Vehicle front structure

Abstract

The invention provides a vehicle front structure. The bumper reinforcement is disposed in front of the front module. The front module includes a front side member. The outer end portion of the bumper reinforcement in the vehicle width direction is disposed on the outer side of the front side member in the vehicle width direction. The front side member has a square groove shape open to the outside in the vehicle width direction. On the front longitudinal beam, the transverse ribs and the longitudinal ribs are formed in the square grooves. Reinforcing blocks (load transmission components) are arranged in grids formed by the transverse ribs and the longitudinal ribs.

Description

Technical Field

[0001] This specification discloses a front structure of a vehicle. Background Technology

[0002] A bumper reinforcement is installed on the front surface of the vehicle as a frame component. The bumper reinforcement extends along the width of the vehicle and is connected to the front longitudinal beam.

[0003] The front longitudinal beam is a skeletal component extending along the longitudinal direction of the vehicle. The front end of the front longitudinal beam connects to the back of the bumper reinforcement. The outer end of the bumper reinforcement in the vehicle width direction is located further outward than this connection point.

[0004] As a method of vehicle crash testing, the small overlap test is known. In the small overlap test, the offset rate is set to 25%. That is, the overlap range between the vehicle and the obstacle is set to 25% of the vehicle's width.

[0005] In a small overlap test, the outer portion of the bumper reinforcement in the vehicle width direction collides with an obstacle. Due to the collision, the outer portion of the bumper reinforcement in the vehicle width direction is bent backwards towards the rear of the vehicle. Therefore, for example, in Japanese Invention Patent Publication 2020-183191, a load-transfer member is provided at the outer end of the bumper reinforcement in the vehicle width direction. The load-transfer member extends from the back of the bumper reinforcement towards the rear of the vehicle. When the bumper reinforcement bends backwards towards the rear of the vehicle and inwards in the vehicle width direction, the load-transfer member collides with the front longitudinal beam. This suppresses bending deformation of the bumper reinforcement and prevents the entry of obstacles.

[0006] Additionally, mudguards are installed on the front longitudinal beams. For example, in Japanese Invention Patent Publication 2021-17100, the mudguards are fixed to the front longitudinal beams via side panel corner plates. In the event of a small overlap collision, the side panel corner plates are positioned on the trajectory of the load-transfer components of the bumper reinforcement. Reinforcing components are provided on the side panel corner plates. Summary of the Invention

[0007] However, sometimes the frame and panel sections of the front of a vehicle are integrally formed by casting. This integrally formed part is also called the front module. If there is a large difference in wall thickness between the different parts of the front module, cracking and deformation may occur during the cooling process due to different shrinkage patterns. Therefore, reinforcing ribs are formed in the frame elements instead of increasing the wall thickness. For example, on the front longitudinal beam, ribs are provided extending along the width direction of the vehicle.

[0008] In a small overlap collision, there is a possibility that the load-transfer components of the bumper reinforcement may collide with the ribs of the front longitudinal beam. If the ribs break due to the collision, it may be difficult to prevent the bumper reinforcement from bending and deforming.

[0009] Therefore, this specification discloses a vehicle front structure capable of suppressing bending deformation of the bumper reinforcement in small overlap collisions.

[0010] This specification discloses a front structure for a vehicle. The front structure includes a front module, a bumper reinforcement, and an extension member. The front module is integrally formed by casting the frame portion and panel portion of the front area of ​​the vehicle. The bumper reinforcement is positioned in front of the front module and extends along the vehicle width direction. The extension member extends from the outer end of the bumper reinforcement in the vehicle width direction toward the rear of the vehicle. The front module includes a front longitudinal beam. The front longitudinal beam extends along the vehicle's longitudinal direction. Furthermore, the front end of the front longitudinal beam is connected to the bumper reinforcement. The outer end of the bumper reinforcement in the vehicle width direction is positioned further outward than the front longitudinal beam in the vehicle width direction. The front longitudinal beam has a square groove shape open outward in the vehicle width direction. Ribs are formed within the square grooves on the front longitudinal beam. The ribs are formed in a lattice pattern and extend outward in the vehicle width direction. Load-transferring members are disposed within the lattice formed by the ribs.

[0011] Based on the above structure, the load-transferring component can withstand the impact of the extended component.

[0012] In addition, in the above structure, the load transfer component can protrude outwards in the vehicle width direction from the rib.

[0013] Based on the above structure, rib breakage can be suppressed.

