Bumper fascia support assembly

A bumper fascia support assembly includes a front support, a bracket and a bumper fascia. The bracket has a support attachment end, a body section and a fascia attachment end. The support attachment end is fixedly attached to a forward facing surface of the front support. The bumper fascia has a central section fixedly attached to the fascia attachment end of the bracket. The body section of the bracket has a controlled deflection structure that is configured with respect to the support attachment end and the fascia attachment end to deform downwardly in response to a prescribed impacting force being applied to the bumper fascia so that the fascia attachment end and the central section of the bumper fascia move downward relative to the support attachment end absorbing impact energy.

BACKGROUND

1. Field of the Invention

The present invention generally relates to a bumper fascia support assembly. More specifically, the present invention relates to a bumper fascia support assembly that includes a bracket having a controlled deflection structure.

2. Background Information

Vehicle bumper structures are constantly undergoing redesign and reconfiguration to improve response to both high speed and low speed impact events. Certain structural elements of a vehicle bumper structure are designed to absorb forces associated with high speed impacts and other structures are designed to absorb forces associated with low speed impacts.

SUMMARY

One object is to provide a bumper fascia support assembly with a support member having a controlled deflection structure that responds to impact events by bending downward in a predetermined manner, where the impact events include a head-on impacting force applied to a bumper fascia that includes a downward impacting force component.

In view of the state of the known technology, one aspect of the present disclosure is to provide a bumper fascia support assembly with a front support, a bracket and a bumper fascia. The bracket has a support attachment end, a body section and a fascia attachment end, the support attachment end being fixedly attached to a forward facing surface of the front support. The bumper fascia has a central section fixedly attached to the fascia attachment end of the bracket. The body section of the bracket has a controlled deflection structure that is configured with respect to the support attachment end and the fascia attachment end to deform downwardly in response to a prescribed impacting force being applied to the bumper fascia so that the fascia attachment end and the central section of the bumper fascia move downward relative to the support attachment end absorbing impact energy.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring initially toFIG. 1, a vehicle10having a bumper fascia support assembly12is illustrated in accordance with a first embodiment. The vehicle10includes, among other things, a vehicle body structure14that includes a roof16, a sill18, an A-pillar20, front fenders22, a radiator fan supporting assembly24(shown inFIG. 2) and the bumper fascia support assembly12. The vehicle body structure14, the roof16, the sill18, the A-pillar20and the front fenders22are all conventional features of the vehicle10. Therefore, further description of these features is omitted for the sake of brevity, except where necessary to understand the invention.

The radiator fan supporting assembly24is part of the vehicle body structure14designed to support a radiator (not shown), cooling fans (not shown) and an air conditioning condenser (not shown) in a conventional manner. As shown inFIGS. 2 and 6, the radiator fan supporting assembly24is formed or constructed with fan openings26, an upper rail28, a lower rail30, side rails32and34, and a central section36between the fan openings26. The radiator fan supporting assembly24also includes flanges and fastener portions located and dimensioned to support the radiator, cooling fans and an air conditioning condenser. The radiator fan supporting assembly24is rigidly attached to frame elements (not shown) of the vehicle body structure14in a conventional manner.

The radiator fan supporting assembly24also includes a first bracket40, a second bracket42and a front support44. The first bracket40and the second bracket42are fixedly attached to the radiator fan supporting assembly24by, for example, removable fasteners or welding techniques. As indicated inFIG. 4, the first bracket40extends forward from the side rail32in order to support a portion of the bumper fascia support assembly12, as described in greater detail below. The second bracket42extends forward from the side rail34in order to also support a portion of the bumper fascia support assembly12, as described in greater detail below. The first bracket40basically constitutes a first lateral attachment bracket and the second bracket42constitutes a second lateral attachment bracket.

The front support44is a vertically oriented bracket having a top end48, a lower end50and a central section52. The top end48is rigidly and fixedly attached to the upper rail28of the radiator fan supporting assembly24by fasteners and/or welding techniques. The lower end50is similarly rigidly and fixedly attached to the lower rail30of the radiator fan supporting assembly24by fasteners and/or welding techniques.

