DEFORMATION PROFILE THE

Description

[0001] The present invention relates to a deformation profile according to the features in the preamble of claim 1, as well as a deformation profile arrangement and a bumper arrangement with such a deformation profile.

[0002] Deformation profiles, in particular crash boxes based on hollow chamber profiles, are known from the prior art. Deformation profiles are mostly part of bumper assemblies that are arranged at the front or rear of a motor vehicle.

[0003] Bumper systems typically feature a crossmember that extends essentially in the transverse direction of the vehicle and usually has a width that is roughly equal to or slightly smaller than the vehicle itself. This crossmember is connected to the vehicle via crumple zones. In the case of a front bumper, the crumple zones are usually located on the front of the longitudinal member. The crossmember and the crumple zones are generally manufactured separately and then joined together. The most common joining methods are bolted or welded connections.

[0004] In the event of a collision between the motor vehicle and an object, the deformation profiles are deformed or compressed in an accordion-like manner, thus converting kinetic energy into forming work.

[0005] To control the direction of deformation and the force required for deformation, holes or slots running transversely to the direction of travel (when installed on the vehicle) can be provided on the side walls or the upper and lower walls. Alternatively, it is also known to form beads into the side walls of the deformation profiles. The upper and / or lower walls of the deformation profiles, however, are designed as a flat surface to allow coupling with additional attachments. When the beads are formed into the side walls of the deformation profiles, forming ridges or bulges are created that protrude beyond the upper and / or lower wall. This makes coupling additional attachments to the upper and / or lower wall of the deformation profile more difficult. Furthermore, the flat surface of the upper and / or lower wall is reduced.

[0006] A generic deformation profile is known from DE 10 2014 115 887 A1. DE 10 2004 002 948 A1 and EP 2 572 941 A1 show deformation profiles with chamfers between the side walls.

[0007] The object of the present invention is to provide a deformation profile and a bumper arrangement in which, despite the aforementioned corrugation arrangement on the side walls, an attachment part can be coupled to the upper and / or lower wall, in particular in a flat, contact position.

[0008] The aforementioned problem is solved according to the invention in a deformation profile with the features in claim 1.

[0009] Advantageous design variants are the subject of the dependent claims.

[0010] The deformation profile according to the invention has two opposing side walls, which are connected by an upper wall and a lower wall. The deformation profile is preferably designed as a component with a rectangular or square cross-section. Preferably, the deformation profile is a crash box, in particular a multi-chamber crash box. Alternatively, the deformation profile can also be a longitudinal beam. A longitudinal beam can be a component located in the front of a motor vehicle, i.e., a front longitudinal beam, or a component located in the rear of a motor vehicle, i.e., a rear longitudinal beam.

[0011] Each of the two side walls has at least one groove extending over its entire height. These grooves control and standardize the folding process of the deformation profile. An upper corner section is formed between each side wall and the top wall. A lower corner section is formed between each side wall and the bottom wall. The side walls are connected to the top wall and the bottom wall, respectively, via these corner sections.

[0012] According to the invention, the deformation profile is now characterized by the fact that the upper corner areas and / or the lower corner areas have a chamfer in cross-section. Particularly in the case of deformation profiles with a rectangular cross-section, ridges are formed when the grooves are pressed into the side walls, which can project beyond the upper and / or lower wall. This leads to an unevenness of the upper and / or lower wall. By having the upper and / or lower corner areas have a chamfer in cross-section, the ridges remain within the corner areas and no longer project beyond the upper or lower wall. Thus, the flat surface of the upper and / or lower wall is not affected. The remaining flat surface of the upper and / or lower wall is therefore suitable for coupling with an additional attachment.

[0013] The deformation profile is a one-piece extruded profile. The two side walls, the top wall, the bottom wall, and optionally one or more intermediate walls are extruded in a single piece from the same material.

[0014] The corner areas according to the invention can be formed either only in the upper area of ​​the deformation profile, only in the lower area of ​​the deformation profile, or in both areas. If only the two upper corners of the upper corner area have a chamfer in cross-section, the surface of the upper wall is correspondingly flat and enlarged, and thus suitable for coupling an additional attachment. The same applies analogously to the lower wall in the case of an embodiment according to the invention in which only the lower corner areas have a chamfer. It is particularly preferred that both the upper and lower corner areas have a chamfer in cross-section, so that neither the upper nor the lower wall is affected by protruding ridges, and a folding behavior that is as symmetrical as possible is achieved upon impact.

[0015] A particularly advantageous embodiment for practical purposes provides that a deformation profile has two opposing ribs in its side walls, with the two opposing ribs being arranged in the same longitudinal section of the deformation profile. The two ribs are diametrically opposed to each other. The deformation profile is designed as a mirror image of the vertical central longitudinal plane. Such a deformation profile is characterized by symmetrical folding behavior, especially in the event of an impact or shock axially along the longitudinal direction of the deformation profile.

