Patent Description:
In the design of a frame portion of a vehicle, there is a compromise between weight and strength. An advantageous manner of obtaining a good compromise is to produce a frame portion from one or more metal plates, or metal alloy plates, formed into a requested shape, e.g. a hat profile.

In general, a frame portion of a vehicle is formed to have a certain rigidity since it may receive various impacts from the outside. At the same time, some frame portions should allow deformation for absorbing impacts, or absorbing energy from impacts, when receiving an overload, e.g. due to a collision with an external object, e.g. another vehicle or a stationary object, e.g. a tree. One example of a vehicle frame portion that should be allowed to deform for absorbing impacts while being rigid is the bumper beam structure, or the vehicle crash box attaching the bumper beam to the vehicle.

<CIT> is the closest prior art and discloses: a vehicle crash box for attaching a bumper beam to a vehicle, wherein the vehicle crash box is attachable to the vehicle, wherein the vehicle crash box comprises a tubular member having a longitudinal extension extending in a longitudinal direction, wherein the tubular member comprises one or more longitudinal walls having a longitudinal extension extending in the longitudinal direction, wherein the vehicle crash box comprises one or more flanges integrally formed with one or more longitudinal walls of the one or more longitudinal walls of the tubular member whereas the one or more flanges and the one or more longitudinal walls are formed from a single piece.

The inventor of the present invention has found drawbacks in conventional solutions for vehicle crash boxes. For example, the inventor of the present invention has found that some conventional solutions for vehicle crash boxes do not provide a sufficient resistance to high loads during a collision.

An object of the invention is to provide a solution which mitigates or solves drawbacks and problems of conventional solutions.

The above and further objects are solved by the subject matter of the independent claim. Further advantageous embodiments of the invention can be found in the dependent claims.

According to a first aspect of the invention, the above mentioned and other objects are achieved with a vehicle crash box for attaching a bumper beam to a vehicle,.

An advantage of the vehicle crash box according to the first aspect is that the rigidity and reinforcement of a vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect for attaching a bumper beam to a vehicle is improved in order to prevent penetration upon collisions while maintaining or providing an advantageous deformation of the vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect for absorbing impacts, or absorbing energy from impacts.

By means of the innovative flange having one or more oblong openings, the vehicle crash box can be efficiently attached to the bumper beam by way of one or more welds in order to improve the rigidity and reinforcement of the vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect. By means of the innovative flange having one or more oblong openings, the amount of weld in the interface of attachment between the vehicle crash box and the bumper beam, which is subjected to high loads upon a collision, for example a high-speed collision, can be increased, and thereby the strength of said interface of attachment can be increased. Thus, an advantage of the vehicle crash box according to the first aspect is that the interface for the attachment of the vehicle crash box to the bumper beam is improved and strengthened. An advantage of the vehicle crash box according to the first aspect is that the weld-interface for the attachment of the vehicle crash box to the bumper beam is improved and strengthened. The increased amount of weld in the interface for attaching the vehicle crash box to the bumper beam made possible by the innovative flange having one or more oblong openings improves and reinforces the attachment of the vehicle crash box to the bumper beam while maintaining or providing an advantageous deformation of the vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect for absorbing impacts or absorbing impact energy. An advantage of the vehicle crash box according to the first aspect is that a failure of a weld joint attaching the vehicle crash box to a bumper beam is prevented, or that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is improved.

An advantage of the vehicle crash box according to the first aspect is that the performance of a vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect in collisions is improved, for example because the vehicle bumper structure including the vehicle crash box is made more rigid and more resistance to high loads while the vehicle bumper structure and the vehicle crash box can be deformed in a more controlled and more predicted manner.

An advantage of the vehicle crash box according to the first aspect is that an improved vehicle crash box is provided. An advantage of the vehicle crash box according to the first aspect is that an improved vehicle bumper structure including one or more vehicle crash boxes is provided.

