Front end panel for electric vehicles

Abstract

The invention relates to a front end panel assembly (100) for an electric vehicle (300), the assembly comprising: an at least partially optically transparent laminate sheet (108) having side edges, the at least partially optically transparent laminate sheet (108) comprising an optically transparent thermoplastic substrate and at least one protective layer; and a spacer structure (112) comprising a base (110) and a peripheral upstanding wall (120) extending from the base, wherein the upstanding wall is connected to the laminate at or near at least a portion of the side edges of the laminate such that a space (122) is formed and enclosed between the laminate sheet and the spacer structure, and wherein the at least one protective layer of the laminate is facing away from the spacer structure.

Description

[0001] This application is a divisional application of the application filed on October 16, 2018, with application number 201880067072.4 and invention title "Front-end panel for electric vehicle". Technical Field

[0002] This invention relates to a front-end panel for electric vehicles, the front-end panel comprising a polycarbonate sheet layer and a spacer or carrier structure. The invention also relates to a front-end panel module for electric vehicles, the front-end panel module comprising a plurality of such front-end panel assemblies. Furthermore, the invention relates to vehicles comprising such a front end. Background Technology

[0003] The shift of the automotive industry from fuel-powered or hybrid vehicles to electric vehicles has many consequences for engine design, as well as for the exterior design of automobiles and motor vehicles, especially the front trim.

[0004] Vehicles, especially automobiles, feature grilles or grates on the front fascia that form a barrier or screen, primarily functioning to allow cooling air into the car's radiator. However, they also play a prominent role in attracting car buyers. Grilles are often distinctive styling elements, and many OEMs use them as their primary brand identifier.

[0005] With the introduction of electric vehicles, the primary function of allowing cool air into the radiator is no longer necessary. This opens up new design possibilities, where the grille can be replaced by a closed component. Summary of the Invention

[0006] According to the present invention, a front-end panel assembly for an electric vehicle is provided, the assembly comprising:

[0007] - At least partially optically transparent laminated sheet having side edges, the at least partially optically transparent laminated sheet comprising an optically transparent thermoplastic substrate and at least one protective layer;

[0008] - A spacer structure comprising a base and peripheral upright walls extending from the base, wherein the upright walls are connected to the laminate at or near at least a portion of a side edge of the laminate, such that a space is formed and closed between the laminate sheet and the spacer structure, and wherein at least one protective layer of the laminate faces away from the spacer structure.

[0009] The assembly forms a closed space or box having one side that provides at least partially optically transparent optically, and multiple sides that provide optically transparent or opaque, or a combination thereof, spacer structures or carrier structures. The laminate sheet and the substrate of the spacer structure are spaced apart by upright walls around the periphery of the spacer structure. The upright walls of the spacer structure are connected to the laminate sheet at or near the peripheral edge of the laminate sheet, such that the assembly forms a closed unit. The laminate sheet may be optically transparent over its entire surface area, but partially opaque or even completely opaque laminate sheets are also possible.

[0010] According to one embodiment, the laminated sheet includes a patterned layer facing the spacer structure, the patterned layer causing portions of the laminate to be opaque for pattern formation. On the inner side of the assembly, the laminated sheet may include a layer that forms a pattern when light is reflected onto or radiated through the laminated sheet. The pattern can be formed by causing portions of the laminated sheet to be opaque or by having a different optical transparency compared to the surrounding area of ​​the laminated sheet.

[0011] The optically transparent thermoplastic substrate is transparent to light visible to the human eye, wherein the transmittance of visible light exceeds 30%. The transparent thermoplastic substrate can be combined with an opaque thermoplastic layer, wherein the opacity is defined as having a visible light transmittance of up to 30%. The transparent and opaque thermoplastic layers can contain similar or different materials. Both the opaque and optically transparent layers can be colored, while the optically transparent substrate remains clear.

[0012] According to one embodiment, the patterned layer may comprise a foil bonded to the surface facing the spacer structure. The foil may be overmolded onto an optically clear substrate, or may be a foil provided to the substrate at a later stage. Alternatively, the patterned layer may be formed by a patterned printing layer on the substrate, such as screen printing. Preferably, the patterned layer comprises an overmolded thermoplastic layer having an open structure. The overmolded patterned layer may be provided onto the optically clear substrate during a dual-injection molding process, also known as 2K-IM. In a first injection molding step, the substrate is fabricated. In a subsequent second injection molding step, the patterned layer is molded onto a first surface of the substrate. A protective layer is then applied to a second surface of the substrate opposite the first surface. The protective layer may comprise a scratch-resistant layer and / or a UV-resistant layer, or any protective layer that renders the substrate suitable for environmental exposure.