[0014] Additionally, in the above structure, a crossbeam can be connected to the front module. The crossbeam extends along the vehicle width direction. Load transfer components can be configured along the extension line of the crossbeam.

[0015] According to the above structure, the collision load is transmitted from the extension component to the crossbeam via the load transfer component.

[0016] Furthermore, in the above structure, the load-transferring component can be an assembly of ribs. In this case, the ribs of the assembly are formed with a higher density than the surrounding area.

[0017] By forming ribs at a high density, when a rib breaks, its fragments are buried within the lattice. As a result, the entry of extended components can be suppressed.

[0018] According to the vehicle front structure disclosed in this specification, bending deformation of the bumper reinforcement in small overlap collisions can be suppressed. Attached Figure Description

[0019] The features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described in conjunction with the following drawings, wherein the same reference numerals denote the same parts.

[0020] Figure 1 It is an exploded perspective view illustrating the structure of a vehicle.

[0021] Figure 2 This is a three-dimensional view illustrating the front module and its surrounding components.

[0022] Figure 3 yes Figure 2 Partial sectional perspective view.

[0023] Figure 4 This is a three-dimensional diagram illustrating the first other example involving the preceding module. Detailed Implementation

[0024] exist Figures 1 to 4 The diagram illustrates a front structure of a vehicle according to this embodiment. This front structure is used in a battery electric vehicle (BEV).

[0025] In addition, Figures 1 to 4 In this diagram, the vehicle's forward / backward direction is represented by the FR axis. The vehicle width direction is represented by the RW axis. The vertical direction is represented by the UP axis. The FR axis is positive in the forward direction. The RW axis is positive in the rightward direction. The UP axis is positive in the vertical direction.

[0026] In addition, Figures 2 to 4 The diagram illustrates the structure of the left side of the vehicle. However, due to the symmetrical structure of the vehicle body, the structure of the right side is also similar. Figures 2 to 4 The corresponding construction.

[0027] 1. Vehicle Structure

[0028] Figure 1 The diagram illustrates the vehicle's skeletal structure and an exploded perspective view of the battery pack 10. The skeletal structure includes a front module 50, a frame 20, and a rear module 30.

[0029] Frame 20 is a frame-shaped skeleton component. Frame 20 supports battery pack 10.

[0030] The front module 50 is a casting in which the frame and panel portions of the front area of ​​the vehicle are integrally formed. Details of the front module 50 will be described later. Similarly, the rear module 30 is a casting in which the frame and panel portions of the rear area of ​​the vehicle are integrally formed.

[0031] 2. Skeleton element connected to the front module

[0032] Multiple skeleton elements are connected to the front module 50. (Refer to...) Figure 2 , Figure 3 The front module 50 is connected to a bumper reinforcement 80, a connecting component 82, and a front crossbeam 85.

[0033] Reference Figure 3The connecting component 82 is an extension of the front longitudinal beam 60. A connecting component 82 is attached to the front end of each of the pair of front longitudinal beams 60, 60. The connecting component 82 is, for example, a hollow component with a rectangular cross-section. The front end of the connecting component 82 is connected to the back of the bumper reinforcement 80. That is, the front end of the front longitudinal beam 60 is connected to the bumper reinforcement 80 via the connecting component 82.

[0034] The front crossbeam 85 extends in a straight line along the vehicle width direction. The front crossbeam 85 extends from one connecting member 82 to the other connecting member 82. Additionally, an extension line L1 is provided on the front crossbeam 85 (see reference). Figure 3 A reinforcing block 70 is configured on the front crossbeam 85. Alternatively, longitudinal ribs 65A to 65C are configured on the extension line L1 of the front crossbeam 85 (refer to...). Figure 4 ) and transverse ribs 64.

[0035] For example, refer to Figure 3 The reinforcing block 70 is adjacent to the outer end of the front crossbeam 85 in the vehicle width direction, separated by the front longitudinal beam 60. Additionally, refer to... Figure 4 The longitudinal ribs 65A to 65C and the transverse ribs 64 are adjacent to the outer end of the front transverse beam 85 in the vehicle width direction, separated by the front longitudinal beam 60.

[0036] As will be described later, the collision load originates from reinforcement block 70 (refer to...). Figure 3 The impact load is transferred to the front crossbeam 85. Alternatively, the impact load is transferred from longitudinal ribs 65A to 65C (see reference). Figure 4 The 64th rib and the transverse rib are transferred to the front crossbeam 85.

