Abstract:
The invention relates to a support for a front module of a motor vehicle comprising a first support part for connection to a chassis of the motor vehicle and left and right brackets, wherein the left and right brackets are configured to receive a headlight unit and for connection to a bumper of the motor vehicle, respectively, wherein the left and right brackets with the left and right elastic elements are connected to the first support part, and comprising means for fixing the elastic elements relative to the chassis when the elastic elements have assumed an assembly position following elastic deformation.

Description:
BACKGROUND  
       [0001]     The invention relates to a support for the front module of a motor vehicle and a method for mounting such a support.  
         [0002]     In the state of the art, various front modules and assembly methods for front modules are disclosed.  
         [0003]     EP 1 232 932 A1, which is the closest state of the art of the invention, discloses a support for the front module of a motor vehicle comprising a support part for connecting it to the fenders and the chassis of the motor vehicle (see the parts  7  and  13  in  FIGS. 1 and 2  of EP 1 232 932 A1). A bracket for receiving a headlight unit (optical unit) and for connection to a bumper is fastened to the support (see the bracket  43 , the optical unit  21 , the bumper  19  and the guide  45  for fastening the bracket to the support, as is illustrated in the figures of EP 1 232 932 A1).  
         [0004]     In the prior art known from EP 1 232 932 A1 the problem occurs that due to the relatively large dimensional tolerances of the body shell of a motor vehicle body, to which the front module needs to be mounted, difficulty relating to the fit may occur during assembly. The joint pattern, particularly with respect to the joints between the bumper and the headlight unit and between the headlight unit and the hood as well as between the bumper and the hood, may therefore be impaired.  
         [0005]     Additional similar front panels are revealed in FR 2 809 061 and DE 199 46 995 A1. Additionally, DE 600 00 006 T2 discloses a frontal assembly for a vehicle comprising a support structure and a headlight, wherein the headlight is rotatably mounted on the support structure between a pre-assembly position and a final assembly position about a slanted axis. EP 1 036 730 A2 reveals a method for precision-mounting front parts of a motor vehicle. To this end, a multitude of mutually influencing tolerances can be taken into consideration.  
       SUMMARY OF THE INVENTION  
       [0006]     By contrast, it is the object of the invention to provide an improved support for the front module of a motor vehicle, a front module as well as an improved assembly method for the front module of a motor vehicle.  
         [0007]     The objects of the invention are achieved with the characteristics of the independent patent claims. Preferred embodiments of the invention are revealed in the dependent claims.  
         [0008]     The invention creates a support for the front module of a motor vehicle comprising a first support part for connection to a motor vehicle chassis and left and right brackets, wherein the left and right brackets are configured for receiving a headlight unit and for connection to a bumper of the motor vehicle, respectively. According to the invention, the brackets are connected to the first support part by means of elastic elements. Furthermore means for fixing the elastic elements relative to the chassis are provided, when the elastic elements have assumed an assembly position following elastic deformation.  
         [0009]     The elastic elements of the inventive support allow for tolerance compensation during the installation of the front module. This way, a high-quality joint pattern can be achieved despite the relatively large dimensional tolerances of the body shell of a motor vehicle, which may be in the millimeter range. Complex adjustments during assembly are therefore eliminated.  
         [0010]     According to one embodiment of the invention, the elastic elements are fixed to the first support part or the chassis by means of a screw connection after the front module has been brought into the installation position and is subject to deformation forces there. Due to the fixation, the elastic elements maintain this deformation position, even when the deformation forces are no longer applied.  
         [0011]     According to one embodiment of the invention, the elastic elements comprise a support surface for the hood of a motor vehicle so that the deformation forces act upon the elastic elements when the hood is closed. By closing the hood, the deformation forces thus act substantially in the vertical direction upon the elastic elements and deforms them. The elastic elements are fixed in this deformation position.  
         [0012]     According to one embodiment of the invention, the elastic elements are configured such that in any case deformation forces are applied by the hood on the elastic elements when the hood is closed, while taking the dimensional tolerances of the motor vehicle body shell and the hood into consideration. To this end, the elastic elements can be configured such that they protrude slightly upward in the direction of the hood.  
         [0013]     According to one embodiment of the invention, the elastic elements have a parallelogram shape. The sides of the elastic elements located on top each other preferably form an angle of &gt;90° prior to any deformation. This way, the elastic elements protrude slightly upward, so that deformation forces are definitely applied on the elastic elements when closing the hood.  