[0013] According to another embodiment, at least the inner surface of the substrate of the spacer structure includes a mirror for reflecting visible light, and the inner surface of the laminated sheet facing the spacer structure includes a translucent mirror, thereby creating an infinite mirror in the front panel assembly. The entire inner surface of the spacer structure can be provided with reflective mirrors, including the inner surface of the peripheral uprights. The infinite mirror exhibits optimal effect when used in combination with a lamp module, such as an LED lamp module.

[0014] According to one embodiment, the component further includes a lamp module enclosed within a space formed between the laminated sheet and the spacer structure. The lamp module can be provided as an illuminated pattern or illuminated sculpture within the space between the laminated sheet and the spacer structure. In that case, the illuminated module can replace the patterned layer on the inner side of the laminated sheet. Alternatively, the illuminated module can be placed behind the patterned layer to enhance and illuminate the pattern when the illuminated module is turned on.

[0015] According to another embodiment, the laminated sheet includes a peripheral opaque strip extending from the side edges of the laminated sheet. The opaque strip or band can be used to conceal any connection areas between the laminated sheet and the spacer structure, enhancing the aesthetic appearance of the front panel assembly. Preferably, the opaque strip is part of a patterned layer and can be used as the starting point for open structural portions of the patterned layer.

[0016] The spacer structure preferably comprises thermoplastic materials, such as polyolefins like PE or PP; polybutylene terephthalate (PBT); acrylonitrile-butadiene-styrene (ABS); acrylic-styrene-acrylonitrile (ASA); polycarbonate; polycarbonate / PET blends; polycarbonate / ABS blends; polycarbonate / ASA blends; copolycarbonate-polyester; acrylonitrile-(ethylene-polyacrylamide modified)-styrene (AES); phenylene ether resin (PPO); PPO / PS blends; polyphenylene ether / polyamide blends; polyamide; phenylene sulfide resin; polyvinyl chloride (PVC); high-impact polystyrene (HIPS); low / high-density polyethylene (L / HDPE); polypropylene (PP); expanded polypropylene (EPP); polymethyl methacrylate; and thermoplastic olefins (TPO). The polymer or thermoplastic material may be a linear polymer or a branched polymer or a combination thereof. The plastic can optionally be reinforced, for example, with fibers, granules, sheets, and combinations comprising at least one of the foregoing, such as, in particular, long glass fibers, short glass fibers, glass beads, talc, mica, inorganic fillers, natural fibers, conductive fillers, and / or carbon fibers. For example, the thermoplastic second component can be made of... The material is formed as commercially available long glass fiber reinforced polypropylene from SABIC.

[0017] The optically transparent thermoplastic material of the laminated sheet preferably comprises polycarbonate or polymethacrylate, or any other optically transparent thermoplastic material. The laminated sheet may be a flat panel, or may have a slight curvature, i.e., a convex shape, for example to have a smooth transition and / or to be flush with other parts of the vehicle's front trim panel.

[0018] According to one embodiment, the substrate of the spacer structure has an inner surface facing the laminated sheet. This inner surface may be smooth, textured, and / or corrugated. Alternatively, the inner surface may be surface-treated. The inner surface of the spacer structure is used to create depth or 3D effects in the front panel assembly.

[0019] When it is desirable to integrate electronic components into an assembly, an assembly having a receiving portion that includes the electronic components for integration with the assembly can be advantageous. Preferably, the receiving portion extends into the laminated sheet and is at least partially enclosed by a spacer structure. The receiving portion can receive any type of electronic component, including a LiDAR module intended for a self-driving vehicle. Front panel assemblies would be highly suitable for integrating such components.