The front support44is configured to retain one or both of the condenser (not shown) and the coolant radiator (not shown). More specifically, one or both of the condenser and the coolant radiator can be installed in the space defined between the front support44and the remainder of the radiator fan supporting assembly24.

The bumper fascia support assembly12is now described with reference toFIGS. 2-5. The bumper fascia support assembly12basically includes the front support44, a bumper fascia54and a bracket56. It should be understood from the drawings and the description herein that the bumper fascia54is configured to cover and conceal a bumper assembly (not shown). As shown inFIG. 5, a space S is provided behind the bumper fascia54to receive the bumper assembly. However, except for the bumper fascia54, the bumper assembly is omitted from the drawings to provide greater clarity. Since bumper assemblies are conventional vehicle features well known in the art, further description of bumper assemblies is omitted for the sake of brevity.

As shown inFIGS. 1-5, the bumper fascia54includes a first lateral end62, a second lateral end64opposite the first lateral end56and a central section66. Each of the first lateral end62and the second lateral end64include attachment projections (not shown) that, for example, attach the bumper fascia54to respective ones of the fenders22in a conventional manner. The first lateral end62and the second lateral end64have respective upper edges62aand64athat are located vertically above an upper edge66aof the central section66of the bumper fascia54with the bumper fascia54installed to the vehicle body structure14. Since the central section66has a lower vertical height that either of the first and second lateral ends62and64, an open space is defined between the first lateral end62and the second lateral end64and above the upper edge66aof the central section66. Accordingly, the upper edge66aof the central section66is shaped to receive a lower edge of a grille G. Hence the grille G (shown inFIG. 1) is located between the first lateral end62and the second lateral end64, and above the central section66of the bumper fascia54.

The central section66of the bumper fascia54includes a plurality of attachment projections70,72and74positioned at the upper edge66athereof, as best shown inFIGS. 3 and 4. The attachment projections70,72and74extend rearward from the upper edge66aof the central section66of the bumper fascia54. The attachment projection70is attached to the first bracket40by, for example, a removable fastener. The attachment projection72is attached to the second bracket42by, for example, a removable fastener. The attachment projection74is attached to the bracket56by a pair of fasteners F1, as is described in greater detail below after a description of the bracket56. The above mentioned fasteners F1can be threaded fasteners or snap fitting fasteners.

Hence, the bumper fascia54is supported by the radiator fan supporting assembly24via the attachment brackets40and42and the bracket56, which is described in greater detail below. The bracket56is located between and spaced apart from the first and second brackets40and42.

A description of the bracket56is now provided with specific reference toFIGS. 7-16. The bracket56basically includes a body section80, a support attachment end82and a fascia attachment end84. When installed within the vehicle10to the front support44, the body section80extends horizontally between the support attachment end82and the fascia attachment end84, as shown inFIG. 8. More specifically, as indicated inFIGS. 8 and 9, the support attachment end82of the bracket56is fixedly attached to the front support44by fasteners F2at a position that is below and spaced apart from the upper end48, and a position that is above and spaced apart from the lower end50of the front support44.

The body section80includes a first reinforcing web86, a second reinforcing web88and a third reinforcing web90. As shown inFIGS. 10,11,14and15, the first reinforcing web86extends along and at least partially defines a first lateral side80aof the body section80in a longitudinal vehicle direction of the vehicle10. As shown inFIGS. 14 and 16, the second reinforcing web88extends along and at least partially defines a second lateral side80bof the body section80in a longitudinal vehicle direction of the vehicle10. As shown inFIGS. 10,12and14, the third reinforcing web90extends along the fascia attachment end84of the bracket56.