         [0014]     According to one embodiment of the invention, one side of a pair of sides of the elastic elements is connected to the first support part. The opposing second side of this pair of sides serves the connection to one of the brackets. By contrast, one side of the other pair of sides serves the introduction of the deformation forces.  
         [0015]     According to one embodiment of the invention, a holder for a screw connection is disposed on the parallelogram-like elastic elements, respectively, in order to fix the elastic elements in their deformed position.  
         [0016]     According to another embodiment of the invention, the brackets are fastened to the first support part by means of additional elastic elements, wherein for an elastic deformation the other elastic elements are configured substantially perpendicular to the direction of the elastic deformation of the elastic elements. This way, further compensation of the tolerances, for example in the lateral, i.e. the y direction, can be created. One of the other elastic elements can be disposed, for example, between one of the brackets and the elastic element and/or between the elastic element and the first support part.  
         [0017]     The invention furthermore relates to a front module for a motor vehicle comprising a support according to the invention, a bumper fastened thereon and headlight units.  
         [0018]     The invention also relates to a method for installing a support for a front module, comprising the following steps: installation of a first support part of the support on the chassis of the motor vehicle; elastic deformation of an elastic element of the support by closing a hood of the motor vehicle; and fixing the elastic element in the deformed position.  
         [0019]     According to one embodiment of the invention, the elastic element is fixed to the support part of the support or to the chassis in the deformed position by means of a screw connection.  
         [0020]     Other aspects, features, advantages, etc. will become apparent to one skilled in the art when the description of the invention herein is taken in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]     For the purposes of illustrating the various aspects of the invention, there are shown in the drawings forms that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. The invention will be explained in more detail hereinafter with reference to the drawings, wherein:  
         [0022]      FIG. 1  is a schematic perspective view of a first embodiment of a support according to the invention;  
         [0023]      FIG. 2  is a perspective view of a second embodiment;  
         [0024]      FIG. 3  is a perspective view of a third embodiment; and  
         [0025]      FIG. 4  is a sectional view of another embodiment of the support during installation in a motor vehicle. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]      FIG. 1  shows a support  100  for a front module of a motor vehicle (the front module is not shown in  FIG. 1 ). The support  100  comprises a support part  102 . The support part  102  serves the connection of the support  100  to the chassis of the motor vehicle. To this end, the support part  102  comprises a mount  104  for example on its lower end for connection to a longitudinal support  106  of the motor vehicle.  
         [0027]     An elastic element  108  is disposed on the support part  102 . The elastic element  108  has a parallelogram configuration in the embodiment shown here. The elastic element  108  comprises substantially parallel legs  110 ,  112  and  114 ,  116 . The elastic element  108  is firmly connected to the support part  102  via the side  110 , for example by means of a screw connection. The side  114  of the elastic element  108  comprises a support surface  118  for introducing deformation forces substantially in the vertical direction, i.e. the z direction. The elastic element  108  can be deformed in the direction of the arrow  120  through such deformation forces.  
         [0028]     A bracket  122  is fastened to the side  112  of the elastic element  108  by means of another elastic element  124 . The elastic element  124  allows tolerance compensation substantially in the lateral, i.e. y direction, as is indicated by the arrow  128 . At the end, the bracket  122  comprises a positioning pin  126  for engaging in an assembly hole of a fender. Since the bracket  122  has a certain elasticity, the positioning pin  126  has various degrees of freedom, as is illustrated by the arrows  130  in  FIG. 1 , so that the positioning pin  126  can be introduced easily in a corresponding assembly hole on the fender side. Tolerance compensation in the y direction is ensured by the elastic element  124 , by means of which the bracket  122  is fastened to the elastic element  108 . The bracket  122  serves the accommodation of a headlight unit (not shown in the figures) as well as the fastening of a bumper (see  FIG. 4 ). Both the headlight unit and the bumper are fastened thereon in relation to an upper edge  132  of the bracket  122  in order to achieve a high-quality joint pattern.  
         [0029]     In a position that is removed from the side  110 —in the embodiment shown here on the bottom of the side  116 —the elastic element  108  comprises a holder  143  for an assembly screw. After the support part  102  has been pre-assembled to the chassis, i.e. for example mounted to the longitudinal support  106 , of the motor vehicle and the bracket  120  has been pre-assembled to one of the fender sides by means of the positioning pin  126 , a hood (see  FIG. 4 ) of the motor vehicle is closed in order to apply deformation forces on the support surface  118 . As a result, the elastic element  108  is deformed in the z direction.  