[0020] The present invention also relates to a front panel module for an electric vehicle, the front panel module comprising a plurality of front panel assemblies as described above. As an example, the front panel module may comprise three front panel assemblies, two of which are mirror images of each other and a third is placed in the middle to form a symmetrical front panel module. The two mirrored assemblies may be partially optically transparent and have patterned or light modules, while the third and middle assemblies may comprise opaque laminated sheets, such that the middle assemblies can act as an integration box for electronic components, while concealing the electronic components from view.

[0021] The present invention further relates to electric vehicles comprising a front panel assembly or front panel module as described above. The front panel assembly or front panel module may form part of the front trim of the vehicle, or may form the entire front trim of the vehicle. According to one embodiment, a pair of headlights are located on either side of the assembly or module, thereby forming a symmetrical front portion of the vehicle. Attached Figure Description

[0022] The features and advantages of the invention will be further understood by referring to the following figures, in which many exemplary embodiments are shown:

[0023] Figure 1a shows a perspective view of the front panel assembly according to a first embodiment of the present invention;

[0024] Figure 1b shows a cross-section along the AA of the front panel assembly of Figure 1a;

[0025] Figure 2 A cross-section of the front panel assembly according to a second embodiment of the present invention is shown;

[0026] Figure 3 A perspective view showing a front panel module including a front panel assembly according to a third embodiment of the present invention. Detailed Implementation

[0027] Figure 1a shows a perspective view of a front panel assembly 100 according to a first embodiment of the present invention. The front panel assembly 100 is provided as a component of a front trim panel 304 of a vehicle 300. The front panel assembly 100 comprises a laminated sheet 108 (see Figure 1b) at its front, the laminate being partially opaque at the opaque peripheral strip 102 and at the opaque lines 104 of the pattern 106. The front panel assembly is located between a pair of headlights 302 on either side of it. At its top, a hood 308 of the vehicle is positioned; at its bottom, a bumper assembly 306 of the vehicle is provided, also see Figure 1b. Figure 3 Adjacent to the opaque perimeter strip and opaque pattern lines, pattern 106 includes an open structured portion in which the optically transparent laminate 108 (see Figure 1b) is visible. Behind the laminate, a corrugated substrate 110 displays the spacer structure 112 (see Figure 1b).

[0028] Figure 1b shows a cross-section along AA of the front panel assembly of Figure 1a. The front panel assembly 100 is shown as having a laminated sheet 108 located at the front end of the vehicle's front trim panel, also referring to Figure 1a, between the headlight assemblies 302. The outer surface of the laminated sheet 108 includes one or more protective layers to protect the laminate, specifically its thermoplastic substrate, from environmental factors such as abrasion and ultraviolet radiation. The laminated sheet 108 includes an optically clear substrate, preferably an optically clear substrate of polycarbonate resin. Additionally, the laminated sheet 108 has a patterned layer 106 consisting of opaque lines 104. An opaque strip 102 may be a portion of the patterned layer 106. Between the opaque lines 104 and the strip 102, the optically clear laminated sheet is exposed. Viewed from the laminated sheet 108, a spacer structure 112 is provided behind the laminated sheet 108. The spacer structure 112 includes a substrate 110 and peripheral upright walls 120 extending from the substrate 110 and connecting to the laminated sheet 108 at or near its side edges, for example, at the location of the peripheral opaque strip 102. The peripheral upright walls 120 space the substrate 110 away from the laminated sheet 108. The laminated sheet 108 and the spacer structure 112 together enclose space 122. The substrate 110 in FIG. 1b is corrugated with a sawtooth wave pattern. Any other corrugated wave pattern may also be used. The corrugated substrate adds a 3D effect to the front panel assembly, specifically to the pattern provided on the laminated sheet. The inner surface 114 of the substrate 110 may be provided with foil, mirror, screen printing, or any other surface reinforcement layer to optimize the 3D effect.

[0029] The front panel assembly further includes a receiving portion 116 to receive electronic components 118, such as sensors or LiDAR components, or lamp modules. The receiving portion 116 extends through the substrate 119 to the laminated sheet 108 and is closed by the peripheral wall 120 of the spacer structure 112.

[0030] Figure 2 A cross-section of a front panel assembly 100 according to a second embodiment of the invention is shown. This second embodiment shows a laminated sheet 108 having a pattern 106, said pattern 106 being a foil 107 having a pre-manufactured pattern made of optically transparent and opaque regions 104, 105, including an opaque strip 102 around the side edges of the laminated sheet 108. A spacer structure 112 includes a substrate 110 and peripheral uprights 120, said uprights extending from the substrate 110... Figure 2 The middle extends toward the side edge of the laminated sheet 108 through the smooth curved transition region 113, or extends substantially vertically at the receiving portion 116.

