VEHICLE FRONT STRUCTURE

Abstract

[Problem to be solved] The efficient arrangement of multiple components around a front end of a front side element while simultaneously achieving impact absorption. [Solution] A vehicle front structure 100 comprises a dashboard 10, a front bumper 20, a front side element 30, a dashboard-side frame 40 arranged outside the front side element 30 in the vehicle width direction and extending from a point above a front wheel T towards the front bumper 20; a bumper 50 extending in the vehicle width direction along a rear side of the front bumper 20; a support 60 supporting a front part of the front side element 30 from below; a front plate 70, which faces a vehicle front and connects a front end of the front side element 30 with a front end of the dashboard-side frame 40, and a coupling plate 90 coupled to the front end of the front side element, which is connected to a vehicle width direction outer part 50a of the bumper 50, an upper part of the support 60 and a vehicle width direction inner part 70a of the front plate 70.

Description

[Technical field]

[0001] The present invention relates to vehicle front structures. [Technical background]

[0002] Patent specification 1 shows an example of a vehicle front structure. In this exemplary structure, a hook support and a radiator support are attached to a front end of a side element (hereinafter referred to as the front side element) that extends longitudinally to the front of the vehicle, with a front transverse element extending laterally to the front of the vehicle being rigidly connected to the hook support and the radiator support. Furthermore, in this structure, the hook support is fitted into a front end of the front side element and is bolted to the front end of the side element to increase the holding strength of the hook support. In a collision, the front side element is plastically deformed to reduce the impact (to absorb the impact). [Bibliography][Patent Literature]

[0003] [Patent 1] JP 2004 - 122 863 A [Disclosure of the invention][Problems to be solved by the invention]

[0004] Furthermore, a vehicle front section with a dashboard-side frame can be located outside a front side element in the vehicle's width direction, extending towards a front bumper, with a support beam providing downward support to the front portion of the front side element. In this case, a front panel is conceivable, connecting a front end of the front side element to a front end of the dashboard-side frame to transfer an impact load generated in a frontal collision towards the dashboard-side frame, which deforms to absorb the impact. In this case, numerous components must be accommodated in the front end region of the front side element, necessitating design considerations to arrange these components around the front end of the front side element while simultaneously achieving impact absorption.

[0005] The object of the invention is therefore to provide a vehicle front structure that is able to arrange several components around a front end of a front side element while simultaneously achieving impact absorption. [Means of solving the problems]

[0006] According to one aspect of the invention, to achieve the above objective, a vehicle front structure is disclosed comprising a dashboard in a vehicle front area, a front bumper arranged in front of the dashboard and extending in the vehicle width direction, a front side element extending from a vehicle width-direction outer area in a lower part of the dashboard towards the front bumper, a dashboard-side frame located in the vehicle width direction outside the front side element and extending from a point above a front wheel towards the front bumper, a bumper extending in the vehicle width direction along a rear side of the front bumper, and a support that supports a front part of the front side element from below, wherein a front plate,which points towards a vehicle front and connects a front end of the front side element to a front end of the dashboard-side frame; and a coupling plate which is coupled to the front end of the front side element, and wherein the coupling plate is connected to a vehicle width-direction outer portion of the bumper, an upper portion of the support and a vehicle width-direction inner portion of the front panel. [Advantageous mode of operation of the invention]

[0007] According to the invention, a vehicle front structure is provided which can effectively accommodate several components around a front end of a front side element while simultaneously achieving impact absorption. [Brief description of the drawings] Fig. Figure 1 is a partial front view of a vehicle front structure according to an embodiment of the invention. Fig. Figure 2 is a side view of the vehicle's front structure. Fig. Figure 3 is a perspective view of a main section of the vehicle's front structure when viewed from the front of the vehicle. Fig. Figure 4 is a perspective view of the main section of the vehicle's front structure when viewed from the underside of the vehicle and from the rear of the vehicle. Fig. Figure 5 is a perspective view of the main section of the vehicle's front structure when viewed from the top of the vehicle and the rear of the vehicle. Fig. Figure 6 is a perspective view to illustrate a structure in a front side element in the vehicle's front structure. Fig. Figure 7 is a front view to illustrate the structure of the front panel element. Fig. Figure 8 is a front view of the main section of the vehicle's front structure. Fig. Figure 9 is a top view of the main section of the vehicle's front structure. Fig. Figure 10 is a partially enlarged front view of a part containing a coupling plate in the vehicle front structure. Fig. 11 is an enlarged top view from direction A in Fig. 10. Fig. Figure 12 is a cross-sectional view along line BB in Fig. 10. [Method of implementing the invention]

[0008] Exemplary embodiments of the invention are described below with reference to the drawings. Fig. 1, Fig. 2 to Fig. Figure 3 are views illustrating a vehicle front structure 100 according to an embodiment of the invention; Fig. Figure 1 is a partial front view of the vehicle's front structure 100; Fig. Figure 2 is a side view of the vehicle's front structure 100; and Fig. Figure 3 is a perspective view of a major section of the vehicle's front structure 100, viewed from the front of the vehicle. In the drawings, an arrow Fr denotes the front in the longitudinal direction of the vehicle; an arrow O denotes the outward direction in the width direction of the vehicle; and an arrow U denotes the upward direction in the height direction of the vehicle. In the following description, the terms "front" and "rear" correspond to the front and rear areas in the longitudinal direction of the vehicle, respectively; the terms "top" and "bottom" correspond to the upward and downward directions in the height direction of the vehicle; and "left" and "right" correspond to the left and right sides in the width direction of the vehicle, respectively, from the perspective of a vehicle occupant looking forward.

[0009] As in the Fig. 1, Fig. 2 to Fig. As shown in Figure 3, the vehicle front structure 100 of this embodiment is primarily used in the front section of a vehicle. Although not specifically limited, the vehicle with the present vehicle front structure 100 is a small car in which the front section (in particular the area from a dashboard 10 to a front bumper 20, which will be explained further below) has comparatively small dimensions in the longitudinal direction of the vehicle. Each of the drawings illustrates a part of the vehicle front structure, including a front wheel T, on the left side of the vehicle. A part of the vehicle front structure with a front wheel on the right side has the same structure as the left section with the left front wheel T, except that the parts are symmetrical in the section with the left front wheel T.

