阅读说明：本技术 电动车辆的前端面板组件 (Front panel assembly for electric vehicle ) 是由 G-J·舍勒肯斯 于 2019-01-28 设计创作，主要内容包括：本发明涉及一种用于电动车辆的前端面板组件,该组件包括：前部盖,该前部盖有侧边缘,前部盖延伸成弯曲形状,以使得第一角度(α)包围在前部盖的第一部分和第二部分之间；以及载体结构,该载体结构包括基部和从该基部伸出的周边壁,其中,该载体结构包括第一部分和第二部分,该第一部分和第二部分包围第二角度(β)；其中,竖直壁在前部盖的侧边缘的至少一部分处或附近与前部盖连接,从而在前部盖和载体结构之间形成空间和包围空间,前部盖的第一部分覆盖载体结构的第一部分,前部盖的第二部分覆盖载体结构的第二部分。本发明还涉及提供有这种前端面板组件的车辆。(The present invention relates to a front panel assembly for an electric vehicle, the assembly comprising: a front cover having side edges, the front cover extending into a curved shape such that a first angle (a) is enclosed between a first portion and a second portion of the front cover; and a carrier structure comprising a base and a peripheral wall extending from the base, wherein the carrier structure comprises a first portion and a second portion, the first portion and the second portion enclosing a second angle (β); wherein the vertical wall is connected with the front cover at or near at least a portion of a side edge of the front cover, thereby forming a space and an enclosed space between the front cover and the carrier structure, a first portion of the front cover covering a first portion of the carrier structure, a second portion of the front cover covering a second portion of the carrier structure. The invention also relates to a vehicle provided with such a front panel assembly.)

1. A front panel assembly (100) for an electric vehicle, the front panel assembly comprising:

a front cover (101) having side edges, the front cover extending into a curved shape such that a first angle a is enclosed between a first portion (101') and a second portion (101 ") of the front cover; and

a carrier structure (102) comprising a base (103) and a peripheral wall (104) extending from the base, wherein the carrier structure comprises a first portion (102') and a second portion (102 ") enclosing a second angle β;

wherein the vertical wall is connected with the front cover at or near at least a part of a side edge of the front cover, thereby forming and enclosing a space between the front cover and the carrier structure, a first part of the front cover covering a first part of the carrier structure, a second part of the front cover covering a second part of the carrier structure.

2. The front face plate assembly of claim 1, wherein: an energy absorbing member (114) is disposed on the second portion of the carrier structure for absorbing energy upon impact.

3. The front face plate assembly of claim 2, wherein: the energy-absorbing component includes one or more inverted U-shaped projections or ribs (126, 128) that extend from the base of the second portion of the carrier structure.

4. The front face plate assembly of claim 2 or 3, wherein: the energy absorbing component includes a foam structure (105) filling at least a portion of the space enclosed between the second portion of the carrier structure and the second portion of the front cover.

5. The front face plate assembly of any preceding claim, wherein: the front cover includes an opaque 3D shaped sheet.

6. The front face plate assembly of any preceding claim, wherein: the front cover includes at least one translucent portion (116, 120).

7. The front face plate assembly of claim 6, wherein: the translucent portion is disposed in the first portion of the front cover.

8. The front face plate assembly of any preceding claim, further comprising: a light module (124) enclosed within a space formed between the first portion of the front cover and the first portion of the carrier structure.

9. The front face plate assembly of any preceding claim, further comprising: a thermoplastic material.

10. The front face plate assembly of any preceding claim, further comprising: for accommodating electronic components (107) integrated with the front panel assembly and/or a receiving portion (106) of the lamp module.

11. The front face plate assembly of claim 10, wherein: the receiving portion is arranged in a first portion (100') of the front panel assembly and is at least partially surrounded by a first portion of the carrier structure.

12. An electric vehicle (200) comprising a front panel assembly (100) according to any preceding claim.

13. The electric vehicle according to claim 12, wherein: the front fascia assembly or front fascia module forms a portion of a front fascia (204) of an electric vehicle.

