Vehicle with front shock absorption system comprising side impact absorbers

Abstract

The invention relates to a vehicle with a front shock absorption system (1) comprising longitudinal side members (3), upper absorbers (5) arranged as an extension of said longitudinal side members (3), and an upper beam (7) transversely connecting the upper absorbers (5), the upper beam (7) having two ends and lateral extensions (15) at its ends, the front shock absorption system (1) further comprising an assembly (9) forming a bumper comprising a bumper skin (13) and at least one reinforcing element (11) comprising a side impact absorber (17) arranged facing one of said lateral extensions (15).

Description

Description Title of the invention: VEHICLE WITH FRONT SHOCK ABSORPTION SYSTEM INCLUDING LATERAL ABSORBERS

[0001] The present invention claims priority from French application 2306792 filed on June 28, 2023, the content of which (text, drawings and claims) is incorporated herein by reference.

[0002] Motor vehicles are equipped with a shock absorption system designed to manage frontal impacts between the vehicle and a pedestrian, particularly at the level of their legs. The objective is, firstly, to absorb the energy of the impact, and secondly, to limit injuries to the pedestrian and prevent them from being placed under the vehicle.

[0003] For this purpose, the shock absorption system generally comprises two parts, a so-called "lower track" part and a so-called "upper track" part, and the performance in terms of pedestrian impact at the leg level is ensured by a compromise of stiffness between the upper track and the lower track.

[0004] The lower barrier is positioned at the central deflector of the vehicle's front bumper and will "whip" the pedestrian's lower leg to prevent them from being pulled under the vehicle. The upper barrier, on the other hand, is positioned at the front bumper beam and dissipates the impact energy to limit pedestrian injuries. The goal is to flatten the leg as much as possible to minimize knee shear. To this end, the upper barrier includes an energy-absorbing device called a "leg absorber," located between the bumper beam and the vehicle's bumper skin. When the leg absorber is compressed during a collision, the upper barrier is positioned further back than the lower barrier relative to the vehicle, thus flattening the pedestrian's leg towards the vehicle's hood.

[0005] Such a device, for example in the form of a polypropylene foam absorber, is described in document EP3300963B1. This device has proven satisfactory and effective in frontal impacts of the pedestrian and repairability type.

[0006] However, when the pedestrian impact is located at the outer edge of the bumper, it has been found that this type of absorber generates rotational movements of the leg, degrading the vehicle's performance in terms of pedestrian protection.

[0007] A solution to this problem remains to be found. Document CN101084140B concerns a vehicle bumper system comprising a beam and a thermoformed energy absorber positioned on one face of the beam. The thermoformed energy absorber has a plurality of elongated crush boxes thermoformed from a base flange. Consequently, the central area has a less aggressive impact, intended to reduce pedestrian injuries upon impact. This configuration is promising but insufficient for pedestrian collisions at the outer edge of the bumper.

[0008] The invention aims to address at least one of the problems and drawbacks encountered in the prior art. In particular, a solution remains to be found to improve a vehicle's performance in protecting pedestrians during an impact with the outer edge of the bumper.

[0009] To this end, and according to a first aspect, the invention relates to a vehicle with a front shock absorption system comprising longitudinal beams, upper absorbers arranged as extensions of said longitudinal beams and an upper beam connecting the upper absorbers transversely, the upper beam having two ends and lateral extensions at its ends, the front shock absorption system further comprising an assembly forming a bumper comprising a bumper skin and at least one reinforcement element; the vehicle being notable in that and in that at least one reinforcement element comprises a lateral absorber arranged opposite one of said lateral extensions.

[0010] As can be understood from the definition just given, the invention is remarkable in that it places deformable absorbers on the outer edge of the bumper, attaching these absorbers (called side absorbers) to the bumper assembly itself, rather than to the upper bumper beam. The side absorbers are not in contact with the bumper beam but rather positioned opposite it. Their placement on the bumper assembly, and preferably on a bumper skin reinforcement, provides stability, preventing it from sliding on, over, or under the upper beam during an impact, and thus avoiding suboptimal behavior in a collision.