[0010] In the present embodiment, the vehicle front structure 100 is used in an electric vehicle. For example, the electric vehicle is equipped with an electric motor (not shown) for driving, wherein the electric motor is powered by a battery.

[0011] Referring to the Fig. 1, Fig. 2 to Fig. 3 The vehicle front structure 100 of this embodiment includes the dashboard 10, the front bumper 20, a front side element 30, a dashboard-side frame 40 (hereinafter referred to simply as the “frame”), a bumper 50, a support 60 and a front panel 70.

[0012] The dashboard 10 is located at the front of the vehicle. For example, it consists of a panel material that separates an engine compartment P from a passenger compartment and extends essentially in the width and height of the vehicle. A drive unit, such as an internal combustion engine and an electric motor (in this example, the electric motor), is located in the engine compartment P, also referred to as the powertrain compartment, and is primarily formed by the dashboard 10, the front bumper 20, and a front hood (not shown) that extends from an upper end of the dashboard 10 to an upper end of the front bumper. Fig. 2 The dashboard-side panel 11 (hereinafter also referred to simply as "panel") is a sheet material extending in the longitudinal direction of the vehicle and connected to a vehicle-width direction outer area of ​​the dashboard 10.

[0013] The front bumper 20 is a component located in front of the dashboard 10 and extending in the width of the vehicle, specifically at a front end of the vehicle. An electrical component E is mounted on an outer portion of the front bumper 20 in the width of the vehicle and projects rearward from the rear of the front bumper 20. Without limiting this to the example shown, the electrical component E is a fog light.

[0014] The vehicle with the front structure 100 of this embodiment is used in a vehicle where the distance between the front end of the front wheel T and the front bumper 20 is particularly short. Therefore, the vehicle is a small car in which the space between the front bumper 20 and the front wheel T is particularly small among small vehicles that have a small engine compartment P in both the longitudinal and lateral directions.

[0015] The front side element 30 is a high-strength component that forms part of a vehicle structural element (vehicle chassis) in the floor of a vehicle body. The front side element 30 extends from an outer surface of a lower part of the dashboard 10 in the vehicle width direction to the front bumper 20 (forward). In other words, the front side element 30 extends from a vehicle width-direction outer surface of a floor panel 12 (see Fig. 2) of the vehicle to its front.

[0016] Fig. Figure 4 is a perspective view of the main section of the vehicle front structure 100 when viewed from the underside and rear of the vehicle, and Fig. Figure 5 is a perspective view of the main section of the vehicle's front structure, viewed from the top and rear of the vehicle. Fig. 6 and Fig. Figure 7 are views illustrating a structure inside the front element 30, wherein Fig. 6 a perspective view and Fig. Figure 7 is a front view. Fig. 5. The front bumper 20 and the electrical component E are omitted, and in the Fig. 6 and Fig. 7 components that are arranged in front of the front side element 30 (carrier 60, front plate 70, coupling plate 90 and the like) are omitted. Fig. Figure 7 shows the external shape of the coupling plate 90 to be described below, with a double dot-dash line.

[0017] Referring to the Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. Figure 7 includes the front side element 30, a side element body 30A, and a side element reinforcement 30B. The side element body 30A has an open, hat-shaped cross-section extending outwards in the vehicle width direction in a cross-sectional view orthogonal to its own longitudinal extent (vehicle longitudinal direction), and it runs in the vehicle longitudinal direction. A side opening in the side element body 30A is closed by the side element reinforcement 30B, which is connected by spot welding to a lower flange 31 and an upper flange 32 of the side element body 30A. As shown in Fig. As shown in Figure 6, this forms a closed cross-sectional structure with an essentially rectangular shape (in other words, a rectangular cylinder shape), viewed in a cross-sectional view orthogonal to the longitudinal extent of the front side element 30. That is, the side element body 30A (the front side element 30) contains a lower wall 33, an upper wall 34 above the lower wall 33, and a vertical wall 35 that connects an inner end of the lower wall 33 in the vehicle width direction to an inner end of the upper wall 34 in the vehicle width direction, wherein the lower flange 31 extends downwards from an outer end of the lower wall 33 in the vehicle width direction and the upper flange 32 extends upwards from an outer end of the upper wall 34 in the vehicle width direction.

[0018] Referring to the Fig. 1, Fig. 2, Fig. 3 to Fig. In the illustrated example, a lower side element 80 extends longitudinally along the vehicle below the front side element 30. Specifically, the lower side element 80 is a high-strength component. The lower side element 80 extends forward from the outer edge of a (not shown) front cross element (in the vehicle width direction) towards the front bumper 20, with the front cross element extending below the dashboard 10 (in the vehicle width direction). A portion of the left or right front side element 30 on the side of the dashboard 10 is connected to the outer edge of the front cross element (in the vehicle width direction). A point on the front end of the lower side element 80 is aligned with a front end point of the front side element 30.

[0019] The frame 40 is a component located outside the front side element 30 in the vehicle width direction and extends from a point above the front wheel T towards the front bumper 20. In the illustrated example, the frame 40 extends outwards in the vehicle width direction from an upper part of the dashboard 10, in particular from the dashboard-side panel 11 (see Fig. 2) towards the front of the vehicle, and it is located above an outer area of ​​a wheel arch (not shown), viewed in the direction of the vehicle's width, which covers the front wheel T. In particular, the frame 40 extends downwards and forwards from an upper part of the plate 10 to a point that is set outwards in the direction of the vehicle's width from a front end of the front side element 30.

[0020] Referring to Fig. In the example shown, the frame 40 is inclined downwards and forwards and extends essentially in a straight line from the side of the instrument panel 10 to a predetermined intermediate point in the longitudinal direction of the vehicle. In the example shown, the location of the intermediate point in the longitudinal direction of the vehicle is set at a predetermined position between the center of the front wheel T in the radial direction and the front end of the front wheel T. The frame 40 curves downwards within the vehicle as it extends from the intermediate point towards the front bumper 20, and it extends in an arc. The frame 40 has a lower end at a point in the vertical direction of the vehicle that aligns with a height point of the lower end of an outer corner of the front bumper 20 in the horizontal direction of the vehicle.