14. The electric vehicle according to claim 12 or 13, wherein: a pair of headlights (202) are on the sides of the front panel assembly or front panel module.

15. The electric vehicle according to any one of claims 12 to 14, wherein: the front panel assembly extends between a fascia of a bumper assembly (206) and a hood or front window (210) of the electric vehicle.

Technical Field

The present invention relates to a front panel assembly for an electric vehicle comprising a front cover and a carrier structure. Furthermore, the invention relates to a vehicle comprising such a front panel assembly.

Background

The transition from fuel-powered vehicles or hybrid vehicles to electrically powered vehicles in the automotive industry has a great impact on engine design and also on the appearance of vehicles and motor vehicles, particularly front trim panels.

The front trim panel of a vehicle, in particular a car, comprises a grille or grille forming a barrier or screen, the main function of which is to enable cooling air to enter the radiator of the car. However, it also plays an important role in attracting car buyers. Grids are often distinctive style components that many OEMs use as their primary brand identity.

In the case of an electric vehicle, it is no longer a primary function to allow cold air to enter the radiator. This opens up new design possibilities, wherein the grid can be replaced by a closing member.

New design possibilities also include the option of integrating one or more functions into the front panel, such as energy absorption upon impact, electronics and lighting features.

Disclosure of Invention

According to the present invention, there is provided a front panel assembly for an electric vehicle, the front panel assembly comprising:

-a front cover having side edges, the front cover extending in a curved shape such that a first angle different from 0 degrees or 180 degrees is enclosed between a first portion and a second portion of the front cover; and

-a carrier structure comprising a base and a peripheral wall extending from the base, wherein the base comprises a first portion and a second portion, the first portion and the second portion enclosing a second angle different from 0 degrees or 180 degrees;

wherein the vertical wall is connected with the front cover at or near at least a portion of a side edge of the front cover so as to form and enclose a space between the front cover and the carrier structure, a first portion of the front cover covering a first portion of the carrier structure, a second portion of the front cover covering a second portion of the carrier structure.

The assembly forms a closed space or box having a curved shape, i.e. the first part of the assembly and the second part of the assembly enclose an angle different from 0 or 180 degrees. The front cover and the base of the carrier structure are spaced apart by a peripheral wall of the carrier structure. The vertical wall of the carrier structure is connected to the front cover at or near its peripheral side edge such that the assembly forms a closed unit. The first and second angles enclosed between the first and second portions of the front cover may be the same or different. The base and front cover of the carrier structure may extend in parallel or in a converging or diverging manner, depending on the continuous or varying height of the vertical walls and the first and second angles of their respective bends.

Wherein a first portion of the front panel assembly may form part of the front fascia and may include typical functions for the front fascia, such as lighting and other electronic functions, and a second portion of the front panel assembly may be used for energy absorption functions. Pedestrian impact safety is an important topic in the automotive industry. In 6 months 2014, EURONCAP issued a program for performing a head model and hood front edge test in order to evaluate the safety of pedestrians when an automobile collides with a pedestrian. Accident data indicates that the hood front edge is responsible for most severe injuries to vulnerable road users (e.g. pedestrians), for example to smaller sized persons (e.g. children). In particular, when the hood front edge reference line is located in the area between 1000mm wrap distance (WAD) (front limit of child head model test area) and WAD930 mm (position of upper load cell of thigh model impactor, upper limit of new thigh test), the area thus determined is not tested.

Typically, the area between WAD1000mm and 930mm is assumed to be unimportant when there is no hard structure beneath the surface that causes damage to the vehicle components. However, when a hard structure is located in this untested area, this area should be considered important in pedestrian protection.

