The present application claims priority from Japanese Patent Application No. 2022-160600 filed on Oct. 4, 2022, the entire contents of which are hereby incorporated by reference.
The disclosure relates to a vehicle body front structure.
Generally, an effective countermeasure for frontal collisions of a vehicle is in not deforming a cabin, namely an occupant space, with the intent to reduce damages of occupants, and various expedients are proposed from that point of view. As one of those expedients, a structure for absorbing collision energy by structural members positioned in front of the cabin has been widely used in recent years.
On the other hand, when a vehicle is, for example, a hybrid electric vehicle (HEV) or an electric vehicle (EV), a battery pack serving as a power source of the vehicle is mounted on a floor surface under the cabin in some cases.
Electric power for driving the vehicle is accumulated in the battery pack. Therefore, if deformation or disconnection generates in the battery pack upon, for example, the frontal collisions of the vehicle, there is a risk that an abrupt abnormal reaction may occur.
Under the above-described situation, when the vehicle is, for example, the HEV or the EV, significance of a structure not deforming the cabin has increased from the viewpoint of not damaging the battery pack.
Furthermore, regarding the frontal collisions of the vehicle, consideration is to be paid to various modes of collisions, such as a full-wrap collision in which the vehicle collides at its entire front side with a collision object, an offset collision in which the vehicle collides at its one front side with a collision object, and a small overlap collision in which an offset rate is about 25%.
Thus, there is a demand for a structure capable of absorbing the collision energy by structural members positioned in front of the cabin or the battery pack and capable of not deforming the cabin and the battery pack in any of those collision modes.
To meet the above-mentioned demand, a structure is proposed (see, for example, Japanese Unexamined Patent Application Publication (JP-A) No. 2017-047780) which comprises a bumper reinforcement (bumper beam) extending in a vehicle width direction on a front side in a vehicle, a pair of left and right side rails (front side frames) extending in a front-rear direction of the vehicle on an outer side in the vehicle width direction, and braces (reinforcements) each joined to the bumper beam at a position on an outer side in the vehicle than the front side frame. When the collision energy generates in the event of the small overlap collision, the reinforcement is brought into engagement with a load bearing portion disposed in the front side frame and transmits a load to the front side frame on an opposite side in the vehicle width direction through a cross-member.
An aspect of the disclosure provides a vehicle body front structure. The vehicle body front structure includes front side frames front side frames in a pair, a cross-member, a bumper beam, reinforcements, and fixing brackets. The front side frames extend in a front-rear direction of a vehicle on both sides of a front of the vehicle in a vehicle width direction. The cross-member extends in the vehicle width direction on a front side of the vehicle and is joined to the front side frames. The bumper beam is joined to respective vehicle front-side ends of the front side frames, extends in the vehicle width direction, and includes both end portions serving as bent portions toward a rear side of the vehicle. The reinforcements have a triangular shape and each include a bottom portion joined to the bumper beam and a tip portion protruding toward an inner rear side of the vehicle. The fixing brackets fixe the reinforcements to the front side frames respectively. The tip portion of each of the reinforcements has a D-shape including a rounded shape that extends in an up-down direction of the vehicle. An axial direction of each of the reinforcements fixed to a corresponding one of the front side frames intersects an outer surface of the corresponding one of the front side frames in the vehicle width direction at a position on a side closer to the front of the vehicle than a joined portion between the corresponding one of the front side frames and the cross-member.
The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate an embodiment and, together with the specification, serve to describe the principles of the disclosure.
According to the technique disclosed in JP-A No. 2017-047780, the reinforcement transmits the collision energy generated in the event of the small overlap collision to the front side frame and the cross-member with the reinforcement pushing the load bearing portion disposed in the front side frame, and a transmission direction of the collision energy is limited to a rear or lateral rear side. This leads to a possibility that the collision energy is not efficiently distributed and transmitted.
It is desirable to provide a vehicle body front structure capable of suppressing deformations of a cabin and a battery pack in any of multiple frontal collision modes.
A vehicle V to which a vehicle body front structure S according to an embodiment is applied will be described below with reference to
The vehicle body front structure S included in the vehicle V, according to the embodiment, is described with reference to
The vehicle V is, for example, an EV using a power unit 20 as a drive source. In another example, the vehicle V may be a HEV using multiple drive sources, such as an engine and the power unit 20.
As illustrated in
The power unit 20 is a drive device constituted by a motor, a transmission, a clutch, a drive shaft, and so on (not illustrated) for driving the front wheels 10. The power unit 20 is installed in a space surrounded by front side frames 100 and cross-members 110A and 110B (described later) and is fixed in a state mounted on an upper surface side of the front side frames 100.