[0021] The frame 40 includes a front surface section 40a, which extends straight vertically within a region of the lower end of the frame 40 and points forward toward a rear of the front bumper 20 in the region of the lower end of the frame. The front surface section 40a forms a front end of the frame 40; it is located between a rear surface of the front bumper 30 and the front end of the front wheel T in the longitudinal direction of the vehicle, and it lies within a tire width of the front wheel T in the width direction of the vehicle.

[0022] In the illustrated example, the frame 40 comprises a frame body 40A and a subframe 40B, which are connected to each other. In this example, a rear end of the frame body 40A is located further back than the rear end of the subframe 40B, and a rear half of the subframe 40B is positioned such that it overlaps a front half of the frame body 40A from the outside in the vehicle width direction. That is, the frame body 40A, which partially overlaps the subframe 40B, deviates from the subframe in the longitudinal direction of the frame, and a lower end of the subframe 40B projects downwards relative to a lower end (front end) of the frame body 40A.

[0023] In particular, the frame body 40A extends over a region from a rear end of the frame 40 to the upper end of the front side panel 40a. The frame body 40A has a substantially cranked cross-section, perpendicular to its own direction of extension (longitudinal direction) in a cross-sectional view. Specifically, the frame body 40A includes a top wall with a surface facing upwards and forwards, a vertical wall 42 extending downwards and rearwards from an inner part of the top wall 41 in the vehicle width direction, and a frame bottom flange 43 extending inwards from a lower edge region of the vertical wall 42 in the vehicle width direction.

[0024] The subframe 40B has an essentially hat-shaped cross-section (see Fig. 4), which extends upwards and forwards in the vehicle in a cross-sectional view orthogonal to its own direction of extension (longitudinal direction). In the area where the frame body 40A overlaps with the subframe 40B, the upper opening in the subframe 40B is closed by the connection with the frame body 40A (an upper part of the top wall 41 of the frame lower flange 43 in the vehicle width direction), which is accomplished by spot welding both a left flange 44 (outer flange in the vehicle width direction) and a right flange 45 (inner flange in the vehicle width direction) of the subframe 40B. This forms a closed cross-sectional structure with an essentially rectangular shape (in other words, a rectangular cylinder shape) in a cross-sectional view orthogonal to the longitudinal direction of the frame 40 in the area where the frame body 40A overlaps with the subframe 40B.

[0025] The bumper 50 is a component that supports the front bumper 20 from the rear and extends along the rear of the front bumper 20 in the direction of the vehicle's width. The bumper 50 is held by the front side element on the left side and the front side element 30 on the right side.

[0026] The support 60 is a component that supports a front part of the front side element 30 from below. According to the Fig. In the example shown, 3 to 5 and 7, the support 60 contains a support body 61 and a support extension 62.

[0027] The support 60 is located on the upper side of a front end of the lower side element 80 and is supported from below by it. The support 60 connects a front end 30a of the front side element 30 to the front end of the lower side element 80, and the front area of ​​the front side element 30 is held by the lower side element 80 via the support 60.

[0028] The support body 61 extends, for example, with a groove-shaped cross-section open outwards in the direction of the vehicle width from the upper surface of the lower side element 80 to an underside of the side element body 30A of the front side element 30. That is, in the illustrated example, the support body 61 includes a front wall 61a, a rear wall 61b, an inner wall 61c, and a bottom wall 61d. A lower end of the support body 61 (i.e., the bottom wall 61d) is attached to the lower side element 80 by a fastening element (in the illustrated example, a bolt 63).

[0029] The support extension 62 includes a front extension 62a, which extends continuously upwards with the front wall 61a, and a side extension 62b, which extends continuously upwards with the inner wall 61c. In the example shown, the support extension 62 projects beyond the upper wall 34 of the front side element 30.

[0030] In the illustrated example, the support 60 is connected to a support reinforcement 64, which is a component that reinforces the front wall 61a of the support 60 from the rear of an outer part in the vehicle width direction and is connected to the support body 61 by spot welding or the like in order to close a side opening of the support body 61. The support body 61 and the support reinforcement 64 form an essentially rectangular-cylindrical column that runs vertically.

[0031] The front panel 70 is a plate that connects the front end 30a of the front side element 30 with the front end (the front surface part 40a) of the frame 40 and points towards the front of the vehicle. The front panel 70 extends from the front end 30a of the front side element 30 to the front end (the front surface part 40a) of the frame 40, its front surface points towards the front of the vehicle, and it is connected to the front side element 30 and the frame 40.

[0032] The front panel 70 has a larger surface area than the front end 30a of the front side element 30 and the front end (the front surface part 40a) of the frame 40 when viewed from the front of the vehicle in a top view. In the illustrated example, the front panel 70 is formed as a plate that extends in the vehicle's width and height directions and has a substantially rectangular outer shape. Thus, the front surface of the front panel 70 forms a plane that points in the direction of the vehicle's front and creates a large area between the front end 30a of the high-strength front side element 30 and the front end (the front surface part 40a) of the frame 40.As a result, during a collision, such as a frontal collision, an impact load introduced into the front part of the vehicle is effectively transferred via the front panel 70 to the front side element 30 and the dashboard-side frame 40 in the vehicle front structure 100, in order to deform the front side element 30 and the frame 40, so that the impact energy during the frontal collision is effectively absorbed as deformation energy. Thus, the vehicle front structure 100 has an impact-absorbing structure that can absorb the impact in a frontal collision.

[0033] The front panel 70 is part of the impact-absorbing structure and is located near and opposite an outer edge of the rear of the front bumper 20 in the vehicle width direction. In other words, the front end 30a of the front side element 30 (and the front end of the frame 40) is located near the rear of the front bumper 20. The outer portion of the rear of the front bumper 20 in the vehicle width direction is located at a point (mounting point) of the electrical component E. That is, a point in the vehicle longitudinal direction of the mounting position of the electrical component E is located near the front end of the front side element 30.