Thus, according to an embodiment, an energy absorbing member is arranged on the second part of the carrier structure for absorbing energy upon impact. The energy absorbing member may be integral with the second portion of the carrier structure, i.e. as a single unit. Alternatively, the energy absorbing member can be attached to the carrier structure at a later stage of assembly. The energy absorbing member may extend at least between WAD930 and 1000mm, preferably beyond these distances, for example from WAD 850 to 1100 mm. The energy-absorbing component may include one or more inverted U-shaped projections extending from the base of the second portion of the carrier structure. These U-shaped projections are designed to deform under impact upon collision with a pedestrian so that impact energy is absorbed by the front panel assembly and injury to the pedestrian can be restrained. Additionally or alternatively, the energy absorbing member may include a foam structure filling at least a portion of the space enclosed between the second portion of the carrier structure and the second portion of the front cover. The foam structure is designed to deform upon impact with a pedestrian and thus absorb impact energy. Preferably, the foam structure fills the space between the carrier structure and the front cover in the second part of the front panel assembly. Preferably, the foam structure fills the entire space enclosed between the second part of the carrier structure and the second part of the front cover.

The foam structure may be formed separately from the front panel assembly or its components and added to the front panel assembly at a later time. Alternatively, the foam structure can be provided by injecting a foam resin into the space between the carrier structure and the front cover.

The front cover may include an opaque 3D shaped sheet. The front cover has a curved shape and can additionally be provided with 3D features, such as protrusions (e.g. ridges) and/or recesses, to give the front cover a special pattern. These 3D features may also have technical functions, such as housing or attaching other vehicle components. The front cover itself may be made of an opaque material, but can also be made opaque by painting or color molding of a translucent material.

Also, the front cover may include at least one translucent portion. Such a translucent portion may be used to integrate functional and/or decorative lighting into the front panel assembly. Preferably, the translucent portion is provided in the first portion of the front cover. The translucent portion may also be transparent. Translucency is an extended set of transparencies. The translucent medium allows light transmission, while the transparent medium not only allows light transmission but also can form an image. Thus, the transparent medium is also translucent, but the translucent medium may be, but need not be, transparent. Opaque is the opposite of translucent. The translucent portion may have a visible light transmission of greater than 10%. Opaque is defined as having a visible light transmission of up to 10%. The transparent portion is optically transparent, i.e., it is transparent to at least light visible to the human eye and can have a visible light transmission of greater than 30%.

The assembly may further include a light module enclosed within a space formed between the first portion of the front cover and the first portion of the carrier structure. The translucent or transparent portion in the first portion of the front cover may form part of a light module, such as an LED light module. The lamp module may comprise a reflector and a lighting component. The reflector may be arranged at the first portion of the carrier structure, for example embedded in a groove-shaped recess. The illumination member may be disposed between the reflector and the front cover. According to an embodiment, the assembly further comprises a lamp module enclosed within a space formed between the front cover and the carrier structure. The lamp module may be provided as an illumination pattern or an illumination etchings in the space between the front cover and the carrier structure.

The assembly may further comprise a receiving portion for an electronic component integrated with the assembly. Preferably, the receiving portion extends to the front cover and is at least partially surrounded by the carrier structure. The receiving portion may receive any type of electronic component, including a LiDAR module for an intended autonomous vehicle. A front panel assembly would be well suited to integrating such components.

The receiving portion may be provided in the first portion of the front cover and at least partially surrounded by the first portion of the carrier structure.

The component may comprise a thermoplastic material. The front cover and/or the carrier structure may be manufactured from a thermoplastic material, for example by injection moulding or thermoforming.

