Fender structure assemblies for vehicles

An attachment bracket for mounting a fender of a vehicle to a side structural member includes a top portion that connects to the fender. A first vertical leg connects to the side structural member. The first vertical leg extends downwardly from an edge of the top portion. A second vertical leg connects to the side structural member. The second vertical leg extends downwardly from an opposite edge of the top portion. The first vertical leg includes a bend separating the first vertical leg into an upper portion and a lower portion. The first vertical leg has a central opening at the bend that is spaced vertically from the top portion and a bottom end of the first vertical leg.

TECHNICAL FIELD

The present specification generally relates to fender structure assemblies for vehicles and, more specifically, to fender panel mounting structures for use in mounting fenders to vehicles.

BACKGROUND

A number of countries have organizations that monitor safety performance of automobiles. For example, the European New Car Assessment Program (Euro NCAP) and the Japan New Car Assessment Program (JNCAP) provide rating schemes for crash testing automobiles. One area of interest relates to pedestrian head impacts, for example, along the front of the vehicle.

It is known that automobile bodies are typically formed of a number of panels that are mounted to support structures. One such panel is a fender structure, which is disposed on an apron structural member. Fender attachment brackets have been proposed for attaching the fender structure to an apron structural member and function to absorb impact energy.

SUMMARY

In one embodiment, an attachment bracket for mounting a fender of a vehicle to a side structural member includes a top portion that connects to the fender. A first vertical leg connects to the side structural member. The first vertical leg extends downwardly from an edge of the top portion. A second vertical leg connects to the side structural member. The second vertical leg extends downwardly from an opposite edge of the top portion. The first vertical leg includes a bend separating the first vertical leg into an upper portion and a lower portion. The first vertical leg has a central opening at the bend that is spaced vertically from the top portion and a bottom end of the first vertical leg.

In another embodiment, a vehicle having a fender structure assembly includes a fender having an outer portion and a connecting portion. An attachment bracket mounts the fender to a side structural member. The attachment bracket includes a top portion connected to the connecting portion. A first vertical leg is connected to the side structural member. The first vertical leg extends downwardly from an edge of the top portion. A second vertical leg is connected to the side structural member. The second vertical leg extends downwardly from an opposite edge of the top portion. The first vertical leg includes a bend separating the first vertical leg into an upper portion and a lower portion. The first vertical leg has a central opening at the bend that is spaced vertically from the top portion and a bottom end of the first vertical leg.

In another embodiment, a fender structure assembly of a motor vehicle includes a fender including an outer portion extending downwardly toward a wheel, a vertical portion extending downwardly from the outer portion and a connecting portion. An attachment bracket mounts the fender to the side structural member. The attachment bracket includes a top portion connected to the connecting portion. A first vertical leg is connected to the side structural member. The first vertical leg extends downwardly from an edge of the top portion and includes two or more openings spaced-apart vertically from each other along a length of the first vertical leg. A second vertical leg is connected to the side structural member. The second vertical leg extends downwardly from an opposite edge of the top portion and includes two or more openings spaced-apart vertically from each other along a length of the second vertical leg. The first and second vertical legs buckle at each of their respective two or more openings upon an impact to the fender structure assembly.

DETAILED DESCRIPTION

FIG. 1generally depicts one embodiment of a motor vehicle10where arrows F, U and IN denote forward, upward and widthwise inward directions of the vehicle10. The vehicle10includes a vehicle body12with a hood14, a front fender16and a boundary line18running along the length of the vehicle10between the hood14and the fender16. The hood14(which may be formed of a metal material) is generally disposed above an engine compartment20so as to be able to open the hood14to gain access to the engine compartment20. The hood14may be formed of multiple panels, such as an outer hood panel22and an inner hood panel24(FIG. 2). The front fender16, which may be formed of a metal or plastic material, is located to a side of the outer hood panel22. As will be described in greater detail below, the front fender16is attached to a side or apron structural member by attachment brackets forming a fender structural assembly generally designated element25that is positioned along the length of the vehicle10.

Referring toFIG. 2, the inner hood panel24is located on a lower side of the outer hood panel22. The inner hood panel24may be attached to the outer hood panel22such that an outer edge portion26of the outer hood panel22is fixed by hemming to an outer flange28of the inner hood panel24that projects outward in the vehicle widthwise direction. Any other suitable connection structure may be used to connect the inner and outer hood panels24and22.