The vehicle crash box may be a vehicle crash box for a motor vehicle with a combustion engine, an electric vehicle having one or more electrical machines and one or more electric batteries, or a hybrid vehicle including both a combustion engine and one or more electrical machines. For example, the vehicle may be a car or a truck.

According to an advantageous embodiment of the vehicle crash box according to the first aspect, the tubular member forms a closed space,
wherein the oblong opening of the flange is located outside the closed space.

An advantage of this embodiment is that the process of welding the vehicle crash box to a bumper beam is facilitated. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved. A "closed space" mentioned above also includes spaces which are substantially, or essentially, closed. For example, there may one or more minor through-holes in one or more longitudinal walls of the tubular member, and/or the ends of the tubular member may be at least partly open.

According to a further advantageous embodiment of the vehicle crash box according to the first aspect, the tubular forms a closed space,
wherein the flange is located outside the closed space.

An advantage of this embodiment is that the process of welding the vehicle crash box to a bumper beam is facilitated. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to another advantageous embodiment of the vehicle crash box according to the first aspect, the bumper beam comprises a first end, a second end and a middle, or intermediate, section located between the first and second ends,.

Thus, according to this embodiment, the flange together with the one or more oblong openings and the associated one or more welds are located toward one of the ends of the bumper beam when the vehicle crash box is attached to the bumper beam. The inventor of the invention has found that the loads on the interface for the attachment of the vehicle crash box to the bumper beam are especially high at this location upon a collision, for example a high-speed collision. Thus, by way of this embodiment, an increased amount of weld for attaching the vehicle crash box to the bumper beam can be applied here via the one or more oblong openings. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to yet another advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a transverse extension extending in a lateral direction in relation to the longitudinal direction. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to still another advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a transverse extension extending in a direction transverse to the longitudinal direction. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to an advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a transverse extension extending in a direction transverse to the longitudinal wall integrally formed with the flange. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to a further advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a longitudinal extension extending in a direction transverse to the longitudinal direction. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the longitudinal direction is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the longitudinal direction is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to another advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a longitudinal extension extending in the longitudinal direction. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the longitudinal direction is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the longitudinal direction is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to still an advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in the direction of the longitudinal extension of the flange. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the direction of the longitudinal extension of the flange is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the direction of the longitudinal extension of the flange is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to yet another advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in a direction transverse to the direction of the longitudinal extension of the flange. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the direction of the longitudinal extension of the flange is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the direction of the longitudinal extension of the flange is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to an advantageous embodiment of the vehicle crash box according to the first aspect, the flange has a longitudinal extension extending in a direction parallel to the longitudinal wall integrally formed with the flange. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to a further advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in a direction transverse to the longitudinal direction. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the longitudinal direction is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the longitudinal direction is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to another advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in the longitudinal direction. An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the longitudinal direction is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the longitudinal direction is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to yet another advantageous embodiment of the vehicle crash box according to the first aspect, the bumper beam has a longitudinal extension configured to extend in a direction transverse to the longitudinal direction,
wherein the oblong opening has a longitudinal extension extending in a direction transverse to the direction of the longitudinal extension of the bumper beam.

An advantage of this embodiment is that movement of the flange and of the vehicle crash box in relation to the bumper beam, or forces on the interface of attachment between the vehicle crash box and the bumper beam, in a direction transverse to the direction of the longitudinal extension of the bumper beam, for example in a vertical direction when the vehicle crash box is mounted to a vehicle having wheels resting on the ground, is further prevented or further counteracted. However, movement of the flange in relation to the bumper beam, and/or forces on the interface of attachment between the vehicle crash box and the bumper beam, in the direction of the longitudinal extension of the bumper beam is/are also prevented or counteracted by way of this embodiment. An advantage of this embodiment is that the resistance to a failure of a weld joint attaching the vehicle crash box to a bumper beam is further improved. An advantage of this embodiment is that the attachment of the vehicle crash box to a bumper beam by way of one or more welds in order to improve the reinforcement of the vehicle bumper structure including the vehicle crash box is further improved. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to still another advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in a direction parallel to the longitudinal wall integrally formed with the flange. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to an advantageous embodiment of the vehicle crash box according to the first aspect, the oblong opening has a longitudinal extension extending in a direction transverse to the longitudinal wall integrally formed with the flange. An advantage of this embodiment is that the performance of a vehicle bumper structure including one or more crash boxes according to this embodiment in collisions is further improved.