[0016] According to the invention, a chamfer angle α is formed between 25° and 65°, preferably between 40° and 50°. That is, the chamfer runs at an angle of preferably between 40° and 50° to an upper or lower wall and the adjoining side wall.

[0017] For the upper corner area, the chamfer angle lies between the chamfer and a top wall plane or horizontal plane. For the lower area, the chamfer angle lies between the chamfer and a bottom wall plane or horizontal plane.

[0018] Furthermore, the chamfer has a cross-sectional length of between 12 mm and 25 mm.

[0019] The upper wall and / or the lower wall has a total external surface area. This total surface area comprises the planar surface extending parallel to the horizontal in a horizontal plane and the portion(s) of the corner surface inclined to the horizontal. According to the invention, the proportion of the planar surface to the total surface area of ​​an upper wall and / or a lower wall is between 30% and 65%.

[0020] The plan area is set up and designed to define at least one additional attachment to the deformation profile.

[0021] The chamfer width is preferably less than one-third, and especially less than one-quarter, of the crash box width. This contributes to achieving a large flat surface.

[0022] In addition to the inventive design of the corner areas as chamfers, the upper or lower corner areas not designed as chamfers can have a concave shape.

[0023] In the case of a concave design of the corner areas, the concave shape preferably has a radius between 12 mm and 25 mm. Preferably, the radius is between 13 mm and 20 mm. In this context, it may be advantageous if the radius is less than one-third, preferably less than one-quarter, of the crash box width. This measure also ensures the largest possible proportion of the flat surface to the total outer surface area of ​​the top and / or bottom wall.

[0024] The deformation profile itself preferably has a wall thickness between 0.5 mm and 4 mm, in particular between 1 mm and 3 mm.

[0025] If only the upper corner regions or only the lower corner regions have chamfers according to the invention, the remaining corner regions of the deformation profile have no chamfer. In particular, no chamfer or no concave shape means that these corners have a chamfer that is at least 20%, in particular 33%, and preferably at least 50% smaller in relation to the corner regions according to the invention with a chamfer.

[0026] Preferably, the top wall and / or the bottom wall is designed to be flat. Such a flat design significantly simplifies the coupling with an additional component. Preferably, the top wall and the bottom wall are not only flat along the length of the section with the corrugations in the side wall (side wall corrugations), but also along the entire length of the deformation profile, resulting in a large, flat connection surface.

[0027] The deformation profile can be produced by extrusion and is preferably made of a light metal material, particularly preferably of an aluminum alloy.

[0028] Preferably, the deformation profile is part of a bumper assembly of a motor vehicle. In this case, the deformation profile can be connected to a flange plate or directly to a cross member by means of screws or a weld. Additionally, the deformation profile can be bolted to the longitudinal member.

[0029] The deformation profile arrangement according to the invention comprises a deformation profile according to the invention and an additional attachment part. The deformation profile arrangement is characterized in that the attachment part is detachably or permanently coupled to the upper wall or the lower wall. Due to the chamfered design of the corner areas, the deformation profile according to the invention has a flat upper wall and / or lower wall. The upper wall and / or lower wall thus have a suitable coupling surface for coupling with an attachment part.

[0030] Add-on parts can include, for example, load path supports, radiator supports, headlight brackets and similar functional and / or safety add-on parts.

[0031] The arrangement according to the invention can also comprise two attachment parts, such that one attachment part is detachably coupled to the upper wall and one attachment part is detachably coupled to the lower wall.

[0032] A deformation profile arrangement is, in particular, a bumper arrangement for a motor vehicle. The bumper arrangement has a cross member which is supported on the motor vehicle, in particular directly or indirectly on longitudinal members of the motor vehicle, by means of two deformation profiles according to the invention. The cross member is connected to the vehicle via the deformation profiles, wherein the deformation profiles are designed as a multi-chamber profile and have at least one inner wall. The inner wall extends parallel to the upper and lower walls between the two side walls. In a longitudinal section, the inner wall has an upwardly or downwardly directed deformation in the form of a hump.

[0033] Further advantages, features, properties, and aspects of the present invention are the subject of the following description. Preferred embodiments are illustrated in schematic figures. These serve to facilitate understanding of the invention. They show: Figure 1a a perspective of a deformation profile known from the prior art, Figure 1b a deformation profile known from the prior art in cross-section according to section II of the Figure 1a Figure 2a shows a perspective of a deformation profile according to the invention, Figure 2 shows a deformation profile according to the invention in cross-section according to section II-II of the Figure 2a Figure 2 shows a deformation profile according to the invention in cross-section as shown in section III-III of the Figure 2a Figure 3a shows a deformation profile according to the invention in cross-section, wherein Figures 3b and 3cFigure 1 does not show a deformation profile according to the invention, and Figure 4 shows a deformation profile arrangement according to the invention comprising a deformation profile and an attachment part.