[0011] In one embodiment, the bumper assembly comprises a bumper skin and at least one reinforcing element. The vehicle is notable in that at least one side impact absorber is made of a material with at least one reinforcing element. Thus, not only is the risk of the side impact absorber detaching during a collision reduced, but its positioning is also maintained during the collision. The side impact absorbers are positioned below the vehicle's headlights and are therefore not at risk of sliding on the upper beam during the impact, which would prevent suboptimal behavior. Preferably, the reinforcing element and the side impact absorber are made of a plastic or composite material containing at least 30% recycled plastic resin. The addition of recycled material reduces the vehicle's environmental footprint.

[0012] In a preferred embodiment, the side extensions extend from the ends of the upper beam toward the rear of the vehicle at an angle of between 5 and 30° to the vehicle's transverse direction. These side extensions are designed to absorb the transverse components of small overlap impacts, as defined by U.S. standards. Their rearward orientation at a specific angle allows them to be adapted to the vehicle's styling.

[0013] Preferably, each or at least one of the side absorbers has a rear face designed, in the event of an impact, to bear against the lateral extension opposite which it is positioned; said rear face is configured to present an angle similar to or equal to that of the said lateral extension. This arrangement will create optimal absorption conditions and also guarantee energy dissipation during an impact. The rear surface of the lateral absorber will conform to the surface of the lateral extension, so that the absorber comes into contact with the lateral extension over its entire contact surface.

[0014] In one embodiment, each or at least one of the lateral absorbers is in the form of a hollow box. This allows the reinforcement and the lateral absorber to be molded in a single piece; the lateral absorber then takes the form of a hollow box open on one of its faces.

[0015] Preferably, each or at least one of the lateral absorbers has a structure exhibiting folds or grooves configured to generate progressive deformation kinetics. The lateral absorber(s) may have a design similar to the upper or lower absorbers.

[0016] In one embodiment, the lateral extensions are elements attached to the upper beam. This configuration facilitates the production of the upper beams.

[0017] According to one embodiment, the lateral extensions have a length between 40 and 80 mm; preferably between 50 and 70 mm.

[0018] In one embodiment, the upper beam further comprises a lower extension arranged centrally along the length of the upper beam. Preferably, the lower extension is in the form of a mounting plate, and a central absorber is fixed to said plate. Indeed, it has been found that the desired pedestrian impact performance can be achieved by adding a central absorber positioned on a lower extension of the upper beam.

[0019] According to a preferred embodiment, each or at least one of the side absorbers has a rear face positioned opposite one of the lateral extensions of the upper beam, and this rear face is spaced away from said lateral extension; preferably, spaced 8 to 25 mm apart. This configuration minimizes the risk of unwanted vibration noise while the vehicle is in motion and also ensures that the absorber and the lateral extension are only stressed in the event of an impact of a certain force.

[0020] According to a second aspect, the invention relates to a bumper skin reinforcement element for a vehicle according to the first aspect, remarkable in that it comprises at least one lateral absorber intended to be positioned opposite a lateral extension of an upper vehicle beam; preferably, the reinforcement element has a body and the lateral absorber(s) are made of the same material as said body.

[0021] According to a third aspect, the invention relates to an assembly forming a bumper comprising a bumper skin and at least one reinforcing element, notable in that the reinforcing element is according to the second aspect.

[0022] According to a fourth aspect, the invention relates to a method for manufacturing a bumper skin reinforcement element for a vehicle. According to the first aspect, the reinforcement element having a body, the method is remarkable in that it includes a step of attaching at least one lateral absorber to the body of the reinforcement element or molding of at least one lateral absorber with said body so that the body and the lateral absorber(s) are made of material with said body

[0023] According to a fourth aspect, the invention relates to a method for manufacturing a bumper skin reinforcement element. According to the second aspect, the reinforcement element having a body, the method is remarkable in that it comprises a step of attaching at least one lateral absorber to the body of the reinforcement element or of molding at least one lateral absorber with said body so that the body and the lateral absorber(s) are formed from a single piece of material with said body.