According to a further advantageous embodiment of the vehicle crash box according to the first aspect, the flange is configured for the attachment to a U-shaped member of the bumper beam, the U-shaped member having a U-shaped cross-section and being configured to open away from the tubular member in the longitudinal direction. An advantage of this embodiment is that the performance of a vehicle bumper structure including a bumper beam having a U-shaped member and one or more crash boxes according to this embodiment in collisions is further improved.

According to another advantageous embodiment of the vehicle crash box according to the first aspect, the U-shaped member of the bumper beam has a convex side and a concave side, and wherein the flange is configured for the attachment to the convex side of the U-shaped member. An advantage of this embodiment is that the performance of a vehicle bumper structure including a bumper beam having a U-shaped member and one or more crash boxes according to this embodiment in collisions is further improved.

According to yet another advantageous embodiment of the vehicle crash box according to the first aspect, the flange and the one or more longitudinal walls integrally formed with the flange are formed from a plate. This is an efficient way to produce the flange and the longitudinal wall integrally formed therewith.

According to still another advantageous embodiment of the vehicle crash box according to the first aspect, one or more of the tubular member and vehicle crash box comprises/comprise or consists/consist of a metal or a metal alloy. This is an efficient way to produce a strong tubular member or a strong vehicle crash box.

According to a second aspect of the invention, the above mentioned and other objects are achieved with a vehicle bumper structure comprising.

Advantages of the vehicle bumper structure according to the second aspect correspond to advantages of the vehicle crash box according to the first aspect and its embodiments mentioned above or below and are thus not repeated here.

Advantages of the below-mentioned embodiments of the vehicle bumper structure according to the second aspect correspond to advantages of the embodiments of the vehicle crash box according to the first aspect mentioned above or below and are thus not repeated hereinbelow.

According to an advantageous embodiment of the vehicle bumper structure according to the second aspect, the bumper beam comprises a U-shaped member having a U-shaped cross-section, wherein the U-shaped member is configured to open away from the tubular member in the longitudinal direction.

The above-mentioned features and embodiments of the vehicle crash box and the vehicle bumper structure may be combined in various possible ways providing further advantageous embodiments.

Further advantageous embodiments of the vehicle crash box and the vehicle bumper structure according to the present invention and further advantages with the embodiments of the present invention emerge from the detailed description of embodiments.

Embodiments of the invention will now be illustrated, for exemplary purposes, in more detail by way of embodiments and with reference to the enclosed drawings, where similar references are used for similar parts, in which:.

With reference to <FIG> and <FIG>, two first embodiments of the vehicle crash box 100a, 100b for attaching, or for the attachment of, a bumper beam <NUM> to a vehicle <NUM> (see <FIG>) according to the first aspect of the invention are schematically illustrated. Further, a first embodiment of the vehicle bumper structure <NUM> according to the second aspect of the invention is schematically illustrated. The bumper beam <NUM> may be provided at the front of the vehicle <NUM> or at the rear of the vehicle <NUM>. For some embodiments, the bumper beam <NUM> may be referred to as a cross beam.

In <FIG>, the vehicle crash box 100a to the left in <FIG> and <FIG> is schematically illustrated in further detail. In <FIG> and <FIG>, the vehicle crash box 100b to the right in <FIG> and <FIG> is schematically illustrated in further detail.