[0034] Fig. 8, Fig. 9, Fig. 10, Fig. 11 to Fig. 12 are views illustrating the main section of the vehicle front structure 100. Fig. Figure 8 is a front view of the main section; Fig. Figure 9 is a top view of the main section; Fig. 10 is a partially enlarged front view of an area containing the coupling plate 90 of the vehicle front structure 100, which will be described below; Fig. 11 is an enlarged top view from direction A in Fig. 10; and Fig. Figure 12 is a cross-sectional view along line BB in Fig. 10.

[0035] Referring to the Fig. In sections 1 to 5, 8 and 9, the vehicle front structure 100 comprises the following assembly to create the layout of the electrical component E described above. In the vehicle front structure 100, (1) the front panel 70 contains a receiving space 71 in which a zone S (hereinafter referred to as the storage zone S) is formed to receive at least a rear portion of the electrical component E, which is mounted in the front bumper 20 and projects rearward from it, and (2) the front side element 30 and the frame 40 are spaced apart from each other in the vehicle width direction and connected to the front panel 70. That is, the front side element 30 and the frame 40 are not directly connected to each other on the side of the front panel 70; they are spaced apart from each other in the vehicle width direction, and there is a gap between the front side element 30 and the frame 40.

[0036] In particular, the front panel 70 has a large front surface that faces the front of the vehicle and is opposite the rear of the front bumper 20. The front panel 70 closes a gap between the front end 30a of the front side element 30 and the support 60, and the front end (the front surface part 40a) of the frame 40. The inner part 70a of the front panel 70, which lies in the direction of the vehicle's width, is connected from the front side to the front end 30a of the front side element 30 and the support 60 by spot welding or the like, and the outer part 70b of the front panel 70, which lies in the direction of the vehicle's width, is connected by spot welding or the like to the front of the front end (the front surface part 40a) of the frame 40.

[0037] Furthermore, in the illustrated example, the front end (the front surface section 40a) of the frame 40 is offset rearward in the longitudinal direction of the vehicle relative to the front end 30a of the front side element 30. In the front panel 70, an intermediate panel section 70m is inclined rearward between the front side element 30 and the frame 40 to move away from the front end 30a of the front side element 30 in the longitudinal direction of the vehicle, while the intermediate panel section extends outward in the vehicle width direction. An inner section 70a and an outer section 70b in the front panel 70 run linearly in the vehicle width direction and are parallel to each other, with the intermediate panel section 70m connecting the inner section 70a to the outer section 70b.

[0038] In the illustrated example, the receiving space 71 contains a plate-shaped ring plate part 71a, which surrounds a rear area of ​​the electrical component E. According to Fig. In section 9, the rear portion of the electrical component E is located in a zone that overlaps the position of the ring plate part 71a in the longitudinal direction of the vehicle. The electrical component E is located between the front wheel T and the front side element 30 in the width direction of the vehicle, with a rear end of the electrical component E projecting rearward relative to a rear side of the ring plate part 71a. Specifically, the congestion zone S in the width direction of the vehicle is located in a region extending from a near point of a virtual outer plane V along an inner surface of the front wheel T in the width direction of the vehicle to a near point of a virtual inner plane V2 along an outer surface of the front side element 30 in the width direction of the vehicle. In the illustrated example, the position of an inner surface of the frame 40 in the width direction coincides with, or substantially coincides with, the position of an inner surface of the front wheel T in the width direction of the vehicle.Therefore, the virtual outer plane V1 also runs along the inner surface of the frame 40 in the direction of the vehicle width.

[0039] In the illustrated example, the receiving chamber 71 contains a cylindrical section 71b that projects from an inner edge 71a1 of the ring plate section 71a towards the rear of the vehicle and is open in the longitudinal direction of the vehicle within the cylindrical section 71b. That is, a hole penetrating the front plate 70 is formed in a portion of the front plate 70 corresponding to the jamming zone S, and the ring plate section 71a forms a portion around the hole. The cylindrical section 71b is formed by chamfering an inner edge of the ring plate section 71a. The cylindrical section 71b of the receiving chamber 71 has no bottom; it is open to the rear.

[0040] In the illustrated example, the front panel 70 includes a lateral reinforcement 72 extending in the vehicle's width direction, and a vertical reinforcement 73 extending in the vehicle's height direction along a front end section (front surface section 40a) of the frame 40. Specifically, lateral reinforcements 72 are located above and below the receiving area 71. The lateral reinforcement 72 consists of a bead that is curved in the forward direction of the vehicle and extends in the vehicle's width direction. In the illustrated example, the lateral reinforcement 72 extends from an inner end of the front panel 70 in the vehicle's width direction to a point in front of the front surface section 40a of the frame 40, and it is also formed with a shape that tapers from top to bottom on the side of the front side element 30.In the illustrated example, the vertical reinforcement 73 runs continuously with the upper and lower lateral reinforcements 72 and consists of a bead that projects in the forward direction of the vehicle, as does the lateral reinforcement 72. The vertical reinforcement 73 extends from an outer area of ​​the upper lateral reinforcement 72 (in the direction of the vehicle's width) to an outer area of ​​the lower lateral reinforcement 72 (in the direction of the vehicle's width). Therefore, the bead, which is composed of the paired upper and lower lateral reinforcements 72 and the vertical reinforcement 73, is a U-shaped bead that is completely open inwards in a front view in the direction of the vehicle's width. The U-shaped bead is arranged such that it surrounds the receiving space 71 in the front view.

[0041] In the illustrated example, the front panel 70 has a lower part with a projection 74 that points in the vehicle width direction and projects towards the front of the vehicle, the projection 74 extending outwards in the vehicle width direction on opposite sides of the receiving space 71. In the illustrated example, the projection 74 is a component separate from the front panel 70 and is connected to the front panel 70 by spot welding or the like. In particular, the projection 74 runs along a lower edge of the front panel 70. The projection 74 is located at a height of the radial center (central axis) of the front wheel T. Although not specifically limited, in the present example the projection 74 includes a connecting flange 74a along the front panel 70, a body part 74b that projects forward from the connecting flange 74a, and an upper projection 74c that projects upward from the front end of the body part 74b.