The side or apron structural member30is located below the boundary line18between the hood14and the front fender16. The apron structural member30extends generally in the lengthwise direction of the vehicle10with the boundary line18. The apron structural member30includes an upper apron member32and a lower apron member34. The upper apron member32includes a vertical portion36that is connected to a horizontal portion38forming a somewhat L-shaped section as viewed in the lengthwise direction of the vehicle10. The lower apron member34includes a horizontal portion40connected to a vertical portion42forming a somewhat L-shaped section as viewed in the lengthwise direction of the vehicle10. The upper and lower apron members32and34may be connected in any suitable manner such as by fasteners, welding, etc. In some embodiments, the upper apron member32and the lower apron member34cooperate to form a closed space or area that extends in the lengthwise direction of the vehicle10. Other configurations are possible for the apron structural member30, such as a U-shaped upper member that is connected to an L-shaped lower member.

Referring toFIGS. 2 and 3, the front fender16includes an outer wall44that extends vertically downward from a top end portion46of the outer wall44toward a front wheel of the vehicle10. An inner wall48extends downwardly from the top end portion46at the boundary line18to a horizontal connecting wall50disposed at least partially below the hood14.

An attachment bracket52connects the front fender16at the horizontal connecting wall50to the upper apron member32at the horizontal portion38. A fastener53may connect the attachment bracket52to the connecting wall50and fasteners55and57may connect the attachment bracket52to the upper apron member32. As will be described in greater detail below, the attachment bracket52includes one or more features that may provide a predictable deformation pattern for the attachment bracket52and absorb impact energy when a headform impacts the hood14of the vehicle10.

Referring toFIG. 4, the attachment bracket52may include a top portion54, a first vertical leg56located at a first end58of the top portion54and a second vertical leg60located at an opposite second end62of the top portion54. The top portion54may include connecting structure63for attaching the attachment bracket52to the horizontal connecting wall50of the front fender16. In one embodiment, the connecting structure63is a bolt receiving structure65having a downwardly extending wall59and an opening61extending therethrough. A foot64and66is illustrated as extending outwardly from the legs56and60away from the top portion54at a bottom edge68and70of each leg56and60. The feet64and66may be used to connect the attachment bracket52to the horizontal portion36of the upper apron member32. The feet64and66may include openings67,69,71and73(seeFIG. 5) through which the fasteners55and57may be inserted. In other embodiments, fasteners55and57may not be used to connect the feet64and66to the upper apron member32. For example, the feet64and66may be welded to the upper apron member32.

The legs56and60may include upper portions72and74and lower portions76and78connected by bends80and82. As can be seen, the upper portions72and74may have an angle θ to the vertical that is greater than an angle of the lower portions76and78to the vertical thereby creating outward bends80and82that extend away from each other. The upper portions72and74, in some embodiments, taper toward each other at a slope greater than the lower portions76and78. In one embodiment, the lower portions76and78are vertical and substantially parallel to each other. In some embodiments, the top portion54has a length L1that is greater than a length L2between bottom edges68and70at a base of the attachment bracket52.

Upper and lower gussets81and83are provided at the ends58and62and bottom edges68and70(seeFIG. 5). The gussets81extend from the upper portions72and74to the top portion54over the ends58and62. The gussets83extend from the lower portions76and78to the feet64and66over the bottom edges68and70. The gussets81and83may provide strength to the attachment bracket52in the widthwise vehicle direction.

In one embodiment, as shown, the leg56includes an extension portion84between the foot64and the lower portion76of the leg56. The extension portion84includes a step86with a flat region90. The extension portion84locates foot64vertically below foot66. Locating foot64below foot66may allow the attachment bracket52to be connected to a horizontal portion36having an upper surface of differing elevations. For example, foot64may rest on a region of the horizontal portion36having an elevation that is lower than another region of the horizontal portion36on which foot66rests. In some embodiments, both legs56and60may have an extension portion84or neither leg may have an extension portion.

Referring toFIG. 5, legs56and60include openings86,88,90,92,94and96that are spaced apart vertically along a length of the legs. Each opening86,88,90,92,94and96is located between the ends58and62and bottom edges68and70of their respective legs56and60. In particular, openings86and92are located at lower portions76and78, openings90and96are located at upper portions72and74and openings88and94are located on or intersect the bends80and82.