The first, second and third reinforcing webs86,88and90define a single, uninterrupted web extending around three sides of the body section80that reinforces the strength of the body section80during head-on impacting events (with a horizontally directed impacting force component). As shown inFIGS. 10,11and14-16, each of the first and second reinforcing webs86and88includes corresponding weakened sections86aand88a. The weakened sections86aand88aalong with a forward portion96of the body section80define a controlled deflection structure. As indicated inFIG. 9, the controlled deflection structure is configured with respect to the support attachment end82and the fascia attachment84to deform downwardly in response to a prescribed impacting force being applied horizontally to the bumper fascia54so that the fascia attachment end84and the central section66of the bumper fascia54move downward relative to the support attachment end82, thereby absorbing impact energy. The controlled deflection structure, including the weakened sections86aand88a, also provide energy absorption during impact events where there is a downward component to the impacting force, such as the force F indicated inFIG. 9. The third reinforcing web90includes a recess90a. However, the recess90ais defined in the third reinforcing web90to provide tool access during installation of the bracket56.

The recesses86aand88a(part of the controlled deflection structure) are formed along a region of the body section80adjacent to but spaced apart from the fascia attachment end84, as shown inFIGS. 7-11.

The body section80also includes a central opening92that is surrounded by an inner webbing94. The forward portion96of the body section80is located between the central opening92and the fascia attachment end84, further defining the controlled deflection structure. As indicated inFIG. 13, the reinforcing webs86,88and90extend downward a first distance D1from an upper surface of the body section80thereby surrounding at least a portion of an outer periphery of the body section80. Hence, the reinforcing webs86,88and90extend continuously along the first lateral side80a, the fascia attachment end84and the second lateral side80bof the main body80.

As shown inFIG. 15, the weakened section86aof the reinforcing web86is basically a first notch formed along the first lateral side80aof the body section80. As shown inFIG. 16, the weakened section88aof the reinforcing web88is basically a second notch formed along the second lateral side80bof the body section80. As best shown inFIGS. 10,11and14, a bending axis A is defined between the weakened section86aand the weakened section88a. It should be understood from the drawings that the weakened section86aand the weakened section88acan be defined by something other than notches or recesses. For example, the weakened section86aand the weakened section88acan be defined by sections of the reinforcing webs86and88having reduced thicknesses.

As shown in FIGS.4and10-16, the support attachment end82of the bracket56includes a vertically extending flange100that extends perpendicularly to the body section80. As shown inFIG. 14, a line L of the body section80extends in a vehicle longitudinal direction through a center of the support attachment end82, forward and through the fascia attachment end84of the bracket56. The line L is centered with respect to the support attachment end82, but is slightly off center with respect to the body section80and the fascia attachment end84. As shown inFIG. 4, the fasteners F1attach the fascia attachment end84of the bracket56to the bumper fascia54at first and second locations that are spaced apart from one another in a vehicle lateral direction such that the line L extends between the first and second locations of the fasteners F1. The flange100includes a first flange portion102, a second flange portion104and a third flange portion106. The second flange portion104extends between the first and third flange portions102and106. The first flange portion102faces the third flange portion106such that the first, second and third flange portions102,104and106define a U-shape when viewed from above or below, as inFIG. 14. An upper portion of the flange100extends upward from the upper surface of the body section80by a distance D2. The flange100also includes a lower portion that extends downward from the upper surface of the main body80by a distance D3. As indicated inFIG. 13, the distance D3is greater than the distance D2.

As indicated inFIG. 14, the support attachment end82has a width that is less than the width of the fascia attachment end84. The support attachment end82includes a projection P that is used to align the support attachment end82with the central section52of the front support44during installation. Specifically, the projection P is inserted into an aperture formed in the central section52, making it easier to then install fasteners through correspondingly aligned apertures of the support attachment end82and the central section52of the front support44, as shown inFIGS. 7-9. As is shown inFIG. 7, the support attachment end82of the bracket56attaches via fasteners F2to the front support44at a first location above the body section80and a second location below the body section80. The locations of the fasteners F2relative to the fascia attachment end84define a triangle that extends along a vertically oriented plane. The locations of the fasteners F2are also aligned with the line L. This geometry provides vertical stability to the bracket56relative to the front support44. Further, as indicated inFIG. 3, the locations of the fasteners F1relative to a rear end of the body section80of the bracket56defines a triangle that extends along a horizontally oriented plane. This geometry provides horizontal stability to the bracket56relative to the front support44and the bumper fascia54.

