Energy absorbing element for vehicle structure

Abstract

A vehicle bumper assembly includes a bumper beam extending from a first beam end to a second beam end to assume an outer bumper surface and an inner bumper surface disposed in substantially spaced relationship from each other. At least one crash box is disposed adjacent one of the first beam end or the second beam end and extends from a first crash box end secured to the inner bumper surface to the second crash box end to define a crash box cavity. A flange plate is secured to the second crash box end and defines an expansion aperture. An energy absorbing structure is housed within the crash box cavity and has a cross-sectional profile that increases from a second absorbing end nested within the expansion hole to a first absorbing end secured to the outer bumper surface for being urged through the expansion hole and radially deforming the expansion hole to absorb additional energy during an impact.

Description

[0001] Cross-references to related applications

[0002] This U.S. non-provisional patent application claims the benefit and priority of U.S. provisional patent application serial number 63 / 698,584, filed on September 25, 2024, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention relates to vehicle structural / body-in-white components, such as vehicle bumper assemblies or vehicle side structures. More specifically, this invention relates to an energy-absorbing structure for use in vehicle structures. Background Technology

[0004] Vehicle structures are known to provide energy absorption characteristics. For example, a vehicle bumper assembly is a component of the vehicle frame and includes a bumper beam and a pair of impact boxes. The impact boxes are positioned at the ends of the transverse members of the vehicle body structure and are also fixed to the bumper beam to absorb a predetermined value of impact load during a frontal or rear impact, thereby reducing or eliminating deformation of the vehicle body structure.

[0005] Vehicle side structures, such as the lower door panels, which are also part of the vehicle's body-in-white, extend across the sides of the vehicle and are designed to absorb energy during side impacts.

[0006] However, current vehicle structures and related components often fail to meet the ever-increasing targets for energy absorption and efficiency driven by increasing vehicle weight and crash requirements. Therefore, there remains a significant and ongoing need for vehicle body-in-white designs incorporating energy-absorbing structures capable of meeting these improved energy absorption characteristics. Summary of the Invention

[0007] The vehicle bumper assembly disclosed in this subject matter includes a bumper beam extending from a first beam end to a second beam end to present an outer bumper surface and an inner bumper surface arranged in an opposing and generally spaced-apart relationship. At least one impact box is disposed adjacent to one of the first or second beam ends and extends from a first impact box end fixed to the inner bumper surface to a second impact box end to define an impact box cavity. A flange plate is fixed to the second impact box end and defines an expansion hole. An energy-absorbing structure is housed within the impact box cavity and its cross-sectional profile increases from a second absorbing end nested within the expansion hole to a first absorbing end fixed to the outer bumper surface, for being pushed through the expansion hole during a frontal or rear impact and causing radial deformation of the expansion hole to absorb additional energy.

[0008] The vehicle side structure disclosed in this subject matter includes an outer side surface and an inner side surface, which are spaced apart from each other to define a side structure cavity. The inner side surface defines at least one expansion hole, and at least one energy-absorbing structure is housed within the side structure cavity. The cross-sectional profile of the at least one energy-absorbing structure increases from a second absorbing end nested within the expansion hole to a first absorbing end fixed to the outer side surface, for being pushed through the expansion hole during a side impact and causing radial deformation of the expansion hole to absorb additional energy.

[0009] These and other features and advantages of the invention will become more apparent to those skilled in the art from the detailed description of the preferred embodiments. The accompanying drawings are described below. Attached Figure Description

[0010] Figure 1 This is a perspective view of a vehicle structure according to one aspect of the present disclosure, the vehicle structure including a bumper beam assembly and a vehicle side structure, each of the bumper beam assembly and the vehicle side structure accommodating a plurality of energy absorption structures, and the cross-sectional profile of each energy absorption structure increasing from a second absorption end nested or pressed within an expansion hole defined by an inner side surface to a first absorption end fixed to an outer side surface.

[0011] Figure 2 This is a front perspective view of the bumper beam assembly, illustrating the energy-absorbing structure housed within the crash box, with its cross-sectional profile increasing from a second absorbing end nested or pressed within an expansion hole defined by a flange plate to a first absorbing end fixed to the outer bumper surface of the bumper beam.

[0012] Figure 3 This is a perspective rear view of the bumper beam assembly in its undeformed state;

[0013] Figure 4 This is a side cross-sectional view of the bumper assembly in an undeformed state, and illustrates a first weld that secures the first energy-absorbing end to the surface of the outer bumper and an optional second weld that secures the energy-absorbing structure to the surface of the inner bumper beam.

