beam and the at least one impact box are configured to absorb the impact energy through their plastic deformation (35).

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