         [0030]     In this deformed position, a screw connection is tightened through the holder  134  in order to fix the elastic element in the deformed position. The holder  134  can be screwed to the support part  102  or to a part of the chassis of the motor vehicle, for example. As a result, tolerance compensation in the z direction can be achieved, so that a high-quality joint pattern can be implemented in relation to the hood, without the otherwise frequently required adjustment of the locking device for the hood and/or other adjustments.  
         [0031]      FIG. 1  illustrates for clarity reasons only the right side of the support with the right elastic element  108  and the right bracket  122 . The support part  102  extends to the left side of the vehicle and comprises there a corresponding left elastic element and left bracket, which are disposed symmetrically to the components shown in  FIG. 1 .  
         [0032]     The support part  102  is made of metal or a hybrid material, for example. The elastic element  108  and the bracket  122  are preferably injection-molded parts, made of polypropylene or polyethylene for example.  
         [0033]      FIG. 2  shows another embodiment. Elements from  FIG. 2  that correspond to elements from  FIG. 1  have been marked with a reference numeral that has been increased by  100 . In the embodiment of  FIG. 2 , the elastic element  224  connects the support part  202  and the elastic element  208 . This is an alternative to the configuration of the corresponding elastic element  124  according to the embodiment from  FIG. 1 .  
         [0034]      FIG. 3  shows another embodiment of the configuration of the elastic element  324 . Elements from  FIG. 3  that correspond to elements from  FIG. 2  have been marked accordingly with a reference numeral that has been increased by another  100 .  
         [0035]      FIG. 4  shows another embodiment of the inventive support  400 . Elements of the embodiment from  FIG. 4  that correspond to elements of the embodiments from  FIGS. 1, 2  and/or  3  have been marked with an accordingly higher reference numeral.  FIG. 4  illustrates the support  400  in the non-deformed state as well as following the deformation, which is shown with dotted lines.  
         [0036]     On the upper side  414  of the support  400  a support element  418  is disposed, which is made of rubber or plastic, for example. A bumper  440  is fastened to the elastic element  408  and/or to the bracket, which is not shown in  FIG. 4 , by means of a fastening element  438 . Pre-assembly of the support  400  takes place with an open hood  442  of the motor vehicle. After the support  400  with the support part  402  has been pre-assembled to the chassis of the motor vehicle, the hood  442  is closed, thus allowing it to apply deformation forces  444  onto the elastic element  408  via the support element  418 . As a result of these deformation forces, the elastic element  408  is moved into the dotted deformed position. The elastic element  408  is fixed in this position, for example by means of a suitable screw connection (see for example the holders  134 ,  234  and  334  in  FIGS. 1, 2  or  3 ).  
         [0037]     In the non-deformed position, the sides of the elastic element  408  located on top of each other, i.e. sides  410  and  414  enclose an angle that is greater than 90 degrees so that the side  414  protrudes slightly upward. This ensures that the elastic element  408  is definitely deformed when closing the hood  442 .  
         [0038]     Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.  
       REFERENCE NUMERAL LIST  
       [0000]    
       
           100  Support  
           102  Support Part  
           104  Mount  
           106  Longitudinal Support  
           108  Elastic Element  
           110  Side  
           112  Side  
           114  Side  
           116  Side  
           118  Support Surface  
           120  Direction of Arrow  
           122  Bracket  
           124  Elastic Element  
           126  Positioning Pin  
           128  Arrow  
           130  Arrow  
           132  Upper Edge  
           134  Holder  
           200  Support  
           202  Support Part  
           208  Elastic Element  
           210  Side  
           212  Side  
           214  Side  
           216  Side  
           222  Bracket  
           224  Elastic Element  
           232  Upper Edge  
           234  Holder  
           300  Support  
           302  Support Part  
           308  Elastic Element  
           310  Side  
           312  Side  
           314  Side  
           316  Side  
           322  Bracket  
           324  Elastic Element  
           332  Upper Edge  
           334  Holder  
           400  Support  
           402  Support Part  
           408  Elastic Element  
           410  Side  
           412  Side  
           414  Side  
           416  Side  
           418  Support Element  
           438  Fastening Element  
           440  Bumper  
           442  Hood  
           444  Deformation Forces