With reference to <FIG>, the vehicle crash box 100a, 100b is attachable to a vehicle <NUM>, for example a motor vehicle with a combustion engine, an electric vehicle having one or more electrical machines and one or more electric batteries, or a hybrid vehicle including both a combustion engine and one or more electrical machines. For example, the vehicle <NUM> may be a car or a truck.

With reference to <FIG>, the vehicle crash box 100a includes a tubular member <NUM>. The tubular member <NUM> has a longitudinal extension <NUM> extending in a longitudinal direction <NUM>. The tubular member <NUM> includes one or more longitudinal walls 108a-d. The longitudinal wall 108a-d has a longitudinal extension 110a-d extending in the longitudinal direction <NUM>. It may be defined that the tubular member <NUM> forms, or defines, a closed space <NUM>. For some embodiments, it may be defined that the one or more longitudinal walls 108a-d forms/form, or defines/define, the closed space <NUM>. For some embodiments, the closed space <NUM> may be described as a room or a compartment. A "closed space" <NUM> mentioned above also includes spaces which are substantially, or essentially, closed. For example, there may one or more minor through-holes in one or more longitudinal walls 108a-d of the tubular member <NUM>, and/or the ends of the tubular member <NUM> may be at least partially open.

With reference to <FIG>, for some embodiments, the vehicle crash box 100a, 100b may be attachable to the vehicle <NUM>, for example to the chassis of the vehicle <NUM>, via an attachment <NUM>, which may be attached, or joined, to the tubular member <NUM>. The attachment <NUM> is attachable to the vehicle <NUM>, for example to the chassis of the vehicle <NUM>. However, other forms of attachment of the vehicle crash box 100a, 100b to the vehicle <NUM> are possible. The attachment <NUM> may be attached to the vehicle by way of various means of attachment, for example bolts, threads, welds etc..

With reference to <FIG>, the vehicle crash box 100a includes one or more flanges <NUM> integrally formed with one or more longitudinal walls 108a-d of the one or more longitudinal walls 108a-d of the tubular member <NUM>. In the embodiment illustrated in <FIG>, the vehicle crash box 100a includes one flange <NUM> integrally formed with one longitudinal wall 108a of the one or more longitudinal walls 108a-d of the tubular member <NUM>. However, for alternative embodiments, the vehicle crash box 100a may include a plurality of flanges integrally formed with one or more longitudinal walls 108a-d of the one or more longitudinal walls 108a-d of the tubular member <NUM>, for example integrally formed with one longitudinal wall of the one or more longitudinal walls 108a-d of the tubular member <NUM>, or integrally formed with two or more longitudinal walls of the one or more longitudinal walls 108a-d of the tubular member <NUM>. For some embodiments, the flange <NUM> may be referred to as a side flange, or a lateral flange.

The fact that the flange <NUM> is integrally formed with a longitudinal wall 108a implies, or means, that the flange <NUM> and the longitudinal wall 108a are formed into a single piece and/or are formed from a single piece. For example, a blank, or any other suitable piece, may be formed into the longitudinal wall 108a and the flange <NUM> integrally formed therewith, by way of hot press forming, or cold working. Expressed alternatively, the fact that the flange <NUM> is integrally formed with a longitudinal wall 108a may imply, or may mean, that the flange <NUM> and the longitudinal wall 108a are made of a single piece, for example a single blank.

With reference to <FIG>, the flange <NUM> forms one or more oblong openings 116a-c, or oblong through-holes, for one or more welds for the attachment of the flange <NUM> to the bumper beam <NUM>. In the embodiment illustrated in <FIG>, the flange <NUM> forms three oblong openings 116a-c for one or more welds. However, for alternative embodiments, the flange <NUM> may form fewer or more oblong openings than three oblong openings 116a-c. For some embodiments, the flange <NUM> may be described to comprise one or more inner walls, wherein one or more of the one or more inner walls of the flange <NUM> may define the one or more oblong openings 116a-c. For some embodiments, two or more oblong openings may extend parallel to one another, or side by side.