The flange100of the support attachment end82of the bracket56defines a rearward-most end surface110of the bracket56. The fascia attachment end84defines a forward-most end surface112of the bracket56. The rearward-most end surface110and the forward-most end surface112extend in directions that are parallel to one another.

The first flange portion102, the second flange portion104and the third flange portion106are angularly offset from one another. Specifically, the first flange portion102extends along a rearward portion of the first lateral side80a, the second flange portion104extends along the support attachment end82and the third flange portion106extends along a rearward portion of the second lateral side80b. At the intersection of the first flange portion102and the second flange portion104, the first flange portion102and the second flange portion104are initially perpendicular to one another. However, the first flange portion102has an arcuate contour, as indicated inFIG. 14. Therefore, a majority of the first flange portion102flares away from the second flange portion104. Similarly, at the intersection of the third flange portion106and the second flange portion104, the third flange portion106and the second flange portion104are initially perpendicular to one another. However, the third flange portion106has an arcuate contour, as indicated inFIG. 14. Therefore, a majority of the third flange portion106flares away from the second flange portion104.

Hence, the arcuate contours (flaring) of each of the first and third flange portions102and106, and the overall height (D2plus D3) of the flange100, provide the flange100with rigidity and overall strength. Specifically, the attachment of the bracket56to the central section52of the front support44provides a large resistance to fracturing and/or bending that might result from force being applied to the bracket54.

The first and third flange portions102and106are further continuous with respective ones of the first and second reinforcing webs86and88. In other words, the first flange portion102and the first reinforcing web86are formed integrally in an uninterrupted manner. Rather, a lower edge of the first flange portion102includes a tapered flange102a, that smoothly transitions to the first reinforcing web86, as indicated inFIG. 15. Similarly, the second flange portion106and the second reinforcing web88are formed integrally in an uninterrupted manner. A lower edge of the third flange portion106includes a tapered flange106a, that smoothly transitions to the second reinforcing web88, as indicated inFIG. 16. The smooth transition between the first and third flange portions102and106and the first and second reinforcing webs86and88further increases amount of force required to bend or fracture the bracket56at the support attachment end82of the bracket56.

As shown inFIGS. 2-5and8-9, the projection74of the central section66of the bumper fascia54is fixedly attached to the fascia attachment end84of the bracket56. The support attachment end82is reinforced by the flange100, as described above. The first and second lateral sides80aand80bare reinforced by the first and second reinforcing webs86and88, respectively. However, the first and second lateral sides80aand80bof the bracket56are weakened by the weakened sections86aand88a. Consequently, the weakened sections86aand88aand the forward portion96together define a controlled deflection structure. Hence, when the bumper fascia54is impacted by a head-on impact with a predetermined level of force, the bumper fascia54transfers a portion of that force as the force F (FIG. 9) causing the controlled deflection structure (the weakened sections86aand88aand the forward portion96) to direct bending and/or fracturing of the bracket56along the bending axis A, as indicated inFIG. 9.

Hence, the bracket56includes the controlled deflection structure (the weakened sections86aand88aand the forward portion96), that responds to impact events by bending downward in a predetermined manner as depicted inFIG. 9, where the impact events include a head-on impacting force applied to a bumper fascia56. Further, since the support attachment end82is reinforced to resist bending and fracture due to the inclusion of the flange100, the support attachment end82is able to withstand forces acting upon it that have a significantly greater level of force as compared to the downward component force F that can cause the controlled deflection structure to bend.

The various elements of the vehicle body structure14and the vehicle10in general, are conventional components that are well known in the art. Since these vehicle related features are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

GENERAL INTERPRETATION OF TERMS