The battery pack 30 is formed in the shape of a flat box, for example. Many battery cells are coupled in series inside the battery pack 30 to be capable of outputting a high voltage supplied to the power unit 20 and accumulating electric power enough for driving the vehicle V to run. The battery pack 30 is installed in a space surrounded by robust frames (described later), such as the torque box 50 and the side sills 60. The battery pack 30 is utilized in vehicles, such as the EV and the HEV.
The toe board 40 is a partition wall that is disposed to rise in the up-down direction of the vehicle on a vehicle front side of a cabin CA and to partition a front wheel drive and the cabin CA of the vehicle V. The toe board 40 is joined to an upper rear side of each of the front side frames 100 (described later) by welding, for example.
The torque box 50 is interposed between the front side frames 100 and the side sills 60 (described later) and couples the front side frames 100 and the side sills 60. The torque box 50 serves as a skeleton extending on a bottom surface of the vehicle V in the vehicle width direction and is joined to one end of each of the front side frames 100 on left and right sides relative to the torque box 50 by welding, for example. The torque box 50 is made of, for example, a metal with high rigidity and has a substantially rectangular enclosed shape in cross-section. The torque box 50 is positioned in front of the battery pack 30, and end portions of the torque box 50 are joined to respective one ends of the side sills 60 on the left and right sides relative to the torque box 50 by welding, for example.
Furthermore, the respective one ends of the front side frames 100 (described later) on the left and right sides relative to the torque box 50 are joined to a front surface side and an upper surface side of the torque box 50 by welding, for example.
An area behind the torque box 50 is a protection area PA. Deformations of the cabin CA positioned above the protection area PA and the battery pack 30 positioned under the protection area PA are suppressed in the protection area PA.
The side sills 60 are disposed on a lateral bottom surface of the vehicle on both sides in the vehicle width direction. Each of the side sills 60 serves as skeleton extending in the front-rear direction, is made of, for example, a metal with high rigidity, and has a substantially rectangular enclosed shape in cross-section. The side sills 60 constitute bottoms of the protection area PA on both sides thereof.
The vehicle body front structure S is constituted inside a vehicle front compartment FA forward of the torque box 50. Details of the vehicle body front structure S are described below.
The vehicle body front structure S according to the embodiment is described with reference to
The vehicle body front structure S is constituted to be bilaterally symmetric in the vehicle width direction.
As illustrated in
The front side frames 100 are disposed in pair on both the sides in the vehicle width direction, are each positioned on a lateral surface side of the power unit 20 to drive the front wheels 10 of the vehicle V, and extend in the front-rear direction of the vehicle. Each of the front side frames 100 constitutes a skeleton of the vehicle V, is made of, for example, a metal with high rigidity, and has a substantially rectangular enclosed shape in cross-section. Vehicle front-side ends of the front side frames 100 are joined to the bumper beam 120 by welding, for example, and vehicle rear-side ends of the front side frames 100 are joined to the torque box 50 by welding, for example.
As illustrated in
As illustrated in
The bumper beam 120 extends in the vehicle width direction in a front end portion of the vehicle and constitutes a skeleton in the front end portion of the vehicle. The bumper beam 120 is made of, for example, a metal and has a substantially rectangular enclosed shape in cross-section. The bumper beam 120 is joined to vehicle front-side ends of the front side frames 100 on both the sides in the vehicle width direction by welding, for example, and portions of the bumper beam 120 on an outer side than its joined portions to the front side frames 100 in the vehicle width direction are bent toward the rear side in the vehicle. Moreover, a central portion of the bumper beam 120 in the vehicle width direction is curved such that the central portion has a convex shape curved toward the front of the vehicle in a plan view.
In the vehicle body front structure S, robust well-shaped skeletons are formed by a combination of the front side frames 100 on both the sides in the vehicle width direction, the cross-members 110A and 110B disposed respectively in front and rear of the power unit 20, the bumper beam 120, the torque box 50, and the side sills 60.
As illustrated in
A fixing bracket 200a (fixing bracket 200aA or 200aB) for fixing the reinforcement 200 to the front side frame 100 is fixedly disposed on a vehicle rear-side inner surface of the reinforcement 200 by welding, for example. The fixing bracket 200a is formed of, for example, a steel sheet and has the shape of a substantially rectangular flat plate. The fixing bracket 200a is folded back at the tip portion 200b of the reinforcement 200 toward the front side in the vehicle. An elongate hole HL with a lengthwise direction being the front-rear direction of the vehicle is formed in the fixing bracket 200a to penetrate therethrough in a thickness direction. The reinforcement 200 is fixed to the front side frame 100 by inserting, for example, a bolt into the elongate hole HL of the fixing bracket 200a and fastening the bolt, thus fixing the reinforcement 200 to the front side frame 100. A gap is formed between the tip portion 200b and the front side frame 100. In addition, an axial direction SS (axial direction SSA or SSB) of the reinforcement 200 fixed to the front side frame 100, the axial direction SS being oriented toward the inner rear side of the vehicle, intersects the outer surface of the front side frame 100 in the vehicle width direction at a position on a side closer to the front of the vehicle than the reinforcing member HC.