With reference to <FIG>, in the illustrated embodiment, the oblong opening 116a-c of the flange <NUM> is located outside, or is external to, the closed space <NUM>. In the illustrated embodiment, the flange <NUM> is located outside, or is external to, the closed space <NUM>. However, for alternative embodiments, the oblong opening of the flange and/or the flange may be located inside the closed space <NUM>.

With reference to <FIG>, the flange <NUM> and the one or more longitudinal walls 108a-d integrally formed with the flange <NUM> may be formed from a plate. The tubular member <NUM> may comprise or consist of a metal or a metal alloy. The vehicle crash box 100a may comprise or consist of a metal or a metal alloy. However, other materials are also possible.

With reference to <FIG> and <FIG>, the illustrated bumper beam <NUM> has a first end <NUM>, a second end <NUM> and a middle section <NUM>, or intermediate section. The middle section <NUM> is located between the first end <NUM> and the second end <NUM>. For some embodiments, the vehicle crash box 100a is configured to position the tubular member <NUM> between the first end <NUM> of the bumper beam <NUM> and the middle section <NUM> of the bumper beam <NUM>, and the vehicle crash box 100a is configured to position the flange <NUM> between the first end <NUM> of the bumper beam <NUM> and the tubular member <NUM>. Thus, according to this embodiment, the flange <NUM> together with the one or more oblong openings 116a-c and the associated one or more welds are located toward one <NUM> of the first and second ends <NUM>, <NUM> of the bumper beam <NUM> when the vehicle crash box 100a is attached to the bumper beam <NUM>. As mentioned above, the inventor of the invention has found that the loads on the interface for the attachment of the vehicle crash box 100a to the bumper beam <NUM> are especially high at this location, i.e. close to the end <NUM>, <NUM> of the bumper beam <NUM>, upon a collision, for example a high-speed collision. Thus, it is advantageous to provide an increased amount of weld for the attachment of the vehicle crash box 100a to the bumper beam <NUM> at this location. However, for alternative embodiments, the vehicle crash box 100a may be configured to position the flange <NUM> between the middle section <NUM> of the bumper beam <NUM> and the tubular member <NUM>, i.e. toward the middle section <NUM> of the bumper beam <NUM>.

With reference to <FIG> and <FIG>, for some embodiments, the tubular member <NUM> may include two or more sections 102a, 102b, for example two or more longitudinal sections 102a, 102b. The two or more sections 102a, 102b may be lateral sections 102a, 102b. Each section 102a, 102b of the tubular member <NUM> may include one or more of the one or more longitudinal walls 108a-d and/or include one or more portions of the one or more longitudinal walls 108a-d. In the illustrated embodiment, the section 102a of the tubular member <NUM> may be described as an outer section 102a, i.e. the outer section 102a is closer to the first end <NUM> of the bumper beam <NUM> in relation to the other section 102b of the tubular member <NUM>, which may referred to as an inner section 102b, when the vehicle crash box 100a is configured to position the tubular member <NUM> between the first end <NUM> of the bumper beam <NUM> and the middle section <NUM> of the bumper beam <NUM>. The two or more sections 102a, 102b may be joined, or attached, to one another by way of welding, or by any other means of attachment, for example an adhesive. In the illustrated embodiment, the outer section 102a of the tubular member <NUM> includes the longitudinal wall 108a which is integrally formed with the flange <NUM>. In the illustrated embodiment, each section 102a, 102b of the tubular member <NUM> is substantially U-shaped.

With reference to <FIG>, the flange <NUM> may be described to have a transverse extension <NUM> extending in a lateral direction <NUM> in relation to the longitudinal direction <NUM>. The flange <NUM> may be described to have a transverse extension <NUM> extending in a direction <NUM> transverse to the longitudinal direction <NUM>. The flange <NUM> may be described to have a transverse extension <NUM> extending in a direction <NUM> transverse to the longitudinal wall 108a integrally formed with the flange <NUM>.