[0031] The inner surface 114 of the spacer structure can be laser-marked to include color changes due to chemical / molecular alterations, carbonization, blistering, melting, ablation, and more. This laser marking adds a 3D effect to the pattern and the spacing between the laminated sheet and the substrate of the spacer structure. Between the substrate and the laminated sheet, the front panel assembly may further include a light module 124 for highlighting the pattern and 3D effect of the front panel assembly. The light module 124 can also be used for design purposes such as branding or as a welcome signal to the vehicle driver.

[0032] Figure 3 A perspective view of a front panel module 130 comprising front panel assemblies 100, 101, and 103 according to a third embodiment of the present invention is shown.

[0033] Three front panel assemblies 100, 101, and 103 together form a front panel module 130. The intermediate front panel assembly 101 has a largely opaque laminated sheet, except for one or more receiving portions 116 for the electronic component 118. Two side front panel assemblies 103, provided on each side of the intermediate front panel assembly 101, comprise a largely optically transparent laminated sheet 108 and a spacer or carrier structure 112 placed behind the laminated sheet. A lamp module 124 is placed within the space enclosed by the laminated structure 108 and the spacer structure 112. This lamp module 124 is designed with a specific pattern that is visible when the lamp module is off and protrudes when the lamp module is on.

[0034] Project List

[0035] 100. Front-end panel components

[0036] 101. Middle Front-End Panel Component

[0037] 102. Opaque strip around the perimeter

[0038] 103. Side Front Panel Component

[0039] 104. Opaque Pattern Lines

[0040] 105. Transparent pattern section

[0041] 106. Pattern Layer

[0042] 107. Foil

[0043] 108. Laminated sheets

[0044] 110. Base

[0045] 112. Spacing structure

[0046] 113. Transition Zone

[0047] 114. Inner surface of the substrate

[0048] 116. Receiving section

[0049] 118. Electronic components

[0050] 120. Surrounding vertical walls

[0051] 122. Space

[0052] 124. Lamp Module

[0053] 130. Front-end panel module

[0054] 300. Vehicles

[0055] 302. Headlights

[0056] 304. Front trim panel

[0057] 306. Bumper assembly

[0058] 308. Engine Hood

[0059] The present invention also includes the following aspects.

[0060] 1. A front-end panel assembly for an electric vehicle, the assembly comprising:

[0061] - At least partially optically transparent laminated sheet having side edges, the at least partially optically transparent laminated sheet comprising an optically transparent thermoplastic substrate and at least one protective layer;

[0062] - A spacer structure comprising a base and peripheral upright walls extending from the base, wherein the upright walls are connected to the laminate at or near at least a portion of a side edge of the laminate, such that a space is formed and closed between the laminate sheet and the spacer structure, and wherein at least one protective layer of the laminate faces away from the spacer structure.

[0063] 2. The component according to aspect 1, wherein the laminated sheet includes a patterned layer facing the spacer structure, the patterned layer causing a portion of the laminate to be opaque for pattern formation.

[0064] 3. The component according to aspect 2, wherein the patterned layer comprises a foil bonded to the surface facing the spacer structure.

[0065] 4. The component according to aspect 2 or 3, wherein the patterned layer comprises an overmolded thermoplastic layer having an open structure.

[0066] 5. The component according to any one of the foregoing aspects, further comprising a lamp module enclosed within the space formed between the laminated sheet and the spacer structure.

[0067] 6. The component according to any one of the foregoing aspects, wherein the spacer structure comprises a thermoplastic material.

[0068] 7. The component according to any one of the preceding aspects, wherein the substrate of the spacer structure has an inner surface facing the laminated sheet, and wherein the inner surface is smooth, textured, and / or corrugated.

[0069] 8. The assembly according to any one of the preceding aspects, wherein at least the inner surface of the substrate of the spacer structure includes a mirror for reflecting visible light, and the inner surface of the laminated sheet facing the spacer structure includes a translucent mirror, such that an infinity mirror is formed in the front panel assembly.