[0034] In the figures, the same reference symbols are used for identical or similar components, even if a repeated description is omitted for the sake of simplicity.

[0035] The Figure 1aFigure 1 shows a deformation profile 1 known from the prior art, which is a crash box designed as a two-chamber hollow profile. The deformation profile 1 has two opposing side walls 2, 3, which are connected by an upper wall 4 and a lower wall 5. The deformation profile 1 has a rectangular cross-section. The term "cross-section" always refers to the cross-section in the yz-plane. Both side walls 2, 3 have corrugations 6 extending over their entire height H. Due to the embossing of the corrugations 6, they have ridges 7 at their upper and lower ends that project beyond the upper wall 4 and the lower wall 5.

[0036] Figure 1b The deformation profile 1, known from the prior art, is shown in cross-section according to section II of the Figure 1a, thus the section through the opposing corrugations 6. Here it is clearly visible that the ridges 7 project beyond the upper wall 4 and the lower wall 5. Therefore, neither the upper wall 4 nor the lower wall 5 has a flat or even surface in the longitudinal section with the corrugations 6, which complicates the coupling of an attachment 8 (not shown in detail here). An upper corner region 9 is formed between the side walls 2, 3 and the upper wall 4, and a lower corner region 10 is formed between the side walls 2, 3 and the lower wall 5. The corner regions are convex and have a radius Ri.

[0037] Figure 2a Figure 1 shows the perspective of a deformation profile 1 according to the invention, which is also a crash box designed as a two-chamber hollow profile. In comparison to the deformation profile 1 according to the prior art, shown in Figure 1, the following applies: Figure 1aAccording to the invention, the upper corner regions 9 and the lower corner regions 10 have a chamfer 11 in cross-section. The bulges 7 formed by the embossing of the beads 6 cause the chamfer 11 to bulge outwards. However, the chamfers 11 ensure that the bulges 7 do not project beyond the upper wall 4 and / or the lower wall 5. Thus, the coupling with an additional attachment 8 is not hindered because the upper wall 4 or lower wall 5 remains flat. Furthermore, the chamfers 11 increase the width B1 of the upper wall 4 and / or the lower wall 5 compared to the width B2 of the upper wall 4 and / or the lower wall 5 of the deformation profile 1 according to the prior art. This results in a larger coupling surface for coupling with an additional attachment 8.

[0038] Figure 2b The deformation profile 1 according to the invention is shown in cross-section in section II-II of the Figure 2a The chamfers 11 have a chamfer angle α of 45°.

[0039] The chamfers 11 also have a cross-sectional length L between 12 mm and 25 mm.

[0040] Figure 2c shows a cross-section of the deformation profile 1 according to the invention as shown in section III-III of the Figure 2a . Here it can be clearly seen once again that the bulges 7 do not extend beyond the upper wall 4 or the lower wall 5.

[0041] The Figures 3a to 3c show alternative design variants of the deformation profile 1 in cross-section according to section II-II of the Figure 2a , where they represent the initial profile or a longitudinal section without corrugations in the side walls.

[0042] According to Figure 3aAccording to the invention, only the upper corner regions 9 are designed as chamfers 11. The lower corner regions 10 have a convex shape with a radius Ri. Due to the design of the upper corner regions 9 according to the invention, in this embodiment only the upper wall 4 is suitable for coupling with an additional attachment 8.

[0043] In Figure 3b The upper corner regions 9 and the lower corner regions 10 have a concave cross-sectional shape 12. This concave shape 12 also prevents the ridges 7 from projecting beyond the upper wall 4 or the lower wall 5. When the grooves 6 are formed into the side walls 2, 3, the corner region 9, 10 is pressed inwards or towards the center by the predefined concave shape. At the same time, the inner wall is locally deformed upwards or downwards, forming a hump. The concave shape 12 has a radius Rk between 12 mm and 25 mm.

[0044] In the alternative embodiment according to Figure 3cOnly the upper corner regions 9 have a concave shape 12. The lower corner regions 10 have a convex shape with a radius Ri. While the upper corner regions 9 with the concave shape 12 have a radius Rk of 20 mm, the lower convex corner regions 10 have a radius Ri of 10 mm. Thus, the radius Ri of the lower corner regions 10 not designed according to the invention is 50% smaller than the radius Rk of the upper corner regions 9 according to the invention. In the longitudinal section not shown, according to section III-III with corrugations, a flat connection surface is only found in the upper wall.

[0045] Figure 4Figure 1 shows a deformation profile arrangement 13 according to the invention, comprising a deformation profile 1 and an attachment 8. The attachment 8 is detachably coupled to the upper wall 4 of the deformation profile 1 by means of a coupling means 14. Since the ridges 7 do not project beyond the upper wall 4, the attachment 8 can be arranged as close as possible to the deformation profile 1 and thus in a space-saving manner.