With reference to <FIG>, the flange <NUM> may be described to have a longitudinal extension <NUM> extending in a direction <NUM> transverse to the longitudinal direction <NUM>. The flange <NUM> may be described to have a longitudinal extension <NUM> extending in the longitudinal direction <NUM>, or in a direction <NUM> parallel to the longitudinal direction <NUM>. In the embodiment illustrated in figures <NUM> to <NUM>, the longitudinal extension <NUM> of the flange <NUM> extends both in a direction <NUM> transverse to the longitudinal direction <NUM> (the middle portion of the longitudinal extension <NUM>) and in the longitudinal direction <NUM> (the two end portions of the longitudinal extension <NUM>). Thus, the flange <NUM> in <FIG> forms a U-shape when viewed from the side, or when viewed in a direction <NUM> transverse to the longitudinal direction <NUM> and in the direction <NUM> of the longitudinal extension <NUM> of the bumper beam <NUM>. For some embodiments, the flange <NUM> may be described to have a longitudinal extension <NUM> extending in a direction <NUM>, <NUM> parallel to the longitudinal wall 108a integrally formed with the flange <NUM>.

With reference to <FIG>, for some embodiments, the oblong opening 116a-c has a longitudinal extension 124a-c extending in the direction <NUM>, <NUM> of the longitudinal extension <NUM> of the flange <NUM>. For alternative embodiments, the oblong opening may have a longitudinal extension extending in a direction <NUM> transverse to the direction <NUM>, <NUM> of the longitudinal extension <NUM> of the flange <NUM>. The oblong opening 116b may have a longitudinal extension 124b extending in a direction <NUM> transverse to the longitudinal direction <NUM>. The oblong opening 116a, 116c may have a longitudinal extension 124a, 124c extending in the longitudinal direction <NUM>, or in a direction <NUM> parallel to the longitudinal direction <NUM>. For some embodiments, it may be defined that the longitudinal extension 124a-c of the oblong opening 116a-c exceeds the width, or the transverse extension, of the oblong opening 116a-c. For some embodiments, the longitudinal extension 124a-c of the oblong opening 116a-c is at least twice as long as the width of the oblong opening 116a-c. For alternative embodiments, the longitudinal extensions of two or more oblong openings may extend side by side. For some embodiments, the longitudinal extension 124a-c of one or more oblong openings 116a-c may be straight, or substantially straight. For some embodiments, the longitudinal extension of one or more oblong openings may be curved, and may, for example, form a curve. For some embodiments, it may be described that the one or more oblong openings 116a-c is/are straight or curved.

With reference to <FIG>, the bumper beam <NUM> has a longitudinal extension <NUM> configured to extend in a direction <NUM> transverse to the longitudinal direction <NUM>. The oblong opening 116a-c may be described to have a longitudinal extension 124a-c extending in a direction <NUM>, <NUM> transverse to the direction <NUM> of the longitudinal extension <NUM> of the bumper beam <NUM>.

With reference to <FIG>, the oblong opening 116a-c may be described to have a longitudinal extension 124a-c extending in a direction parallel to the longitudinal wall 108a integrally formed with the flange <NUM>. For alternative embodiments, the oblong opening may have a longitudinal extension extending in a direction <NUM> transverse to the longitudinal wall 108a integrally formed with the flange <NUM>.

With reference to <FIG>, for some embodiments, the flange <NUM> may be configured for the attachment to a U-shaped member <NUM> of the bumper beam <NUM>. The U-shaped member <NUM> has a U-shaped cross-section and is configured to open away from, or configured to open in a direction <NUM> away from, the tubular member <NUM> in the longitudinal direction <NUM>. The U-shaped member <NUM> of the bumper beam <NUM> may be defined to have a convex side <NUM> and a concave side <NUM>. The flange <NUM> may be configured for the attachment to the convex side <NUM> of the U-shaped member <NUM> of the bumper beam <NUM>. For some embodiments, the U-shaped member <NUM> may be referred to as a cross member.