With the above-described vehicle body front structure S according to the embodiment, when frontal collisions of the vehicle V with a collision object occur, collision energy is absorbed in the vehicle body front structure S, and deformations of the cabin CA and the battery pack 30 disposed in the protection area PA are suppressed.
In the event of the full-wrap collision, impact absorbing structures on both sides in the vehicle width direction work. In the events of the offset collision and the small overlap collision, the impact absorbing structure on a side where the collision has occurred works mainly. The action working in the event of the full-wrap collision will be described below with reference to
When the frontal collision of the vehicle V with a collision object FB occurs, the collision energy generates in a direction denoted by an arrow A. In the event of the full-wrap collision, as illustrated in
As illustrated in
With the progress of the collapse of each front side frame 100, the collision energy in a direction denoted by an arrow C (arrow CL or CR) is transmitted to the reinforcement 200. At that time, due to the collision energy in the direction denoted by the arrow B and the collision energy in the direction denoted by the arrow C, the collision energy toward the rear side in the vehicle is transmitted to the fixing bracket 200a of the reinforcement 200. Accordingly, the reinforcement 200 and the fixing bracket 200a are pushed in a direction denoted by an arrow D (arrow DL or DR). Because the tip portion 200b of the reinforcement 200 has the D-shape, the tip portion 200b is smoothly pushed in the direction of the arrow D along the outer surface of the front side frame 100 in the vehicle width direction. Furthermore, the fixing bracket 200a is forced to slide toward the rear side in the vehicle and is ruptured at the elongate hole HL at which the fixing bracket 200a is fixed by the bolt, for example. Hence the fixing bracket 200a is detached from the front side frame 100, and the reinforcement 200 does not anymore take part in the absorption of the collision energy because of loss of a fixing shaft.
With a further increase of the collision energy, as illustrated in
As described above, the reinforcement 200 and the fixing bracket 200a do not anymore take part in the absorption of the collision energy because of the loss of the fixing shaft. Thus, the collision energy is transmitted to the robust well-shaped skeletons that are formed by joining the front side frame 100A and the front side frame 100B on both the sides in the vehicle width direction, the cross-member 110A and the cross-member 110B disposed respectively in front and rear of the power unit 20, the bumper beam 120, the torque box 50, and the side sills 60. Hence the collision energy is distributed to the well-shaped skeletons and is absorbed by the deformations of the well-shaped skeletons.
When input of the collision energy is ended and the transmission of the collision energy to the front side frames 100 is ended, the absorption of the collision energy due to the deformation of the vehicle body front structure S is ended.
The case of collision on the left side of the vehicle V when viewed from the front will be described with reference to
As illustrated in
To the reinforcement 200, the collision energy in the direction denoted by the arrow SC is transmitted from the bumper beam 120. The collision energy denoted by an arrow SD is transmitted to the tip portion 200b of the reinforcement 200. Because a direction denoted by the arrow SD is substantially the same as the axial direction SS of the reinforcement 200 oriented toward the inner rear side of the vehicle, the collision energy acting to deform the front side frame 100 is transmitted to the tip portion 200b of the reinforcement 200. Moreover, because the axial direction SS of the reinforcement 200 is oriented to a position closer to the front side in the vehicle than the reinforcing member HC, the tip portion 200b of the reinforcement 200 is brought into contact with the recess HS of the reinforcing member HC disposed within the front side frame 100 while deforming the front side frame 100. The reinforcement 200 is guided to move toward the rear side in the vehicle with the presence of the recess HS while the front side frame 100 is further collapsed.
With a further increase of the collision energy, as illustrated in
In addition, the collision energy denoted by an arrow SG and transmitted toward the rear side in the vehicle through the front side frame 100 is distributed to a direction toward the cross-member 110B as denoted by an arrow SI and a direction toward the torque box 50 as denoted by an arrow SH.
As described above, the collision energy transmitted through the reinforcement 200 is transmitted to the robust well-shaped skeletons that are formed by joining the front side frame 100A and the front side frame 100B on both the sides in the vehicle width direction, the cross-member 110A and the cross-member 110B disposed respectively in front and rear of the power unit 20, the bumper beam 120, the torque box 50, and the side sills 60. Thus, the collision energy is distributed to the well-shaped skeletons and is absorbed by the deformations of the well-shaped skeletons.
