Front-end module for a vehicle

Abstract

Front end module (1) for a vehicle (2), comprising: a bumper cover (5) with at least one recess (6) for attaching the front end module (1) to a vehicle structure (4) along a longitudinal direction (3) (X-direction) of the vehicle (2), at least one fastening structure configured to attach the front end module (1) to the vehicle structure (4) in a longitudinal direction (3), and at least one cover (8) that can be attached to the bumper cover (5) from the outside to close the at least one recess (6) after the front end module (1) has been attached.

Description

[0001] The technical field of the invention is front-end modules for vehicles.

[0002] The state of the art includes various solutions for attaching front-end modules to vehicle structures as well as measures for covering mounting openings.

[0003] DE 199 12 181 A1 describes a method for assembling components of a front end of a motor vehicle, in which a bumper cover is screwed on.

[0004] DE 10 2008 051 290 A1 discloses a method for attaching a front-end module to a body shell of a vehicle.

[0005] DE 10 2008 012 667 A1 describes a front-end module for a motor vehicle that is attached to a vehicle structure along the longitudinal direction of the vehicle. The known front-end module has at least one recess for attaching the front-end module to the vehicle structure and a mounting structure for longitudinal installation.

[0006] DE 10 2008 060 714 A1 also describes a front-end module for a motor vehicle, comprising a bumper cover with at least one recess for attachment to a vehicle structure.

[0007] The object of the invention is to provide a front-end module for a vehicle that enables and ensures simple attachment to the vehicle structure along the longitudinal direction.

[0008] The invention relates to a front-end module for a vehicle, comprising a bumper cover with at least one recess. The recess is provided for attaching the front-end module to a vehicle structure along a longitudinal direction (X-direction) of the vehicle. The front-end module also includes at least one mounting structure configured to attach the front-end module longitudinally to the vehicle structure. Furthermore, the front-end module includes at least one cover that can be attached to the bumper cover from the outside to close the at least one recess after the front-end module has been attached.

[0009] A front-end module is a pre-assembled unit comprising essential components of a vehicle's front end, fulfilling both functional and structural requirements. It serves as a central unit for integrating and assembling various components that together form the front of a vehicle. The front-end module is bolted to the longitudinal (X-direction) of the vehicle, for example, to impact absorbers on longitudinal members. The longitudinal (X-direction) of the vehicle refers to the axis running along the direction of travel, i.e., from the front of the vehicle to the rear. To facilitate assembly, the bumper cover has at least one recess, which, for example, provides clearance for a bolted connection. This design prevents collisions between the bolting tools and the bumper cover, which would occur with a conventional design.

[0010] Longitudinal (X-direction) mounting offers several advantages. Direct bolting allows for quick and precise installation of the front-end module, as no additional steps such as removing the bumper cover are required. Bolting along the longitudinal axis increases the module's stability and load-bearing capacity, since the forces are absorbed along the vehicle's main load axis. Furthermore, the specially designed cutouts in the bumper cover allow for easy maintenance or removal of the front-end module without having to remove the entire bumper cover.

[0011] The front-end module can include several other components, including a crash management system positioned as a cross member between the longitudinal members, designed to absorb and distribute impact energy; a radiator package containing the radiator, fan, and other thermal management elements for efficient engine cooling; an upper chord that serves as a load-bearing component to increase the module's stability and as an attachment point for other components; and headlights that contribute to vehicle lighting and safety as integrated lighting units.

[0012] The bumper cover is an outer covering that serves both aesthetic and aerodynamic functions. It protects the underlying structures and acts as a mounting point for other components. The cutouts in the bumper cover allow for precise and direct mounting of the front-end module to the vehicle structure. After installation, the cutouts are sealed with a cover or lighting element to prevent the ingress of water and dirt and to maintain the appearance of the bumper cover.

[0013] The cover can be designed in two versions: as a single, large component that completely covers one or more recesses, or as several smaller covers, each individually attached to the recesses. In both cases, the cover can be flush-mounted to optimize the vehicle's aerodynamics and fitted with a seal to ensure a reliable seal. Alternatively, the cover, or an integrated lighting device, can perform additional functions such as ambient lighting or signal lights, enhancing the safety and functionality of the front-end module.