[0014] Figure 5 This is a perspective rear view of the bumper beam assembly in a deformed state; and

[0015] Figure 6 This is a side cross-sectional view of a bumper assembly in a deformed state, illustrating the enlarged cross-sectional profile of the energy-absorbing structure being pushed through the expansion hole and causing the expansion hole to deform radially to absorb additional energy during a frontal or rear impact. Detailed Implementation

[0016] Referring to the accompanying drawings, similar reference numerals in several views indicate corresponding parts. Figure 1 This is a perspective view of a vehicle structure 10, which includes a bumper assembly 12 extending across the front (or rear) portion of the vehicle structure 10 and vehicle side structures 14 (e.g., lower door panels) extending across the sides of the vehicle 10. The vehicle structure 10 is known for providing energy absorption characteristics, and therefore... Figure 1 As further illustrated in the present invention, at least one (and preferably both) of the bumper assembly 12 or the vehicle side structure 14 includes at least one energy-absorbing structure 16 for absorbing additional energy during axial and non-axial loads on the bumper assembly 12 or during respective front, rear or side impacts on the vehicle side structure 14.

[0017] like Figures 2 to 3 As best illustrated, the bumper assembly 12 includes a bumper beam 18 that extends laterally across the front (or rear) of the vehicle structure 10 from a first beam end 20 to a second beam end 22, presenting an outer bumper surface 24 and an inner bumper surface 26, which are arranged in an opposing and spaced-apart relationship to define a bumper cavity between them. A pair of impact boxes 28 are disposed adjacent to a corresponding one of the first beam end 20 or the second beam end 22, and each impact box extends from a first impact box end 30 fixed to the inner bumper surface 26 to a second impact box end 32 to define an impact box cavity 34. Figures 2 to 3 As best illustrated in the diagram, the collision box 28 may have a generally rectangular cross-sectional profile, such as defined relative to an axis A extending between the first collision box end 30 and the second collision box end 32. However, without departing from the scope of this subject matter disclosure, the collision box 28 may have other cross-sectional profiles.

[0018] The bumper assembly 12 also includes a pair of flanges 36, each flange 36 being secured to a corresponding second impact box end 32 in the impact box 28 for connecting the bumper assembly 12 to the vehicle structure 10, particularly the body-in-white. Each of the flanges 36 defines an expansion hole 38, which can be aligned with an axis A extending through the impact box cavity 34. However, the arrangement of the expansion holes 38 can occur anywhere along the flanges 36, particularly if the impact box 28 does not extend along axis A.

[0019] The bumper assembly 12 includes at least one energy-absorbing structure 16, and preferably a pair of energy-absorbing structures 16, each energy-absorbing structure 16 being received within a corresponding one in the crash box 28, and extending within the crash box cavity 34 from a first absorbing end 42 fixed to the outer bumper surface 26 of the bumper beam 18 to a second absorbing end 44 nested or pressed into an expansion hole 38 of the flange plate 36. If the crash box 28 extends along axis A, the energy-absorbing structure 16 may also extend along that axis A. However, the energy-absorbing structure 16 may be received in any location within the crash box 28 without departing from the scope of this subject matter disclosure. Figure 4 As shown in the optimal diagram, the first absorber end 42 can be fixed to the outer surface 24 of the outer bumper via the first weld 46. Figure 4 As further shown, the energy-absorbing structure 16 also extends through the bumper beam 18 and can be fixed to the inner bumper surface 26 via a second weld 47, which is located on the outer or inner side of the inner bumper surface 26.

[0020] like Figures 2 to 6 As illustrated, the cross-sectional profile of the energy-absorbing structure 16 increases as it extends from the second absorption end 44 (nested within the expansion hole 38) to the first absorption end 42 (attached to the outer bumper surface 24). For example, the energy-absorbing structure 16 may be conical, and taper radially outward as it extends from the second absorption end 44 to the second absorption end 42. However, in light of the following disclosure, it will be appreciated that the energy-absorbing structure 16 may have other increased cross-sectional profiles (e.g., stepped bore shape) without departing from the scope of this disclosure and the relevant functionality of the energy-absorbing structure 16.