[0037] The bumper reinforcement 80 is a frame element disposed on the front surface of the vehicle. The bumper reinforcement 80 is positioned in front of the front module 50. (See reference...) Figure 3 The bumper reinforcement 80 is connected to the front longitudinal beam 60 via the connecting member 82. The outer end of the bumper reinforcement 80 in the vehicle width direction is positioned further outward in the vehicle width direction than the front longitudinal beam 60.

[0038] The bumper reinforcement 80 extends along the width of the vehicle. For example, both ends of the bumper reinforcement 80 in the width direction slope towards the rear of the vehicle along the appearance of the front surface of the vehicle.

[0039] An extension portion 84 is provided at the outer end of the bumper reinforcement 80 in the vehicle width direction. For example, the extension portion 84 is provided at both ends of the bumper reinforcement 80 in the vehicle width direction. The extension portion 84 is an extension component attached to the bumper reinforcement 80. The extension portion 84 is, for example, L-shaped when viewed from above.

[0040] The extension portion 84 extends from the outer end of the bumper reinforcement 80 in the vehicle width direction toward the rear of the vehicle. For example, the extension portion 84 extends from both ends of the bumper reinforcement 80 in the vehicle width direction toward the outer side in the vehicle width direction. Furthermore, the extension portion 84 extends toward the rear of the vehicle.

[0041] Reference Figure 3 In a small overlap collision, obstacle 100 collides with bumper reinforcement 80. Upon impact, the outer portion of bumper reinforcement 80 in the vehicle width direction undergoes bending deformation. This bending deformation causes the outer portion of bumper reinforcement 80 in the vehicle width direction to bend inwards and rearwards towards the vehicle.

[0042] Along with this bending deformation, the extension 84 also shifts inward in the vehicle width direction and towards the rear of the vehicle. Furthermore, the rear end 84A of the extension 84 collides with the front longitudinal beam 60. Here, as described later, the rear end 84A of the extension 84 collides with the reinforcing block 70. As a result, the bending deformation of the bumper reinforcing member 80 is suppressed.

[0043] 3. Front Module

[0044] Reference Figure 1 The front module 50 is formed by casting the frame and panel portions between the left and right front wheels of the vehicle into a single piece. For example, the front module 50 is manufactured by die casting aluminum.

[0045] The front module 50 has a front bulkhead 54 and a pair of front wheel arches 53, 53 as the panel part. In addition, the front module 50 has a pair of suspension towers 51, 51, a pair of radiator brackets 52, 52 and a pair of front longitudinal beams 60, 60 as the frame part.

[0046] For example, such as Figure 2 As shown, reinforcing ribs are formed in the frame portion. For example, the radiator bracket 52 includes an upper bracket 52A and a side bracket 52B. Multiple ribs extending outward in the vehicle width direction are formed on the upper bracket 52A and the side bracket 52B.

[0047] 4. Front longitudinal beam

[0048] Reference Figure 2 The front longitudinal beam 60 is a skeletal component extending along the longitudinal direction of the vehicle. The front longitudinal beam 60 has a square groove shape that is open on the outer side in the vehicle width direction. Specifically, the front longitudinal beam 60 has an upper wall 60A, a lower wall 60B, and a side wall 60C. The upper wall 60A and lower wall 60B extend in the vehicle width direction. The inner ends of the upper wall 60A and lower wall 60B in the vehicle width direction connect to the side wall 60C. The side wall 60C extends in the height direction.

[0049] Multiple ribs are formed within a square groove formed by the upper wall 60A, lower wall 60B, and side wall 60C. These ribs are formed in a lattice pattern within the square groove. Each rib extends outward from the side wall 60C in the vehicle width direction. For example, a transverse rib 61A and a longitudinal rib 62B are provided on the front longitudinal beam 60.

[0050] Transverse rib 61A is positioned between the upper wall 60A and the lower wall 60B. The front longitudinal beam 60 is divided into upper and lower chambers by the transverse rib 61A. Longitudinal rib 62A is positioned in the upper chamber. Longitudinal rib 62B is positioned in the lower chamber. Multiple longitudinal ribs 62A and 62B are spaced apart along the longitudinal direction of the vehicle. In addition, longitudinal ribs 62A and 62B are offset in the longitudinal direction of the vehicle.

[0051] Furthermore, the front end portion of the front longitudinal beam 60 is divided into a grid pattern by longitudinal ribs 62C, 62D, transverse ribs 61A, 61B, 61D, and lower wall 60B. Reinforcing blocks 70 are disposed within the grid. For example, the reinforcing blocks 70 are accommodated in slots 69 with the same height as the extension 84.