[0042] The projection 74 extends along an inclined shape of the front plate 70. Furthermore, in the illustrated example, the projection 74 extends with respect to an outside in the vehicle width direction to a front point of the front end (of the front surface part 40a) of the frame 40 and with respect to an inside in the vehicle width direction to a near point of the virtual inner plane V2 along the outer surface of the front side element 30 in the vehicle width direction.

[0043] In the illustrated example, a front end of the projection 74 extends forward relative to the front end of the electrical component E. A rear end of the electrical component E extends rearward relative to the rear of the ring plate part 71a of the front plate 70, as explained above. In particular, the rear end of the electrical component E extends rearward relative to a rear end of the cylinder part 71b. The front end of the electrical component E extends forward relative to a front end (summit of the bead) of the lateral reinforcement 72 of the front plate 70. That is, the front end of the electrical component E is located between a front end of the front plate 70 and the front end of the projection 74 in the longitudinal direction of the vehicle.

[0044] As explained above, numerous components, such as the bumper 50, the support 60, and the front panel 70, must be grouped around the front end 30a of the front side element 30. The vehicle front structure 100 of this embodiment further comprises the following arrangement to create a vehicle front structure that can effectively arrange a plurality of components around the front end of the front side element 30 while simultaneously achieving impact absorption in the event of a frontal collision.

[0045] Referring to the Fig. 7, Fig. 8 to Fig. The vehicle front structure 100 includes the coupling plate 90 in addition to the components listed above. The coupling plate 90 is a thin metal plate; it serves as a hub for coupling several components to the front end 30a of the front side element 30.

[0046] The coupling plate 90 is located between the front side element 30 and the front bumper 20; it is coupled to the front part 30a of the front side element 30. The coupling plate 90 is coupled to a vehicle width-direction outer part 50a of the bumper 50, an upper part of the support 60, and the vehicle width-direction inner part 70a of the front panel 70. In other words, components (the front side element 30, the bumper 50, the support 60, and the front panel 70) are joined by the coupling plate 90, which couples the several components together, and the several components are arranged in a small space around the near-front end of the front side element 30.

[0047] In particular, with regard to the front side element 30, the front wall 61a of the support body 61 of the support 60 is joined to the front end lower flange 33a by spot welding or the like (see Fig. 6) connected, extending downwards from a front end of the lower wall 33 of the front side element 30, and a lower end part of the rear wall 61b of the support body 61 (see Fig. 4) is connected to the lower wall 33 of the front side element 30 by spot welding or the like. Consequently, the support 60 connects the front side element 30 to the lower side element 80. The front extension 62a is located as close as possible to a front end opening of the front side element 30. The front extension 62a is connected to a front end upper flange 34a by spot welding or the like (see Fig. 6 and Fig. 7) connected, extending upwards from a front end of the upper wall 34 of the front side element 30. The side extension 62b is connected to the vertical wall 35 of the front side element 30 by spot welding or the like. That is to say, in the present embodiment, the support 60 (the support extension 62) includes the side extension 62b, which is connected to a side wall (the vertical wall 35) of the front side element 30.

[0048] In this embodiment, the front side element 30 includes a side element outer flange 36, which extends outwards in the vehicle width direction from the front end of the front side element 30 (see the Fig. 4 to 7, 9, 11 and 12). In the example shown, the side element outer flange 36 extends outwards in the vehicle width direction from a front end of the side element reinforcement 30B. According to Fig. 4 The side element outer flange 36 runs continuously with a support outer flange 64a, which extends outwards in the vehicle width direction from a front end of the support reinforcement 64, which closes the side opening of the support body 61 of the support 60. The support reinforcement 64 bends in its middle section in the vehicle width direction, so that its lower part is located inwards in the vehicle width direction opposite the upper part, and the support outer flange 64a is bent in the same way. An upper end of the support outer flange 64a overlaps a rear side of a lower end part of the side element outer flange 36 and is connected to the rear side by spot welding or the like.An outer surface of the front extension 62 of the support 60 in the vehicle width direction is connected to the side element outer flange 36 by spot welding or the like, and the outer surface of the front wall 61a of the support 60 in the vehicle width direction is connected to the support outer flange 64a by spot welding or the like. Therefore, the front wall 61a and the front extension 62a of the support 60 are supported from the rear by the front end lower flange 33a, the front end upper flange 34a and the side element outer flange 36 of the front side element 30, as well as by the support outer flange 64a of the support reinforcement 64.

[0049] Referring to Fig. 7, an outer area of ​​an upper part of the support extension 62 (the front extension 62a) of the support 60 is cut out in the vehicle width direction. In a state in which the support 60 is connected to the front end 30a of the front side element 30 (the front end lower flange 33a, the front end upper flange 34a, and the like), a portion of the front opening of the front side element 30 remains open corresponding to the cutout of the support extension 62. The coupling plate 90 serves to close the area of ​​the front end opening of the front side element 30 corresponding to the cutout of the support extension 62.

[0050] In particular, according to the Fig. 7, Fig. 8, Fig. 9, Fig. 10, Fig. 11 to Fig. 12 The coupling plate 90 of a front extension 62a of the carrier 60 is superimposed, as well as the front end upper flange 34a and the side element outer flange 36 of the front side element 30, in order to close the front part of an upper left corner circumferential region of the front end opening of the front side element 30. The front extension 62a of the carrier 60 is enclosed between the front end upper flange 34a and the coupling plate 90. In this state, in this embodiment, the coupling plate 90 is connected to at least the side element outer flange 36 by spot welding or the like. In the illustrated example, the coupling plate 90 is connected to the side element outer flange 36 and the front end upper flange 34a of the front side element 30 by spot welding and is thus coupled to the front end 30a of the front side element 30.