When input of the collision energy is ended and the transmission of the collision energy to the front side frame 100 is ended, the absorption of the collision energy by the deformation of the vehicle body front structure S is ended.
The vehicle body front structure S according to the disclosure includes a pair of the front side frames 100 (the front side frame 100A on one side in the vehicle width direction and the front side frame 100B on the other side) extending in the front-rear direction of the vehicle on both sides of a front portion of the vehicle V in the vehicle width direction, the cross-member 110A and the cross-member 110B extending in the vehicle width direction on the front side in the vehicle and joining the front side frame 100A and the front side frame 100B, and the bumper beam 120 joining the vehicle front-side end of the front side frame 100A and the vehicle front-side end of the front side frame 100B, extending in the vehicle width direction, and having both end portions formed as bent portions toward the rear side in the vehicle. The vehicle body front structure further includes the reinforcement 200 having the triangular shape and including the bottom portion BT joined to the bumper beam 120 and the tip portion 200b protruding toward the inner rear side of the vehicle, and the fixing bracket 200a fixing the reinforcement 200 to each of the front side frames 100. The tip portion 200b of the reinforcement 200 has the D-shape including the rounded shape that extends in the up-down direction of the vehicle, and the axial direction SS of the reinforcement 200 fixed to the front side frame 100 intersects the outer surface of the front side frame 100 in the vehicle width direction at the position on the side closer to the front of the vehicle than the joined portion CN between the front side frame 100 and the cross-member 110A.
In the event of the full-wrap collision, the collision energy toward the rear side in the vehicle is transmitted to the reinforcement 200. Because the tip portion 200b of the reinforcement 200 has the D-like tip shape, the tip portion 200b is smoothly pushed toward the rear side in the vehicle along the vehicle outer-side surface of the front side frame 100. Accordingly, the fixing bracket 200a is disengaged from the front side frame 100, and the tip portion 200b of the reinforcement 200 is guided, because of the loss of the fixing shaft, to the position at which the tip portion 200b does not take part in the absorption of the collision energy by the well-shaped skeletons. On the other hand, in the event of the small lap collision, the collision energy applied in the axial direction SS of the reinforcement 200 is transmitted to the reinforcement 200. The reinforcement 200 is forced to dig into the cross-member 110A and to be fixed there while deforming the front side frame 100.
Thus, in the event of the full-wrap collision, the vehicle body front structure S can move the reinforcement 200 to the position at which the reinforcement 200 does not take part in the absorption of the collision energy by the well-shaped skeletons. In the event of the small lap collision, the vehicle body front structure S can fix the reinforcement 200 to the cross-member 110A such that the collision energy can be distributed to the members optimum for the collision mode. Hence the vehicle body front structure S can distribute the collision energy to the members optimum for the collision mode and can absorb the collision energy inside the vehicle front compartment FA.
As a result, the deformations of the cabin CA and the battery pack 30 in the protection area PA can be suppressed.
Furthermore, in the vehicle body front structure S according to the embodiment, the front side frame 100 includes the reinforcing member HC disposed in the joined portion CN between the front side frame 100 and the cross-member 110A, the reinforcing member HC having the recess HS spanning from the front-side outer surface of the front side frame 100 in the vehicle width direction to the rear-side inner surface of the front side frame 100 in the vehicle width direction.
In the event of the small overlap collision, because the axial direction SS of the reinforcement 200 is oriented to the position closer to the front side in the vehicle than the reinforcing member HC, the tip portion 200b of the reinforcement 200 is brought into contact with the recess HS of the reinforcing member HC disposed within the front side frame 100. The reinforcing member HC guides the reinforcement 200 toward the cross-member 110A with the presence of the recess HS, thereby causing the reinforcement 200 to be fixed to the cross-member 110A.
Stated another way, since the reinforcing member HC guides the reinforcement 200 toward the cross-member 110A with the presence of the recess HS such that the reinforcement 200 is reliably fixed to the cross-member 110A, the vehicle body front structure S can distribute the collision energy to the front side frame 100B on the other side to the collision side. Hence the vehicle body front structure S can distribute the collision energy to the members optimum for the collision mode and can absorb the collision energy inside the vehicle front compartment FA.
As a result, the deformations of the cabin CA and the battery pack 30 in the protection area PA can be suppressed.
Thus, the embodiment of the disclosure can provide the vehicle body front structure capable of suppressing the deformations of the cabin and the battery pack in any of multiple frontal collision modes.
While the embodiment of the disclosure has been described in detail above with reference to the drawings, practical configurations are not limited to those described in the above embodiment, and other designs and so on not departing from the gist of the disclosure also fall within the scope of the disclosure.
Number | Date | Country | Kind |
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2022-160600 | Oct 2022 | JP | national |