Referring briefly toFIG. 5A, the openings (opening86is shown for exemplary purposes) may be oval in shape and formed of a pair of circles (represented by dotted lines98and100) having a radius R. Two substantially straight parallel lines102and104are tangent to both the circles98and100. In some embodiments, a length l of the openings86,88,90,92,94and96is greater than the radius R. In one embodiment, the radii R of each opening86,88,90,92,94and96are the same. Alternatively, the radii R of one or more opening86,88,90,92,94and96may be different and/or the radii of an individual opening (i.e., of circles98and100) may be different. An axis A of the openings86,88,90,92,94and96passing through the center of the openings86,88,90,92,94and96is substantially horizontal and the openings may have one or two axes of symmetry. Each opening86,88,90,92,94and96inFIG. 4has two axes of symmetry.

Referring again toFIG. 5, each leg56and60has a height H measured between the ends58and62and bottom edges68and70and each opening has a horizontal axis A1, A2and A3(only openings86,88and90are shown with axes A1, A2and A3for clarity). As an example of one embodiment, a vertical distance from the bottom edge68to A1may be between about 12 percent and about 35 percent, such as about 18 percent of the height H of the leg56, a vertical distance from the bottom edge to A2may be between about 30 percent and about 50 percent of the height H of the leg56, such as about 38 percent (e.g., less than 50 percent) and a vertical distance from the bottom edge to A3may be between about 50 percent and about 90 percent, such as about 82 percent (e.g., greater than 50 percent) of the height H of the leg56. In some embodiments, axis A2coextends with the bend80. The radius R of the openings86,88,90,92,94and96may be less than the height H of the leg56, such as between about one percent and about ten percent, such as about five percent of the height H of the leg56. In some embodiments, a distance between A1and A2is less than a distance between A3and A2. In other embodiments, the distance between A1and A2and A3and A2may be about the same or the distance between A3and A2may be less than the distance between A1and A2.

Each leg56and60also has a width W measured from one vertical edge106to an opposite vertical edge108. In some embodiments, the width W is substantially the same along the entire height H of the legs56and60. In other embodiments, the width W may change (e.g., the legs may taper in the widthwise direction). Each opening86,88,90,92,94and96has a length l1, l2and l3running along the respective axes A1, A2and A3. In the illustrated embodiment, length l2is greater than lengths l1and l3. In some embodiments, lengths l1and l3may be about the same or different. As an example of one embodiment, length l1and l2may be less than the width W, such as between about 20 percent and about 40 percent, such as about 34 percent of the width W and length l3may be less than the width W, such as between about 40 and about 60 percent, such as about 53 percent of the width W. In some embodiments, each opening86,88,90,92,94and96may be centered between the vertical edges106and108.

The openings86,88,90,92,94and96may be provided to create regions R1, R2and R3of weakness along the legs56and60. The openings86,88,90,92,94and96provide a localized increase in stress by reducing the area over which a force may be distributed. The openings86,88,90,92,94and96are shaped to create a predictable horizontal buckling of the legs56and60in response to a force F applied at the top portion54.

Referring toFIGS. 6 and 7, the attachment bracket52is shown in a buckled configuration. Initial, primary buckling occurs at the bend80and at opening96. Primary buckling occurs at the bend80as region R2may be the weakest due to the bend80and larger opening88. Secondary buckling occurs at openings86,90,92and94. Thus, buckling may occur at all six openings86,88,90,92,94and96.

The above-described attachment bracket52allows for greater vertical bracket displacement and lower head decelerations which can lower head injury values (HIC). Referring toFIG. 8, a graph of acceleration versus time is shown for the attachment bracket52with the openings86,88,90,92,94and96compared to an attachment bracket similar to the attachment bracket52without the openings86,88,90,92,94and96. The graph ofFIG. 8may be generated using the JNCAP testing procedures for child pedestrians. As can be seen, the attachment bracket52with openings86,88,90,92,94and96provides a decrease in headform acceleration within region A compared to the attachment bracket without openings86,88,90,92,94and96. Referring now toFIG. 9, a graph of acceleration versus stroke shows that the attachment bracket52with openings86,88,90,92,94and96gives more displacement (see region D) than the attachment bracket without openings86,88,90,92,94and96.

The above attachment bracket52may be formed of any suitable material such as a metal material (e.g., steel). Any suitable process or combination of processes may be used to form the attachment bracket52such as bending, stamping, machining, etc.

The above-described attachment bracket52provides an attachment structure that may be used to absorb impact energy during a front collision. The attachment bracket52may provide for lower head decelerations and greater vertical displacement, which can reduce HIC values. Under JNCAP testing conditions, HIC values may be reduced by about 15 percent to 20 percent or more by utilizing the attachment brackets52.