[0051] In the present embodiment, the coupling plate 90 is equipped with a towing nut N. The towing nut N is used for towing another vehicle or the like and is welded to the coupling plate 90 as it passes through it. A rear portion of the towing nut N is located inside the closed structure of the front side element 30. The rear portion of the towing nut N is connected to a side portion of the front side element 30 in the vehicle width direction. In the illustrated example, a convex section 30B1 is formed in a portion of the side element reinforcement 30B of the front side element 30, which corresponds to the towing nut N. This convex section is bulged outwards in the vehicle width direction. The rear portion of the towing nut N runs along an inner surface of the convex section 30B1 of the side element reinforcement 30B of the front side element 30 and is connected to the inner surface of the convex section 30B1.

[0052] Referring to the Fig. 8, Fig. 9, Fig. 10, Fig. 11 to Fig. 12 The outer vehicle-width section 50a of the bumper 50 is connected to the front end 30a of the front side element 30. In the illustrated example, the outer vehicle-width section 50a of the bumper 50 is attached to the front extension 62a of the support 60 by fastening elements (in the illustrated example by bolts 51), which is welded to the front end 30a of the front side element 30, and is thus connected to the front end 30a of the side element 30.

[0053] In particular, according to Fig. 11 Side parts of the front extension 62a and the coupling plate 90 are arranged in the vehicle side direction between an inner part of the front end upper flange 34a of the front side element 30 and the vehicle width direction outer part 50a of the bumper 50, and the coupling plate 90 is enclosed between the front extension 62a and the vehicle width direction outer part 50a of the bumper 50. According to Fig. 12 The outer vehicle-width section 50a of the bumper 50 is attached to the coupling plate 90 and the front extension 62a by two upper and lower bolts 51, the inner part of the coupling plate 90 being enclosed in the vehicle-width direction between the outer vehicle-width section 50a and the front extension 62a. In other words, the outer vehicle-width section 50a of the bumper 50 and the upper part (the front extension 62a) of the support 60 are connected to the coupling plate 90 by bolts.

[0054] In particular, the bolts 51 are inserted into respective bolt receiving holes formed in the bumper 50 and the coupling plate 90, and into bolt receiving holes 62a1 in the front extension 62a. By screwing the ends of the bolts 51 into weld nuts 62a2, which are welded to the rear of the front extension 62a, the bumper 50 and the coupling plate 90 are connected to the front end 30a of the front side element 30 via the front extension 62a of the carrier 60.

[0055] Viewed from the front of the vehicle, in this example the upper end of the coupling plate 90 is aligned with an upper end position of the front end upper flange 34a of the front side element 30, and an inner end of the coupling plate 90 in the vehicle width direction is aligned with a point of an inner end of the support 60 in the vehicle width direction, and does not project inwards with respect to the side extension 62b in the vehicle width direction, while an outer plate part 90a as the outer part of the coupling plate 90 in the vehicle width direction projects outwards (extends outwards) to an outer end of the support 60 and relative to an outer end of the side element outer flange 36 of the front side element 30 in the width direction.The outer plate section 90a of the coupling plate 90 bends towards the rear of the vehicle in a plate bending area 90a1, the bending area being located near the outer end of the side element outer flange 36 in the vehicle width direction, while the outer plate section of the coupling plate extends along a rear side of the inclined intermediate plate section 70m of the front plate 70. In particular, the location of the plate bending section 90a1 is aligned with the location of a bending area at the boundary between the vehicle width inner section 70a of the front plate 70 and the intermediate plate section 70m. An outer part of the intermediate plate section 70m in the vehicle width direction is curved such that it connects smoothly to the vehicle width outer section 70b. Furthermore, an area of ​​the coupling plate 90 inside, with respect to the plate bending area 90a in the vehicle width direction, forms a plate flat part 90b, which is flat and points towards the front of the vehicle.The vehicle-width inner part 70a of the front plate 70 is superimposed from the front on the plate flat part 90b of the coupling plate 90, as well as on the outer part of the front extension 62a of the support 60 in the vehicle width direction, on the outer part of the front wall 61a in the vehicle width direction, and on the support outer flange 64a of the support reinforcement 64.

[0056] In the present embodiment, the vehicle width inner part 70a of the front plate 70 has an upper area which is connected to the coupling plate 90, for example by spot welding or the like, and the vehicle width inner part 70a of the front plate 70 has a lower area which is connected to the carrier 60, for example by spot welding.

[0057] In particular, the upper area of ​​the vehicle-width inner section 70a of the front panel 70 is connected to an area within the panel bending area 90a1 in the vehicle-width direction in a lower area of ​​the panel flat section 90b of the coupling plate 90. Furthermore, the lower area of ​​the vehicle-width inner section 70a of the front panel 70 is connected to the outer area of ​​the front wall 61a in the vehicle-width direction. In the illustrated example, the vehicle-width inner section 70a of the front panel 70 has an intermediate area in the vehicle-height direction, which is connected to an outer section of the front extension 62 in the vehicle-width direction. The vehicle-width inner section 70a of the front panel 70 is solidly supported from the rear by the coupling plate 90, as well as by the respective flanges located behind the front extension 62a and the front wall 61a (side element outer flange 36 and support outer flange 64a).In particular, the upper area of ​​the vehicle-width inner part 70a of the front plate 70 is supported from the rear by an overlap area of ​​the coupling plate 90 with the side element outer flange 36, while the intermediate area of ​​the vehicle-width inner part of the front plate is partially supported from the rear by an overlap area of ​​the outer part of the front wall 61a in the vehicle-width direction, a lower part of the side element outer flange 36 and an upper part of the support outer flange 64a (elements of three superimposed pieces).

[0058] In the example shown, an upper area of ​​the intermediate plate section 70m of the front plate 70 is connected to an area of ​​the outer plate section 90a of the coupling plate 90 outside the plate bending area 90a1 in the vehicle width direction. This means that the connection point between the front plate 70 and the coupling plate 90 is designed to span the plate bending area 90a1 of the coupling plate 90 and a bending area of ​​the front plate 70.