[0024] The invention will be well understood and other aspects and advantages will become clear upon reading the following description, given with reference to the attached figures listed below.

[0025] Figure 1 is a side view of a front shock absorption system according to the invention.

[0026] Figure 2 is an isometric view of an upper beam of a front shock absorption system with lateral extensions.

[0027] In the following description, the term "include" is synonymous with "include" and is not restrictive in that it permits the presence of other elements in the bumper skin reinforcement, the bumper assembly, the vehicle, or other stages in the process to which it relates. It is understood that the term "include" includes the terms "consist of." The terms "external" and "internal" will refer to what is oriented toward the outside of the vehicle and toward the inside of the vehicle, respectively.

[0028] In this description, the terms "longitudinal," "longitudinally," "transverse," and "transversely" are used in relation to the vehicle's frame of reference in the mounting configuration, unless otherwise specified. "Longitudinal" refers to the vehicle's principal direction of travel. "Transverse" refers to a direction perpendicular to the vehicle's principal direction of travel. "Front" refers to the vehicle's principal direction of travel. "Rear" refers to the opposite of the front of the vehicle. "Low" and "lower" indicate a closer proximity to the ground than "high" and "upper," respectively.

[0029] Reciting numeral ranges by endpoints includes all whole numbers and, where applicable, fractions within that range (for example, 1 to 5 includes 1, 2, 3, 4, and 5 when referring to, say, a number of items, and may also include 1.5, 2, 2.75, and 3.80 when referring to, say, measurements). Reciting endpoints also includes the endpoint values ​​themselves (for example, 1.0 to 5.0 includes both 1.0 and 5.0). Any numeral range cited here is intended to include all subranges subsumed within it.

[0030] The reference throughout this description to "an embodiment" means that a particular feature, structure, or characteristic described in relation to the embodiment is included in at least one embodiment of this disclosure. Particular features, structures, or embodiments may be combined in any appropriate manner, as will be apparent to a person skilled in the art from this description, in one or more embodiments. Furthermore, while some embodiments described here include some features but not others included in other embodiments; combinations of features from different embodiments are assumed to be within the scope of disclosure and to form different embodiments, as understood by a person skilled in the art.

[0031] Unless otherwise defined, all terms used in this disclosure, including technical and scientific terms, have the meanings commonly understood by a person skilled in the art to whom this disclosure pertains. By way of additional guidance, definitions of the terms used in the description are included to enhance understanding of the implications of this disclosure.

[0032] Throughout the description, the different figures use the same reference signs to designate identical or similar entities.

[0033] Reference will be made to Figure 1, which illustrates an example of an embodiment of a vehicle according to the invention. The vehicle, with a front shock absorption system 1 according to the invention, comprises longitudinal beams 3, upper absorbers 5 arranged as extensions of said longitudinal beams 3, and an upper beam 7 transversely connecting the upper absorbers 5. The front shock absorption system 1 further comprises an assembly 9 forming a bumper, including at least one reinforcement 11 and a bumper skin 13. As also visible in Figure 2, the upper beam 7 has lateral extensions 15 configured to extend said upper beam 7 transversely outwards from the vehicle beyond the upper absorbers 5. The lateral extensions are fixed to the ends of the upper beam 7.

[0034] The invention is remarkable in that the bumper assembly 9 comprises lateral absorbers 17 arranged to be positioned opposite the lateral extensions 15. The lateral absorbers 17 are therefore supported by the bumper assembly 9 and not by the upper beam 7, but they cooperate with it to absorb an impact. During the collision kinematics, a lateral absorber 17 will initially move forward until it rests against the lateral extension 15 of the upper beam 7, and then it will deform to absorb the impact.

[0035] To this end, the lateral absorbers 17 are dimensioned so that their rear face, or bearing face, is separated from the lateral extension 15, defining an air gap. Thus, according to a preferred embodiment of the invention, each or at least one of the lateral absorbers 17 has a rear face positioned opposite one of the lateral extensions 15 of the upper beam 7 in such a way that said rear face is spaced from said lateral extension 15 by a distance of between 8 and 25 mm; preferably between 10 and 20 mm.