[0014] One advantage of the front-end module is that the bumper cover features at least one recess, allowing for direct attachment of the module to the vehicle structure along the longitudinal (X-direction). This enables the bumper cover to be an integral part of the front-end module, meaning the entire module, including the headlights, is pre-adjusted to the correct tolerances. This saves assembly steps in production and, compared to the previous technology, allows for X-shaped mounting of the front-end module from the front. Simultaneously, externally attachable covers ensure that the recesses can be sealed after installation, preventing the ingress of water and dirt and maintaining the aesthetic integrity of the bumper cover.

[0015] Advantageously, the cover can be fitted into the recess of the bumper cover in a form-fitting manner, creating a flush connection with the outer surface of the bumper cover. This has the advantage that the outer surface of the cover blends seamlessly into the outer surface of the bumper cover, resulting in a uniform appearance.

[0016] Advantageously, the cover can be detachably attached to the bumper cover using a clip mechanism, allowing for removal of the cover to provide access to the mounting structure. The clip mechanism enables tool-free attachment and removal, simplifying maintenance of the front-end module.

[0017] Advantageously, the recess can be positioned and shaped to provide access for a screw connection to attach the front-end module to the vehicle structure. This ensures precise and efficient mounting of the front-end module.

[0018] Advantageously, the cover can have a seal that, when installed, rests against the edges of the bumper cover recess to prevent water and dirt from entering the recess. The seal contributes to the longevity of the screw connection and the vehicle structure.

[0019] Advantageously, the bumper cover can include several recesses at designated attachment points for mounting the front-end module, with each recess having a cover designed to completely conceal it after installation. Attaching the module at multiple points increases its stability and load-bearing capacity.

[0020] Advantageously, the bumper cover can be made of a plastic material that is adapted to the aesthetic and functional requirements of the bumper cover. Plastic materials are lightweight and robust, thus reducing the overall weight of the vehicle.

[0021] Advantageously, the cover can include an integrated lighting device, which can be used as ambient lighting or a signal light. This expands the functionality of the front-end module.

[0022] A further object of the invention is a method for mounting the front-end module comprising the following steps: positioning the front-end module on a vehicle structure along the longitudinal direction (X-direction) of the vehicle, attaching the front-end module to the vehicle structure by means of at least one screw connection accessible through at least one recess in the bumper cover, and closing the at least one recess after the front-end module has been attached by means of a cover that can be attached from the outside.

[0023] One advantage of the method is that it enables efficient and precise assembly of the front end module, whereby the positioning and attachment of the front end module to the vehicle structure along the longitudinal direction (X-direction) of the vehicle simplifies the assembly.

[0024] Advantageously, the cover can be fitted into the recess and secured using a clip mechanism, allowing it to be removed without tools if necessary to access the screw connection. This simplifies the disassembly of the front-end module.

[0025] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or on their own, without leaving the scope of the present invention.

[0026] The invention is schematically illustrated with reference to embodiments in the drawings. It shows: Fig. 1 a schematic representation of a front-end module according to the invention for a vehicle; Fig. 2 the assembled front-end module from Fig. 1 ; Fig. 3 another embodiment of the front end module according to the invention, in which the bumper cover has two rectangular recesses; Fig. 4 the frontend module Fig. 3 after completion of assembly.

[0027] The figures are described in a coherent and comprehensive manner. The same reference symbols are assigned to the same components.

[0028] The Fig. Figure 1 shows a schematic representation of an embodiment of a front-end module 1 for a vehicle 2, which can be mounted on a vehicle structure 4 in the longitudinal direction 3 (X-direction) of the vehicle 2. The front-end module 1 comprises a bumper cover 5, which has several recesses 6 to allow the attachment of the front-end module 1. The recesses 6 in the bumper cover 5 are positioned to allow access to screw connections 7, which connect the front-end module 1 to the vehicle structure 4.

[0029] Fig. Figure 2 shows the assembled frontend module 1. Fig. 1, in which the recesses 6 are completely closed by a large cover 8. The cover 8 is attached to the bumper cover 5 and integrated flush with its outer surface to ensure a uniform appearance. The function of the cover 8 is to protect the underlying recesses 6 and screw connections 7 by preventing the ingress of water and dirt. The cover 8 also contributes to the aerodynamic optimization of the vehicle 2. In addition, the Fig. 2, that the cover 8 occupies a central position to cover several recesses 6 simultaneously. The external design of the front-end module 1 exhibits a seamless design that meets both functional and aesthetic requirements.