[0059] As explained above, the vehicle-width outer part 50a of the bumper 50 and the upper part (the front extension 62a) of the carrier 60 are connected by bolts to the coupling plate 90, which is coupled to the front end 30a of the front side element 30, and the vehicle-width inner part 70a of the front plate 70 is connected to the coupling plate by spot welding.

[0060] In the present embodiment, the front element 30 includes a weakening section 37 adjacent to the side extension 62b behind it. The weakening section 37 is located on the vertical wall 35 of the side element body 30A of the front element 30. The weakening section 37 is a zone whose strength is lower than the strength (e.g., compressive strength) of another zone in the front element 30. Although not specifically limited, in this embodiment the weakening section 37 is formed by openings that penetrate the vertical wall 35. The openings for forming the weakening section 37 are located at several positions spaced apart in a vertical direction. A portion of the vertical wall 35 corresponding to the weakening section 37 is offset inwards along the entire vertical direction relative to the front element 30.

[0061] The vehicle front structure 100 of this embodiment includes the front plate 70 opposite the vehicle front, which connects the front end 30a of the front side element 30 with the front end (the front surface part 40a) of the frame 40. Therefore, in a collision such as a frontal collision, the impact load acting on the vehicle front section is effectively transferred by the front plate 70 to the front side element 30 and the dashboard-side frame 40 in order to deform these two parts, thus effectively absorbing the impact energy as deformation energy in a frontal collision. The vehicle front structure 100 further includes the coupling plate 90, which is coupled to the front end 30a of the front side element 30. The outer vehicle width section 50a of the bumper 50, the upper part of the support 60, and the inner vehicle width section 70a of the front plate 70 are connected to the coupling plate 90.As a result, the vehicle front structure 100 effectively couples several components (the front side element 30, the bumper 50, the support 60, and the front panel 70) together using the coupling plate 90, so that the multiple components can be effectively arranged within a small space near the front end of the front side element 30. Connecting the multiple components with the coupling plate 90 also increases their strength and rigidity, and the shape of the front end 30a of the front side element 30 is kept light in the event of a frontal collision. Consequently, the impact load introduced from the front during a frontal collision is reliably transferred to the front side element 30, and the intended deformation (impact absorption mode) can occur in a frontal collision.

[0062] As explained above, in the vehicle front structure 100 of this embodiment it is possible to arrange several components around the front end of the front side element 30 while achieving impact absorption.

[0063] In this embodiment, the inner vehicle-width section 70a of the front panel 70 has an upper area that is connected to the coupling plate 90, and the inner vehicle-width section 70a of the front panel 70 is connected to the support 60 at a lower area. Therefore, the upper and lower areas of the inner vehicle-width section 70a of the front panel 70 are solidly supported from the rear by other components (the coupling plate 90 and the support 60).If the front plate 70 is shaped such that it bends the vehicle-width inner part 70a, for example as in the present embodiment, backwards and outwards in a frontal collision, the probability increases that the front plate 70 will bend backwards from a starting point of a bending area near the vehicle-width inner part 70a, which facilitates the control of a deformation section so that the intended deformation (impact absorption mode) can easily take place in a frontal collision.

[0064] Since, in this embodiment, the support 60 includes the side extension 62b, which is connected to the vertical wall 35 forming a side wall of the frontal side element 30, the impact load is effectively transferred into the vertical wall 35 of the frontal side element 30 via the side extension 62b in the event of a frontal collision. As a result, the deformation of the frontal side element 30 in a frontal collision is greatly enhanced, and effective impact absorption is achieved.

[0065] In this embodiment, the front side element 30 contains the weakening part 37 adjacent to and behind the side extension 62b. Therefore, in a frontal collision, the deformation of the front side element 30 in the weakening part 37 is reliably promoted, and the impact absorption is achieved more effectively.

[0066] In this embodiment, the front side element 30 includes the side element outer flange 36, which extends outwards in the vehicle width direction from the front end of the front side element 30, and the coupling plate 90 is connected to at least the side element outer flange 36. Therefore, the outward deflection of the coupling plate 90 in the vehicle width direction during a frontal collision is reduced, which in turn reduces the collapse of the shape of the front end 30a of the front side element 30 due to the deflection of the coupling plate 90. Thus, the intended deformation of the front side element 30 in a frontal collision is achieved more reliably and easily.

[0067] In this embodiment, the coupling plate 90 is equipped with the towing groove N. As explained above, the strength of the coupling plate 90 is increased by connecting the several components to the coupling plate 90, and the support strength for the towing nut N is easily ensured by arranging the towing nut N on the high-strength coupling plate 90. Furthermore, the rear part of the towing nut N is connected to the side part of the front side panel 30 in the vehicle width direction (with the inner surface of the side element reinforcement 30B) in order to effectively increase the strength against a load acting on the towing nut N in the longitudinal direction of the vehicle.

[0068] Furthermore, in this embodiment, during a frontal collision, the electrical component E is retracted and fits into the receiving space 71 as it moves along the front panel 70 towards the rear of the vehicle. The vehicle's front structure 100 effectively absorbs the impact load introduced from the front of the vehicle, with the front panel 70 effectively transferring the impact load to the front side element 30 and the frame 40, while the front side element 30 and the frame 40 can deform to effectively absorb the impact energy. Therefore, in this embodiment of the vehicle's front structure 100, the electrical component E and several components (bumper 50, support 60, front panel 70, and coupling plate 90) are arranged in a small space around the front end 30a of the front side element 30, enabling the vehicle's front structure to absorb the impact in a frontal collision.This means that while the layout for the electrical component E in the small space is accomplished by the receiving space 71, the impact absorption can be facilitated by the front panel 70.

[0069] In this embodiment, the ring plate part 71a prevents the electrical component E from being moved around (vertically and laterally) due to the impact of a frontal collision, thus preventing contact between the electrical component E and the front wheel T, and also preventing unintentional contact between components and the front wheel T. Furthermore, the shape of the receiving space 71 is maintained by the cylinder part 71b during a minor collision, and the strength of the front plate 70 is ensured. As a result, the impact absorption performance can be maintained, for example, after a serious frontal collision following a minor collision.