[0036] It will be understood that, according to the invention, the lateral absorbers 17 are arranged opposite the lateral extensions 15 and are therefore not aligned with the upper absorbers 5. They are in fact offset along the transverse direction, the upper absorbers 5 having a more internal position than the lateral absorbers 17.

[0037] As is known, a set 9 forming a bumper is one of the body parts of a vehicle, such as a motor vehicle, that are visible to the user. Many body parts of a vehicle are now made of plastic. This reduces the vehicle's overall weight and therefore its greenhouse gas emissions, such as carbon dioxide, and / or improves the vehicle's range for electric vehicles. For example, the bumper assembly (9) generally includes a bumper skin (13), which is often made up of several components. These components include the side skirts (or bumper cheeks), the lower valance, the deflector, the air vent(s) (when present), the license plate bracket, and various wheel trims. The bumper skin (13) often exhibits a degree of flexibility, which means it is often reinforced with one or more bumper skin reinforcement elements (11), all supported by a bumper frame.Thus, in the invention, the assembly 9 forming a bumper comprises a bumper skin 13 and at least one bumper skin reinforcement element 11, hereinafter referred to as reinforcement element 11.

[0038] In order to preserve the external appearance of the bumper skin from an aesthetic point of view, a person skilled in the art would benefit from the side absorbers 17 being fixed or carried by reinforcement elements 11 rather than on or by the bumper skin 13.

[0039] Thus, according to an embodiment not shown, at least one lateral absorber 17 is attached to a reinforcing element. This attachment can be made by any means, such as gluing, clipping, or screwing.

[0040] However, a person skilled in the art would benefit from at least one lateral absorber 17 being formed from the same material as the reinforcing element 11 to which it is attached. In other words, it is advantageous for a lateral absorber 17 to be molded as a single piece with a reinforcing element 11. This not only reduces the risk of the lateral absorber 17 detaching during a shock, but also makes the assembly more robust and more economical in terms of production and assembly costs. Therefore, preferably, the reinforcing element 11 has a body, and the lateral absorber(s) 17 are formed from the same material as this body.

[0041] According to a preferred embodiment, at least one bumper skin reinforcement 11 and / or at least one side absorber 17 is made of a plastic or composite material.

[0042] According to a preferred embodiment, the plastic material is selected from the group comprising polypropylene, polyamide, polyphthalamide, polyetheretherketone, polyphenylene sulfide, polyamide-imide, polyetherimide, polyarylamide, polyepoxide, unsaturated polyester, vinyl ester, or polyester-vinyl ester resins. For example, the composite material comprises a matrix of a plastic material as described above with reinforcement. For example, the reinforcement comprises glass fibers, carbon fibers, plant-based fibers, talc, or a mixture of the aforementioned elements.

[0043] According to one embodiment, at least one bumper skin reinforcement 11 and / or at least one side absorber 17 is made of a plastic or composite material with a plastic material matrix and reinforcement, and at least one bumper skin reinforcement 11 and / or at least one side absorber 17 comprises at least 10% by weight of recycled plastic resin based on the total weight of the plastic material; preferably at least 20% by weight, and more preferably at 30% by weight, and even more preferably at 40% lighter by weight. The use of recycled plastic material reduces the vehicle's ecological footprint.

[0044] According to one embodiment, at least one bumper skin reinforcement 11 and / or at least one side absorber 17 is made of a plastic or composite material with a plastic material matrix and reinforcement, and at least one bumper skin reinforcement 11 and / or at least one side absorber 17 comprises 10 to 80% by weight of recycled plastic resin based on the total weight of the plastic material; more preferably 20 to 60% by weight or 30 to 50% by weight.

[0045] It will be understood that the lateral absorbers 17 are designed to dampen an impact and therefore have a shape adapted to their function. Thus, according to an embodiment not shown, the lateral absorbers 17 may be in the form of a leaf spring, particularly when attached to a reinforcing element. If they are made of material with a reinforcing element, but not exclusively, the lateral absorbers 17 will advantageously be in the form of hollow boxes capable of being compressed to dampen an impact. Preferably, each or at least one of the lateral absorbers 17 has a structure exhibiting folds or grooves configured to generate progressive deformation kinetics. Optionally, the lateral absorber(s) 17 have a general shape of a right prism with a triangular base.