[0046] In an alternative embodiment of the deformation profile arrangement 13, an additional attachment 8 can be detachably coupled to the lower wall 5.

[0047] The deformation profiles 1 according to the representations of the Figures 2 as well as 3b) and 3c) and Figure 4are designed as multi-chamber profiles. In the deformation profiles 1 shown, these are divided into two chambers by an inner wall 15. The inner wall 15 extends parallel to the upper wall 4 and the lower wall 5 between the two side walls 2, 3. A deformation profile 1 can also have more than one inner wall 15.

[0048] The inner wall 15 has a hump 16 in a longitudinal section with a groove 6, directed upwards towards the upper wall 4. It is also possible that a hump is formed downwards towards the lower wall 5.

[0049] In particular, the invention also relates to a deformation profile arrangement in the form of a bumper arrangement for a motor vehicle. The bumper arrangement comprises a cross member and two deformation profiles according to any one of claims 1 to 7, by which the cross member is connected to a vehicle, wherein the deformation profiles 1 are designed as a multi-chamber profile and have at least one inner wall 15 which runs parallel to the upper wall 4 and the lower wall 5, wherein the inner wall 15 has an upwardly or downwardly directed hump 16 in the longitudinal section with a groove 6.

[0050] The deformation profiles 1 are extruded. The side walls 2, 3, the top wall 4 and the bottom wall 5, as well as optional inner walls 15, are manufactured as a single-piece, uniformly material extruded profile.

[0051] The upper wall 4 and / or the lower wall 5 of a deformation profile 1 has a total external surface area, which comprises a planar surface extending parallel to the horizontal in a horizontal plane and the corner area surfaces inclined to the horizontal in the corner areas 9 and / or in the corner areas 10. The proportion of the planar surface to the total surface area is between 30% and 65%. Reference symbol:

[0052] 1 - Deformation profile 2 - Side wall 3 - Side wall 4 - Top wall 5 - Bottom wall 6 - Corrugations 7 - Beads 8 - Attachment 9 - Upper corner areas 10 - Lower corner areas 11 - Chamfer 12 - Concave shape 13 - Deformation profile arrangement 14 - Coupling agent 15 - Inner wall 16 - Hump H - Height Ri - Radius of the convex shape Rk - Radius of the concave shape α - Chamfer angle

Claims

1. Deformation profile (1) having two opposing side walls (2, 3), wherein the side walls (2, 3) are connected by an upper wall (4) and a lower wall (5) and both side walls (2, 3) have at least one bead (6) which extends over the entire height (H) of the respective side wall (2, 3), wherein between the side walls (2, 3) and the upper wall (4) an upper corner region (9) is formed in each case and between the side walls (2, 3) and the lower wall (5) a lower corner region (10) is formed in each case, wherein the deformation profile (1) is extruded, characterized in that the upper corner regions (9) and / or the lower corner regions (10) have a chamfer (11) in cross-section, wherein the chamfer (11) has a chamfer angle (α) between 25° and 65° and the chamfer (11) in cross-section has a length (L) between 12 and 25 mm.

2. Deformation profile (1) according to claim 1, characterized in that two beads (6) are formed opposite each other in the side walls (2, 3) and in the same longitudinal portion.

3. Deformation profile (1) according to claim 1 or 2, characterized in that the deformation profile (1) is a crash-box, in particular a multi-chamber crash-box, or a longitudinal beam.

4. Deformation profile (1) according to any one of claims 1 to 3, characterized in that the chamfer (11) has a chamfer angle (α) between 35° and 55°, preferably between 40° and 50°.

5. Deformation profile (1) according to any one of claims 1 to 4, characterized in that the upper wall (4) and / or the lower wall (5) has / have a total outer surface-area which comprises a planar face which extends in a horizontal plane in a plane-parallel manner with respect to the horizontal and in the corner regions (9) and / or in the corner regions (10) corner region faces which extend in an inclined manner with respect to the horizontal, wherein the proportion of the planar face over the total surface-area is from 30 % to 65 %.

6. Deformation profile arrangement (13) comprising a deformation profile (1) according to any one of claims 1 to 5 and an attachment component (8), characterized in that the attachment component (8) is releasably coupled to the upper wall (4) or the lower wall (5).

7. Bumper arrangement comprising a crossbeam and two deformation profiles according to any one of claims 1 to 5, through which the crossbeam is connected to a vehicle, wherein the deformation profiles (1) are in the form of multi-chamber profiles and have at least one inner wall (15) which extends parallel with the upper wall (4) and the lower wall (5), wherein the inner wall (15) in the longitudinal portion with a bead (6) has a boss (16) which is directed upwards or downwards.