[0021] More specifically, see reference Figures 5 to 6 During a frontal or rear-end collision event, a pair of impact boxes 28 begin to buckle and absorb the impact load / energy. Simultaneously, the energy-absorbing structure 16 is pushed through its corresponding expansion hole 38 in the flange plate 36, causing the expansion hole to deform radially (i.e., expand). This is a result of the increased cross-sectional profile of the energy-absorbing structure 16 being pushed through the expansion hole 38 by the force of the frontal or rear-end impact (see...). Figure 6 In other words, as the increasing cross-sectional profile of the energy-absorbing structure 16 passes through the expansion hole 38, this increase in size establishes and applies a radial force that causes the expansion hole 38 to expand. For example, if the energy-absorbing structure 16 has a conical cross-sectional shape, the expansion hole 38 initially has an original (undeformed) diameter D1 (see...). Figure 4 When the energy-absorbing structure 16 is pushed through the expansion hole 38, it deforms into a larger radial expansion diameter D2 (see...). Figure 6The radial expansion and deformation of the expansion hole 38 caused by the energy-absorbing structure 16 advantageously provides absorption of additional energy beyond that absorbed by the buckling impact box 28 itself, and provides increased overall impact efficiency, which results in reduced barrier intrusion and a smaller impact structure size for the bumper assembly 12.

[0022] For example, as a result of including the energy-absorbing structure 16, the increased collision box efficiency provides the ability to stop the barrier earlier during a collision event (with less intrusion of the collision barrier into the vehicle). This allows for a reduction in the length of the collision box 28 while still ensuring that components in the "safe zone," such as the cooler module, headlights, etc., are protected in low-speed collision events. Furthermore, by reducing the length of the collision box 28, the bumper beam 18 can also be moved rearward, thus reducing the vehicle's mounting height (distance from the front wheels to the front dashboard), thereby saving materials, weight, and cost.

[0023] Advantageously, the force / displacement curve representing the impact of the energy absorption device 16 on the expansion hole 38 can be easily adjusted by modifying the geometry (i.e., cross-sectional profile) of the energy absorption device 16. In other words, the geometry of the energy absorption device 16 can be customized to meet the desired crash performance of the impact box 28 and the associated bumper assembly 12.

[0024] The inclusion of the energy-absorbing structure 16 within the impact chamber 28 also allows the energy-absorbing structure 16 to provide an additional guiding effect to the impact chamber 28 as it collapses or buckles during axial or non-axial loads. In other words, the energy-absorbing structure 16 advantageously guides the collapse of the impact chamber 28 during frontal or rear impacts, providing the impact chamber 28 with improved and more predictable folding behavior, even under non-axial impact loads.

[0025] like Figure 2 and Figure 4 As best illustrated in the diagram, the first end 42 of the energy-absorbing structure 16, when implemented in the bumper assembly 12, may also define an internal thread 48 for receiving the installation of a tow hook.

[0026] like Figure 1 As illustrated in the diagram, based on the aforementioned principles, the energy absorption structure 16 can also be implemented in the vehicle side structure 14 used in the vehicle structure 10 to provide improved collision efficiency and enhance the safety of the battery and passengers during side impacts. More specifically, as shown in the diagram... Figure 1 As best illustrated in the diagram, the vehicle side structure 14 (e.g., the lower door panel) extends from the front end 50 (adjacent to the front wheel) to the rear end 52 (adjacent to the rear wheel) to present an outer side surface 54 and an inner side surface 56, which are arranged in a spaced-apart relationship and together define the side structure cavity 58.

[0027] The inner side surface 56 defines at least one expansion hole 38, and at least one energy-absorbing structure 16 is disposed within the side structure cavity 58, extending from a first absorbing end 42 fixed to the outer side surface 54 to a second absorbing end 44 nested or pressed within the at least one expansion hole 38. Similar to the embodiment described above with respect to the bumper assembly 12, as the energy-absorbing structure 16 extends from the second absorbing end 44 (nested within the expansion hole 38) to the first absorbing end 42 (fixed to the outer side surface 54), the cross-sectional profile of the energy-absorbing structure 16 increases in size.

[0028] During a side impact event, the vehicle side structure 14 begins to collapse and absorb the impact load / energy. Simultaneously, the energy-absorbing structure 16 is pushed through the expansion aperture 38, and additional energy is absorbed due to friction and expansion of the expansion aperture 38. In other words, the increased cross-sectional profile of the energy-absorbing structure 16 applies a radial force 38 through the expansion aperture 38, causing it to expand. The expansion and deformation of the expansion aperture 38 caused by the energy-absorbing structure 16 advantageously provides absorption of additional energy exceeding that absorbed by the vehicle side structure 14 itself, and provides increased overall collision efficiency. Figure 1 It can be seen that the energy absorption structure 16 will intrude into the bottom of the vehicle body (body-in-white) or the battery structure 60.