The thermoplastic material may be: polyolefins, such as PE or PP; polybutylene terephthalate (PBT); acrylonitrile-butadiene-styrene (ABS); acrylic-styrene-acrylonitrile (ASA); polycarbonate (PC); polycarbonate/PET blends; polycarbonate/PBT blends; polycarbonate/ABS blends; polycarbonate/ASA blends; a copolycarbonate-polyester; acrylonitrile- (ethylene-polypropylene diamine modified) -styrene (AES); phenylene oxide resin (PPO); PPO/PS mixtures; mixtures of polyphenylene ethers/polyamides; a polyamide; polyphenylene sulfide resin; polyvinyl chloride (PVC); high Impact Polystyrene (HIPS); low/high density polyethylene (L/HDPE); polypropylene (PP); expanded polypropylene (EPP); poly (methyl methacrylate); and thermoplastic olefins (TPO). The polymer or thermoplastic material may be a linear polymer or a branched polymer or a combination thereof. The plastic can optionally be reinforced, for example with fibers, particles, flakes, and combinations comprising at least one of the foregoing, such as, in particular, long glass fibers, short glass fibers, glass beads, talc, mica, inorganic fillers, natural fibers, conductive fillers, and/or carbon fibers. For example, the thermoplastic second component can be made of

Formed of a material which is long glass fiber reinforced polypropylene commercially available from SABIC.

Preferably, the front cover and the carrier structure are made of a polypropylene compound or a copolymer thereof. A preferred alternative can include a PPO/PS mixture (NORYL from SABIC)^TM) And polycarbonate/PET mixtures or polycarbonate/PBT mixtures (XENOY from SABIC)^TM). The translucent portion of the front cover may include a translucent PP compound, such as QRYSTAL from SABIC^TMPolycarbonate or PMMA. At least a portion of the front cover may be provided with a protective layer. The protective layer canTo include a scratch and/or UV resistant layer, or any protective layer that renders the front cover suitable for environmental exposure, particularly for PCs.

The front cover may be a flat panel or may have a slight curvature, i.e., a convex shape, such as a smooth transition and/or flush with other components of the front fascia of the vehicle.

The invention also relates to an electric vehicle comprising a front panel assembly as described above. The front fascia assembly may form a portion of a front fascia of a vehicle, where the fascia is a generic name for a group of front end components of the vehicle. The first portion of the front fascia assembly may be part of a front fascia of a vehicle because the first portion may replace a grille of the vehicle. A pair of headlights may be on the sides of the assembly. The front panel assembly may thus be arranged between the headlights of a vehicle. The front panel assembly may extend between a bumper fascia and a front window of a vehicle. The first portion of the front face plate assembly may be proximate to a bumper fascia, such as a covering of a bumper beam, and the front face plate may further extend over a front portion of the vehicle to a lower edge of a front window of the vehicle, such that the second portion of the front face plate assembly may form a replacement for a hood of the vehicle. Alternatively, the second portion of the front panel assembly may abut an edge of a front hood of the vehicle.

Drawings

A more complete understanding of the features and advantages of the present invention may be acquired by referring to the following drawings of several exemplary embodiments, in which:

FIG. 1 illustrates, in exploded view, a front face plate assembly in accordance with a first embodiment of the present invention;

FIG. 2 illustrates, in exploded view, a front face plate assembly in accordance with a second embodiment of the present invention; and

FIG. 3 illustrates a perspective view of a vehicle including a front panel assembly according to the present invention.

Detailed Description

Fig. 1 shows a front panel assembly 100 according to a first embodiment of the present invention in an exploded view, and fig. 2 shows a front panel assembly according to a second embodiment of the present invention in an exploded view.

The carrier structure 102 is arranged behind the front cover 101, seen from the front cover 101. The carrier structure 102 comprises a base 103 and a peripheral wall 104, which peripheral wall 104 extends from the base 103 and is connected with the front cover 101 at or near its side edges. A peripheral vertical wall 104 spaces the base 103 from the front cover 101. The front cover 101 and the carrier structure 102 together enclose a space.

The front panel assembly 100 has a curved shape. To obtain such a curved shape, the base 103 of the carrier structure 102 is bent, thereby forming the carrier structure 102 into a curve. The front cover 101 also has a curved shape.