[0030] The Fig. Figure 3 shows a schematic representation of another embodiment of a front-end module 1 for a vehicle 2, in which the bumper cover 5 has two rectangular recesses 9, 10. Each of these recesses 9, 10 provides access to four recesses 6 below, which enable the front-end module 1 to be attached to the vehicle structure 4 by means of the respective screw connections 7.

[0031] The rectangular recesses 9, 10 are arranged symmetrically on both sides of the bumper cover 5 and facilitate the assembly of the front end module 1 by providing direct access to the screw connections 7 underneath.

[0032] Fig. Figure 4 shows the frontend module 1. Fig.3 after completion of the assembly, wherein the rectangular recesses 9, 10 are each closed with a cover 11 and 12, thereby protecting the underlying recesses 6 and screw connections 7 from external influences such as water, dirt or corrosion.

[0033] The rectangular design of the recesses 9, 10 enables precise alignment of the covers 8 and ensures that the mounting points can be functionally and visually seamlessly integrated into the design of the bumper cover 5. REFERENCE MARK LIST: 1 Frontend module 2 vehicles 3 Longitudinal direction (X-direction) 4 Vehicle structure 5 Bumper Cover 6 recess 7 Screw connection 8 Large-area lid 9 Rectangular cutout (left side) 10 Rectangular cutout (right side) 11. Cover for left rectangular opening 12 lids for right rectangular opening

Claims

[1] Front end module (1) for a vehicle (2), comprising: a bumper cover (5) with at least one recess (6) for attaching the front end module (1) to a vehicle structure (4) along a longitudinal direction (3) (X-direction) of the vehicle (2), at least one fastening structure configured to attach the front end module (1) to the vehicle structure (4) in a longitudinal direction (3), and at least one cover (8) that can be attached to the bumper cover (5) from the outside to close the at least one recess (6) after the front end module (1) has been attached. [2] Front end module (1) according to claim 1, wherein the cover (8) is positively attached to the recess (6) of the bumper cover (5) so that when the recess is closed with the cover, a flush connection with the outer surface of the bumper cover (5) is created. [3] Front end module (1) according to claim 1 or 2, wherein the cover (8) is detachably attached to the bumper cover (5) by means of a clip mechanism, so that the cover (8) can be removed to allow access to the fastening structure. [4] Front end module (1) according to one of the preceding claims, wherein the recess (6) is positioned and shaped to provide access for a screw connection (7) for fastening the front end module (1) to the vehicle structure (4). [5] Front end module (1) according to one of the preceding claims, wherein the cover (8) has a seal which, when the recess is closed with the cover in the assembled state, rests against the edges of the recess (6) of the bumper cover (5) to prevent water and dirt from entering the recess (6). [6] Front end module (1) according to one of the preceding claims, wherein the bumper cover (5) comprises several recesses (6) at fixed attachment points for the attachment of the front end module (1), wherein for each recess (6) a cover (8) is designed such that it completely covers the respective recess (6) after assembly. [7] Front end module (1) according to one of the preceding claims, wherein the bumper cover (5) is made of a plastic material and the lid (8) is adapted to the aesthetic and functional requirements of the bumper cover (5). [8] Front end module (1) according to one of the preceding claims, wherein the cover (8) comprises an integrated lighting device which is designed as an ambient light or as a signal light. [9] Method for mounting a front-end module (1) according to any one of claims 1 to 8, comprising the steps: positioning the front-end module (1) on a vehicle structure (4) along the longitudinal direction (3) (X-direction) of the vehicle (2), attaching the front-end module (1) to the vehicle structure (4) by means of at least one screw connection (7) accessible through at least one recess (6) in the bumper cover (5), and closing the at least one recess (6) after the front-end module (1) has been attached by means of a cover (8) that can be attached from the outside. [10] Method according to claim 9, wherein the cover (8) is inserted into the recess (6) in a form-fitting manner and is secured by means of a clip mechanism, so that the cover (8) can be removed without tools if necessary to make the screw connection (7) accessible again.

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