[0052] The reinforcing block 70 is a load-transfer component. For example, the reinforcing block 70 is a solid element. For example, the reinforcing block 70 is a resin element with added glass fiber.

[0053] exist Figure 3 The diagram illustrates a cross-sectional perspective view of the front module 50 cut off at the same height as the upper wall of the connecting member 82. Adhesive 76 is applied to the bottom of the groove 69, or in other words, to the side wall 60C. A reinforcing block 70 is inserted into the groove 69. Furthermore, the reinforcing block 70 is fixedly attached to the groove 69 by the adhesive 76.

[0054] The shape of the reinforcing block 70 can be adapted to the groove 69. That is, the reinforcing block 70 is formed in a manner that is equal to the opening width and opening height of the groove 69.

[0055] On the other hand, the reinforcing block 70 may protrude outward in the vehicle width direction from the longitudinal ribs 62C, 62D and the transverse ribs 61A, 61B. For example, the outer end 70A of the reinforcing block 70 in the vehicle width direction is positioned further outward in the vehicle width direction than the longitudinal ribs 62C, 62D and the transverse ribs 61A, 61B. With such a configuration, the extension 84 can be specifically supported by the reinforcing block 70.

[0056] For example, if the front module 50 is made of aluminum casting, it is more prone to rib fracture compared to other steel materials. The deformation pattern of aluminum is called localized tension (point tension). That is, unlike uniform tension where deformation occurs evenly around the origin of the deformation, the load is concentrated at the point of load input. Therefore, fracture may occur at the location subjected to the load.

[0057] By replacing the longitudinal ribs 62C, 62D and the transverse ribs 61A, 61B with a structure in which the extension portion 84 is supported by a reinforcing block 70, the breakage of these ribs is suppressed. Furthermore, by supporting the extension portion 84 with the reinforcing block 70, bending deformation of the bumper reinforcement 80 can be prevented. That is, obstructions 100 are prevented from passing through the bumper reinforcement 80.

[0058] Reinforcing block 70 is positioned on the extension line L1 of the front crossbeam 85 (refer to...) Figure 3 Therefore, the load input from the extension 84 to the reinforcing block 70 is transferred to the front crossbeam 85.

[0059] 5. Other examples of the first longitudinal beam

[0060] exist Figure 4 The example illustrates a front longitudinal beam 60 in a first alternative example. In this example, ribs replacing the reinforcing block 70 are formed within a groove 69. Specifically, a lattice structure of longitudinal ribs 65A, 65B, 65C and transverse ribs 64 is formed within the groove 69. The lattice structure formed by the longitudinal ribs 65A, 65B, 65C and transverse ribs 64 forms an assembly of ribs with a higher density than the surrounding area.

[0061] The extension 84 is supported by longitudinal ribs 65A, 65B, 65C and transverse ribs 64, which break. The broken fragments fill the groove 69. That is, the fragments of the ribs filling the groove 69 prevent the extension 84 from entering.

[0062] Longitudinal ribs 65A, 65B, 65C and transverse ribs 64 are arranged on the extension line of the front crossbeam 85. Therefore, the load input from the extension 84 to the longitudinal ribs 65A, 65B, 65C and transverse ribs 64 is transferred to the front crossbeam 85.

Claims

1. A front structure of a vehicle, comprising: The front module allows the frame and panel parts of the front area of ​​the vehicle to be integrally formed by casting. A bumper reinforcement is positioned in front of the front module and extends along the vehicle width direction; and The extension component extends from the outer end of the bumper reinforcement in the vehicle width direction toward the rear of the vehicle. The front module has a front longitudinal beam. The front longitudinal beam extends along the longitudinal direction of the vehicle, and its front end is connected to the bumper reinforcement. The outer end of the bumper reinforcement in the vehicle width direction is positioned further outward in the vehicle width direction than the front longitudinal beam. The front longitudinal beam is a square groove shape with an open outer side in the vehicle width direction. On the front longitudinal beam, ribs extending outward in the vehicle width direction are formed in a lattice pattern within square grooves. Load transfer components are arranged within the grid formed by the ribs.

2. The vehicle front structure according to claim 1, wherein, The load-transfer component protrudes outward from the rib in the vehicle width direction.

3. The vehicle front structure according to claim 1, wherein, A crossbeam extending along the vehicle width direction is connected to the front module. The load transfer component is arranged on the extension line of the crossbeam.

4. The vehicle front structure according to claim 3, wherein, The load-transferring component is an assembly of ribs with a higher density than the surrounding structure.

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