[0070] 9. The component according to any one of the foregoing aspects, comprising a receiving portion for electronic components to be integrated with said component.

[0071] 10. The component according to aspect 9, wherein the receiving portion extends to the laminated sheet and is at least partially enclosed by the spacer structure.

[0072] 11. The component according to any one of the foregoing aspects, wherein the laminated sheet includes a peripheral opaque strip extending from a side edge of the laminated sheet.

[0073] 12. A front panel module for an electric vehicle, the front panel module comprising a plurality of front panel assemblies according to any one of the preceding aspects.

[0074] 13. An electric vehicle comprising a front panel assembly according to any one of aspects 1 to 11 or a front panel module according to aspect 12.

[0075] 14. The vehicle according to aspect 13, wherein the front panel assembly or front panel module forms part of the front trim panel of the vehicle.

[0076] 15. The vehicle according to aspect 13 or 14, wherein a pair of headlights are located on either side of the component or the module.

Claims

1. A front panel assembly for forming a closed space by replacing the grille in an electric vehicle, the assembly comprising: - At least partially optically transparent laminated sheet having side edges, the at least partially optically transparent laminated sheet comprising an optically transparent thermoplastic substrate and at least one protective layer, wherein the at least partially optically transparent laminated sheet is shaped to be flush with the components of the front trim panel; A spacer structure comprising a base and peripheral upright walls extending from the base, wherein the upright walls are connected to the laminate at or near at least a portion of a side edge of the laminate, such that a closed space is formed between the laminate and the spacer structure, and wherein at least one protective layer of the laminate faces away from the spacer structure. The at least partially optically transparent laminated sheet has a slight curvature to be flush with the front trim panel components.

2. The component of claim 1, wherein the laminated sheet includes a patterned layer facing the spacer structure, the patterned layer causing a portion of the laminated sheet to be opaque for pattern formation.

3. The component of claim 2, wherein the patterned layer comprises a foil bonded to the surface facing the spacer structure.

4. The component according to claim 2 or 3, wherein the patterned layer comprises an overmolded thermoplastic layer having an open structure.

5. The component according to claim 1 or 2, further comprising a lamp module enclosed within the space formed between the laminated sheet and the spacer structure.

6. The component according to claim 1 or 2, wherein the spacer structure comprises a thermoplastic material.

7. The component according to claim 1 or 2, wherein the substrate of the spacer structure has an inner surface facing the laminated sheet, and wherein the inner surface is smooth, textured, and / or corrugated.

8. The component according to claim 1 or 2, wherein at least the inner surface of the substrate of the spacer structure includes a mirror for reflecting visible light, and the inner surface of the laminated sheet facing the spacer structure includes a translucent mirror, such that an infinity mirror is created in the front panel assembly.

9. The component of claim 1 or 2, comprising a receiving portion for integration with electronic components of the component.

10. The component of claim 9, wherein the receiving portion extends to the laminated sheet and is at least partially enclosed by the spacer structure.

11. The component of claim 1 or 2, wherein the laminated sheet includes a peripheral opaque strip extending from a side edge of the laminated sheet.

12. The component according to claim 1 or 2, wherein the inner surface of the spacer structure is laser-marked to include discoloration due to chemical / molecular alteration, carbonization, blistering, melting, and ablation.

13. A front panel module for an electric vehicle, the front panel module comprising a plurality of front panel assemblies according to any one of claims 1 to 12.

14. The front panel module of claim 13, wherein the front panel module comprises three front panel components, wherein the first front panel component and the second front panel component are mirror images of each other and the third front panel component is placed in the middle to form a symmetrical front panel module.

15. The front panel module of claim 14, wherein the first front panel assembly and the second front panel assembly are partially optically transparent and have patterned or light modules, and the third front panel assembly comprises an opaque laminated sheet, such that the third front panel assembly acts as an integration box for electronic components while concealing the electronic components from view.

16. An electric vehicle comprising a front panel assembly according to any one of claims 1 to 12 or a front panel module according to any one of claims 13 to 15.

17. The vehicle of claim 16, wherein the front panel assembly or front panel module forms part of the front trim panel of the vehicle.

18. The vehicle according to claim 16 or 17, wherein the components or modules are flanked by a pair of headlights.

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