[0046] According to the invention, the upper beam 7 has lateral extensions 15 configured to extend said upper beam 7 transversely outwards from the vehicle beyond the upper shock absorbers 5. The lateral extensions 15 are preferably metal parts, for example made of steel, which are either machined from or added to the upper bumper beam 7; preferably added. The lateral extensions 15 are advantageously formed from a piece of sheet steel. For example, from a piece of sheet steel with a thickness between 1.0 and 2.5 mm; preferably between 1.2 and 2.0 mm. The lateral extensions 15 are preferably fixed to the front face of the upper bumper beam 7. The lateral extensions 15 can be fixed to the upper bumper beam 7 by any means, and preferably by welding.

[0047] The lateral extensions 15 are in the form of an elongated body so as to have a length between 40 and 80 mm; preferably between 50 and 70 mm.

[0048] The lateral extensions 15 are in the form of an elongated body with a first part fixed to one end of the upper beam 7, and a second part projecting from the end in a longitudinal direction of the upper beam 7. In the case of a curved beam, this refers to the average longitudinal direction. The lateral extension 15 may also include stiffening elements such as ribs, corrugations, etc., particularly on its second part. The first part includes means for attaching the lateral extension 15 to the upper beam 7, for example, one or more tabs for welding the lateral extension 15 to the beam. It is also possible that the lateral extension 15 includes a tab for attachment to the upper face of the upper beam 7.

[0049] The second part extends from the first part and preferably forms an angle with it. The angle of the second part is generally chosen to increase the curvature at the end of the upper beam and to meet stylistic requirements. Thus advantageously, the lateral extensions 15 extend from the ends of the upper beam 7 towards the rear of the vehicle in a direction forming an angle between 5 and 30° with the transverse direction of the vehicle; preferably from 10 to 20°.

[0050] A person skilled in the art will benefit from each or at least one of the side absorbers 17 having a rear face designed, in the event of an impact, to rest on the side extension 15 opposite which it is positioned, said rear face being configured to have an angle similar or equal to that of said side extension.

[0051] Preferably, the bearing surface of the side absorbers 17 has an inclination forming an angle between 5 and 30° with the transverse direction of the vehicle; preferably from 10 to 20°. Optionally, the bearing surface of the side absorbers 17 has a curve or shape complementary to the curve or shape of the surface of the lateral extension 15 with which it will come into contact during a collision kinematic.

[0052] According to a preferred embodiment of the invention, the upper beam 7 further has a lower extension 19 arranged centrally along the length of the beam. This extension is intended to support a central absorber 23. Thus, the lower extension advantageously takes the form of a mounting plate 21, and a central absorber 23 is fixed to said mounting plate 21.

[0053] The Centra 23 absorber is preferably a foam absorber, for example, made of a foam chosen from polyether, polyester, polypropylene, polyethylene, or polyurethane foam, preferably polyethylene foam. For example, the foam could be expanded polyethylene foam of the NEOPOLEN® type.

[0054] According to an embodiment of the invention shown in Figure 1, the vehicle comprises a shock absorption system including an upper track and a lower track. The upper track includes the upper beam 7. The lower track of the vehicle includes side members 27, lower absorbers 29 arranged as extensions of said side members 27, and a lower beam 33 transversely connecting the lower absorbers 29. According to a preferred embodiment shown in Figure 1, the lower beam 33 has lower lateral extensions 31 configured to extend said lower beam 33 transversely outwards from the vehicle beyond the lower absorbers 29. The lower lateral extensions 31 are fixed to the ends of the lower beam 33.The lower beam 33 is positioned further forward than the upper beam 7. This way, in the event of a collision with a pedestrian's leg, the leg will be more easily forced towards the vehicle's hood. Indeed, the lower track is positioned at the level of the central deflector of the vehicle's front bumper and will "whip" the lower part of the pedestrian's leg to prevent them from being pulled under the vehicle.