[0070] In the present embodiment, the stiffness of the front plate 70 can be increased by the lateral reinforcement 72 and the vertical reinforcement 73, thereby improving the impact absorption performance. In the illustrated example, the deformation of the inclined part of the front plate 70 is reduced by the lateral reinforcement in a frontal collision. In a frontal collision, the deformation of the part of the front plate 70 located in front of the front end (the front surface part 40a) of the frame 40 is reduced by the vertical reinforcement 73, and the front end (the front surface part 40a) of the frame 40 makes secure contact with a large area of ​​the front part of the front wheel T. As a result, the impact energy is effectively absorbed by the frame 40 and the front wheel T, thus increasing the impact absorption performance.

[0071] In this embodiment, the front plate 70 is equipped in its lower region with a projection 74 that extends in the direction of the vehicle's width and projects towards the front of the vehicle, with the projection 74 extending outwards in the direction of the vehicle's width on opposite sides of the receiving space 71. Consequently, the stiffness of the front plate 70 can be further increased, and in a frontal collision, the impact load is effectively transferred to the front end (the front surface part 40a) of the frame 40. As a result, the backward deformation of the frame 40 is promoted, and impact absorption is achieved even more effectively. Furthermore, the projection 74 helps to maintain the perforated shape of the receiving space 71.In a frontal collision, the projection 74 can strike the lower part of a collision object, deflecting the front part of the collision object forward and directing obstacles over the front hood, which is advantageous, for example, in terms of pedestrian protection. The front end of the projection 74 extends forward relative to the front end of the electrical component E. In a minor collision, the electrical component E is protected and damage to this component is prevented. Furthermore, in a frontal collision, obstacles can be reliably deflected upwards, thus providing more reliable protection for pedestrians, for example.

[0072] One embodiment of the invention has been explained above; however, the invention is not limited to the embodiments described above; rather, it can be modified or adapted based on the technical idea of ​​the invention.

[0073] For example, the outer plate section 90a of the coupling plate 90 can be extended linearly outwards in the direction of the vehicle's width to run continuously with the flat plate section 90b without being curved towards the rear of the vehicle. Furthermore, the cylindrical section 71b of the receiving chamber 71 can have a bottom; it does not need to be open at the rear. The receiving chamber 71 can also omit the cylindrical section 71b. At least one element of the lateral reinforcement 72, the vertical reinforcement 73, and the projection 74 can be present, or none of these elements can be present. The projection 74 can be integrated with the front plate 70. [List of reference symbols] 10 Dashboard 11 (dashboard-side) plate 12 Base plate 20 front bumper 30 Front panel element 30a Front end 30A Side element body 30B Side element reinforcement 30B1 Curved section 31 Lower flange 32 Top flange 33 Lower wall 33a Front end lower flange 34 Upper wall 34a Front end upper flange 35 Vertical wall 36 Side element outer flange 37 Weakening part 40 (dashboard-side) frame 40a Front surface part (front end) 40A Frame body 40B subframe 41 Upper wall 42 Vertical wall 43 Frame lower flange 44 left flange 45 right flange 50 bumpers 50a Vehicle width outer part 51 bolts 60 carriers 61 Carrier bodies 61a Front wall 61b Back panel 61c Interior wall 61d Floor wall 62 Carrier extension 62a Front extension 62a1 Bolt insertion hole 62a2 Weld nut 62b Page extension 63 bolts 64 Beam reinforcement 64a Carrier outer flange 70 Front panel 70a Vehicle width inner part 70b Vehicle width outer part 70m intermediate plate 71 Recording Room 71a Ring plate part 71a1 Inner edge 71b Cylinder part 72 lateral reinforcement 73 vertical reinforcement 74 lead 74a Connecting flange 74b Body part 74c upper lead 80 lower side element 90 coupling plate 90a Outer plate part 90a1 Plate bending area 90b Flat plate 100 vehicle front structure E electrical component N tow nut P Engine compartment S Congestion zone (zone) T front wheel V1 virtual outer plane V2 virtual inner plane QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2004 - 122 863 A

[0003]

Claims

Vehicle front structure (100), comprising: an instrument panel (10) in a vehicle front area, a front bumper (20) arranged in front of the instrument panel (10) and extending in the vehicle width direction, a front side element (30) extending from a vehicle width-direction outer area in a lower part of the instrument panel (10) towards the front bumper (20), an instrument panel-side frame (40) located in the vehicle width direction outside the front side element (30) and extending from a point above a front wheel (T) towards the front bumper (20), a bumper (50) extending in the vehicle width direction along a rear side of the front bumper (20), and a support (60) supporting a front part of the front side element (30) from below, characterized in that the vehicle front structure (100) further comprises: a front panel (70),which points towards a vehicle front and connects a front end (30a) of the front side element (30) with a front end (40a) of the dashboard-side frame (40); and a coupling plate (90) which is coupled to the front end (30a) of the front side element (30), and wherein the coupling plate (90) is connected to a vehicle width-direction outer portion of the bumper (50), an upper portion of the support (60) and a vehicle width-direction inner portion of the front panel (70). Vehicle front structure (100) according to claim 1, wherein the inner part of the front plate (70) has an upper area connected to the coupling plate (90) in the vehicle width direction, and the inner part of the front plate (70) has a lower section connected to the support (60) in the vehicle width direction. Vehicle front structure (100) according to claim 1, wherein the support (60) has a side extension (62b) which is connected to a side wall of the front side element (30). Vehicle front structure (100) according to claim 3, wherein the front side element (30) has a weakening part (37) which is adjacent to and behind the side extension (62b). Vehicle front structure (100) according to claim 1, wherein the front side element (30) includes a side element outer flange (36) which extends outwards in the vehicle width direction from a front end (30a) of the front side element (30), and wherein the coupling plate (90) is connected at least to the side element outer flange (36). Vehicle front structure (100) according to one of claims 1 to 5, wherein the coupling plate (90) is equipped with a towing nut (N), and a rear part of the towing nut (N) is connected to a side part of the front side element (30) in the vehicle width direction.

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