[0029] like Figure 1 and Figure 6 As best illustrated in the diagram, the vehicle side structure 14 preferably includes a plurality of energy-absorbing structures 16 disposed within a side structure cavity 58 at intervals between a front end 50 and a rear end 52. In this arrangement, the inner side surface 56 defines a plurality of expansion holes 38, each expansion hole 38 for receiving a second absorbing end 44 of a corresponding one of the energy-absorbing structures 16. During a side impact, the energy-absorbing structures 16 closest to and adjacent to the impact area will be propelled through their respective expansion holes 38 to absorb additional energy from the vehicle side structure 14.

[0030] While preferred embodiments of the invention have been shown and described, it is contemplated that various modifications can be made to the invention by those skilled in the art without departing from the spirit and scope thereof. In other words, this disclosure is not intended to be exhaustive or limiting. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. The same may also apply to variations in many other respects. These variations should not be considered a departure from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A vehicle bumper assembly, comprising: The bumper beam extends from the end of a first beam to the end of a second beam to present an external bumper surface and an internal bumper surface that are positioned opposite each other and generally spaced apart. At least one collision box is disposed adjacent to one of the ends of the first beam or the second beam, and extends from the end of the first collision box fixed to the surface of the inner bumper to the end of the second collision box to define a collision box cavity; A flange plate, which is fixed to the end of the second collision box and defines an expansion hole; and An energy-absorbing structure, housed within the impact chamber cavity, with a cross-sectional profile increasing from a second absorbing end nested within the expansion hole to a first absorbing end fixed to the surface of the outer bumper, is designed to be pushed through the expansion hole during a frontal or rear impact and to radially deform the expansion hole to absorb additional energy.

2. The vehicle bumper assembly according to claim 1, wherein, The energy absorption structure is conical in shape and extends radially outward from the second absorption end toward the first absorption end.

3. The vehicle bumper assembly according to claim 2, wherein, When the energy-absorbing structure is pushed through the expansion hole, the expansion hole, which has an original undeformed diameter, deforms into a radial expansion diameter larger than the original undeformed diameter.

4. The vehicle bumper assembly according to claim 1, wherein, The first absorbing end of the energy absorbing structure is fixed to the surface of the outer bumper via a first weld.

5. The vehicle bumper assembly according to claim 4, wherein, The energy-absorbing structure is fixed to the surface of the inner bumper via a second weld.

6. The vehicle bumper assembly according to claim 1, wherein, The impact box extends along an axis between the ends of the first and second impact boxes, and the energy absorption structure and the expansion hole are aligned on the axis.

7. The vehicle bumper assembly according to claim 1, wherein, The at least one collision box includes a pair of collision boxes, each collision box being disposed adjacent to a corresponding one of the ends of the first beam and the second beam, and each collision box accommodating a corresponding energy absorption structure.

8. A vehicle side structure, comprising: An outer side surface and an inner side surface, the outer side surface and the inner side surface being spaced apart from each other to define a side structure cavity; The inner side surface defines at least one expansion hole; as well as At least one energy-absorbing structure is housed within the side structure cavity, and its cross-sectional profile increases from a second absorbing end nested within the expansion hole to a first absorbing end fixed to the outer side surface, for being pushed through the expansion hole during a side impact and causing the expansion hole to deform radially to absorb additional energy.

9. The vehicle side structure according to claim 8, wherein, The inner side surface defines a plurality of expansion holes, and the energy absorption structure includes a plurality of energy absorption structures housed within the cavity of the side structure, and each energy absorption structure extends from a first absorption end fixed to the outer side surface to a second absorption end nested within a corresponding expansion hole among the plurality of expansion holes.

10. The vehicle side structure according to claim 9, wherein, Each of the plurality of energy absorption structures is conical in shape and tapers radially outward from the second absorption end to the first absorption end.

11. The vehicle side structure according to claim 8, wherein, The side structure of the vehicle is the lower panel of the door.

12. A vehicle structure comprising: An outer surface and an inner surface, the outer surface and the inner surface being arranged in a spaced-out relationship to define a structural cavity; The internal surface defines at least one expansion hole; and An energy-absorbing structure, housed within the structural cavity, with a cross-sectional profile increasing from a second absorbing end nested within the expansion hole to a first absorbing end fixed to the outer surface, is designed to be pushed through the expansion hole during an impact and to radially deform the expansion hole to absorb additional energy.

13. The vehicle structure according to claim 11, wherein, The energy absorption structure is conical in shape and extends radially outward from the second absorption end toward the first absorption end.

14. The vehicle structure according to claim 12, wherein the first absorbing end of the energy absorbing structure is fixed to the outer surface via a weld.

15. The vehicle structure according to claim 12, wherein, When the energy-absorbing structure is pushed through the expansion hole, the expansion hole, which has an original undeformed diameter, deforms into a radial expansion diameter larger than the original undeformed diameter.

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