The carrier structure 102 has a first portion 102 'and a second portion 102 "and the front portion is covered by a first portion 101' and a second portion 101". An angle α, β is enclosed between the respective first and second portions, wherein the angles α, β are greater than 0 degrees and less than 180 degrees. The angles α and β can be similar, but can also be different. The peripheral wall 104 of the carrier structure 102 attached to the front cover 101 (not shown) can accommodate the difference in the angles alpha, beta.

The first part 101' of the front cover and the first part 102' of the carrier structure together form a first part 100' of the front panel assembly. The second part 101 "of the front cover and the second part 102" of the carrier structure form a second part 100 "of the front panel assembly.

The first portion 102' of the carrier structure 102 includes a plurality of receiving portions 106 for receiving electronic components 107, such as sensors or LiDAR components or light modules 124. The receiving portion 106 is provided in the base 103 and extends to the front cover 101. The lamp module 124 comprises a reflective member 122, e.g. a V-shaped reflector, and a lighting device 110, e.g. an LED strip, which lighting device 110 is arranged near or inside the reflector.

The first portion 101' of the front cover 101 includes a plurality of openings 118 to accommodate the translucent portion 116 and the transparent portion 120. The translucent portion 116 is aligned with the lamp module 124 in the receiving portion of the first portion 102 such that when the lamp module 124 is used, i.e. the lighting device is switched on, light will be transmitted through the translucent portion 116. The transparent portion 120 is aligned with the receiving portion of the electronic component. In particular, when the electronic components include sensors (parking sensors, motion sensors, etc.) and/or LiDAR devices, the transparency of the front cover 101 at this location is important for high transmission of electromagnetic radiation.

The second portion 100 "of the front panel assembly 100 includes an energy-absorbing member 114 to absorb impact energy in the event of a collision (e.g., head-on collision) with a pedestrian or an injured road user. The embodiment of fig. 1 illustrates such an energy-absorbing component 114 including a plurality of projections 126 extending from the base 103 of the carrier structure 102. These projections are designed to crush upon impact of a collision, thereby absorbing impact energy and limiting injury to the vehicle and impacted objects, particularly pedestrians. The embodiment in fig. 2 illustrates such an energy-absorbing component 114 that includes a plurality of ribs 128 extending from the base 103 of the carrier structure 102. The ribs 128 are provided for increasing the rigidity of the base 103 at the second portion 102 "of the carrier structure 102. By providing a relatively rigid base 103, the foam structure 105 is adequately supported by the base 103 and can therefore absorb at least a portion of the impact energy upon impact.

In addition, the energy absorbing component 114 includes a foam structure 105 disposed between the ribs and the front cover 101. The foam structure fills the space enclosed in the second part 100 "of the front panel assembly between the front cover 101 and the carrier structure 102.

Fig. 3 illustrates a perspective view of a vehicle 200 including a front panel assembly 100 according to the present invention. The front panel assembly 100 is provided as part of a front fascia 204 of the vehicle 200. The front panel assembly 100 includes a front cover 101 at its front (see also fig. 1 and 2). The front panel assembly 100 is disposed between a pair of headlights 202 at its sides. At its top end, a hood 208 of the vehicle is disposed, and at its bottom end, a bumper assembly 206 of the vehicle is disposed. Alternatively, the top end of the front panel assembly 100 can extend toward the front window 210 of the vehicle.

Parts list

100 front panel assembly

100' first part of front panel assembly

Second part of 100' front panel assembly

101 front cover

101' first part of front cover

101' front cover second part

102 carrier structure

102' first part of the Carrier Structure

102 "second part of the carrier structure

103 base part

104 peripheral wall

105 foam structure

106 receiving part

107 electronic component

108 inner surface of the base

110 lighting device

112 translucent portion

113 transparent part

114 energy absorbing member

116 translucent portion

118 opening

120 transparent part

122 reflector

124 lamp module

126 projection

128 Ribs

200 vehicle

202 front lamp

204 front decorative board

206 Bumper component

208 engine hood

210 front window