[0055] The invention also relates to a method for manufacturing a bumper skin reinforcement element 11 for a vehicle as described above, the reinforcement element having a body. The method is notable in that it includes a step of attaching at least one side absorber 17 to the body of the reinforcement element 11 or of molding it. less a lateral absorber 17 with said body so that the body and the lateral absorber(s) 17 are made of material with said body.

[0056] Finally, the invention relates to a method of manufacturing a vehicle and / or an assembly 9 forming a bumper, remarkable in that it includes a step of manufacturing a reinforcement element, the reinforcement element having a body, the method is remarkable in that it includes a step of fixing at least one side absorber 17 on the body of the reinforcement element 11 or of molding at least one side absorber 17 with said body so that the body and the side absorber(s) 17 are made of material with said body and a step of assembling or mounting said reinforcement element 11 on said vehicle or in said assembly 9 forming a bumper.

Claims

Claims

1. Vehicle with front shock absorption system (1) comprising longitudinal stretchers (3), upper absorbers (5) arranged as an extension of said longitudinal stretchers (3) and an upper beam (7) transversely connecting the upper absorbers (5), the upper beam (7) having two ends and lateral extensions (15) at its ends, the front shock absorption system (1) further comprising an assembly (9) forming a bumper comprising a bumper skin (13) and at least one reinforcing element (11); the vehicle being characterized in that and in that at least one reinforcing element (11) comprises a lateral absorber (17) arranged opposite one of said lateral extensions (15).

2. Vehicle according to claim 1, the vehicle being characterized in that at least one lateral absorber (17) is integral with at least one reinforcing element (11); preferably, the reinforcing element (11) and the lateral absorber (17) are made of a plastic or composite material comprising at least 30% recycled plastic resin.

3. Vehicle according to one of claims 1 or 2, characterized in that the lateral extensions (15) extend from the ends of the upper beam (7) towards the rear of the vehicle in a direction forming an angle of between 5 and 30° with the transverse direction of the vehicle; preferably, each or at least one of the lateral absorbers (17) has a rear face intended, during an impact, to rest on the lateral extension (15) opposite which it is arranged, said rear face is configured to have an angle similar to or equal to that of said lateral extension (15).

4. Vehicle according to one of claims 1 to 3, characterized in that each or at least one of the lateral absorbers (17) is in the form of a hollow box; preferably, each or at least one of the lateral absorbers (17) has a structure showing folds or grooves configured to generate progressive deformation kinetics.

5. Vehicle according to one of claims 1 to 4, characterized in that the lateral extensions (15) are elements attached to the upper beam (7) and / or the lateral extensions (15) have a length of between 40 and 80 mm; preferably between 50 and 70 mm.

6. Vehicle according to one of claims 1 to 5, characterized in that the upper beam (7) further has a lower extension (19) arranged centrally along the length of the upper beam (7); preferably, the lower extension (19) is in the form of a fixing plate (21) and in that a central absorber (23) is fixed to said fixing plate (21).

7. Vehicle according to one of claims 1 to 6, characterized in that each or at least one of the lateral absorbers (17) has a rear face placed opposite of one of the lateral extensions (15) of the upper beam (7) and in that said rear face is arranged spaced from said lateral extension (15); preferably, spaced by 8 to 25 mm.

8. Reinforcing element (11) for a vehicle bumper skin according to one of claims 1 to 7, characterized in that it comprises at least one lateral absorber (17) intended to be positioned opposite a lateral extension of an upper beam of the vehicle; preferably, the reinforcing element (11) has a body and the lateral absorber(s) (17) are integral with said body.

9. Assembly (9) forming a bumper comprising a bumper skin (13) and at least one reinforcing element (11), characterized in that the reinforcing element (11) is according to claim 8.

10. Method for manufacturing a reinforcement element (11) for a vehicle bumper skin according to one of claims 1 to 7, the reinforcement element having a body, the method is characterized in that it comprises a step of fixing at least one lateral absorber (17) to the body of the reinforcement element (11) or of molding at least one lateral absorber (17) with said body so that the body and the lateral absorber(s) (17) are integral with said body.

Images