With reference to <FIG> and <FIG>, and as mentioned above, a first embodiment of the vehicle bumper structure <NUM> according to the second aspect of the invention is schematically illustrated. The vehicle bumper structure <NUM> includes a bumper beam <NUM> according any one of the embodiments disclose above or below. The vehicle bumper structure <NUM> includes one or more vehicle crash boxes 100a, 100b, for example two vehicle crash boxes 100a, 100b, according to any one of the embodiments disclose above or below. For embodiments of the vehicle bumper structure <NUM>, the vehicle crash boxes 100a, 100b may be defined to be attached to the bumper beam <NUM>, for example via the one or more flanges <NUM>, for example by way of one or more welds. For embodiments of the vehicle bumper structure <NUM> and as mentioned above, the bumper beam <NUM> may include a U-shaped member <NUM> having a U-shaped cross-section and being configured to open away from the tubular member <NUM> in the longitudinal direction <NUM>.

For some embodiments, two or more welds may be applied in parallel in the same oblong opening 116a-c. For example, the one or more welds may be applied by way of MIG (metal inert gas), MAG (metal active gas), or CMT (cold metal transfer), welding, or by way of any other suitable welding procedure.

With reference to <FIG> and <FIG>, for some embodiments, the vehicle bumper structure <NUM> may comprise the one or more welds. For some embodiments of the vehicle bumper structure <NUM>, it may be defined that the flange <NUM> is attached to the bumper beam <NUM>, and thus attaching the vehicle crash box 100a, 100b to the bumper beam <NUM>, for example by way of the one or more welds.

For some embodiments, the bumper beam <NUM> may include, or may be provided with, one or more patches, for example attached to the convex side <NUM> of the U-shaped member <NUM> of the bumper beam <NUM>. When such a patch is present, the flange <NUM> may be attachable, or attached, to said patch.

With reference to <FIG> and <FIG>, the vehicle crash box 100b to the right in <FIG> and <FIG> is schematically illustrated in further detail. The vehicle crash box 100b illustrated in <FIG> and <FIG> essentially corresponds to the vehicle crash box 100a of <FIG>. However, the vehicle crash box 100b in <FIG> and <FIG> is configured to position the tubular member <NUM> between the second end <NUM> of the bumper beam <NUM> and the middle section <NUM> of the bumper beam <NUM>, and the vehicle crash box 100b is configured to position the flange <NUM> between the second end <NUM> of the bumper beam <NUM> and the tubular member <NUM>. Thus, according to the embodiment of <FIG> and <FIG>, the flange <NUM> together with the one or more oblong openings 116a-c and the associated one or more welds are located toward the second end <NUM> of the bumper beam <NUM> when the vehicle crash box 100b is attached to the bumper beam <NUM>.

With reference to <FIG>, a second embodiment of the vehicle crash box <NUM> according to the first aspect of the invention and a second embodiment of the vehicle bumper structure <NUM> according to the second aspect of the invention are schematically illustrated. Several features of the the vehicle crash box <NUM> of <FIG> may correspond to features of the vehicle crash box 100a of <FIG>, and several features of the vehicle bumper structure <NUM> of <FIG> may correspond to features of the vehicle bumper structure <NUM> of <FIG> and <FIG> and are thus not described in further detail here to avoid repetition. The vehicle crash box <NUM> of <FIG> differs from the vehicle crash box 100a of <FIG> in that the vehicle crash box <NUM> comprises three flanges 414a-c integrally formed with one longitudinal wall 408a of the one or more longitudinal walls 408a-d of the tubular member <NUM>, wherein each flange 414a-c comprises an oblong opening 416a-b for one or more welds for the attachment of the flange 414a-c to a bumper beam <NUM> (the oblong opening of the lower flange 414c is not shown in <FIG>). The three flanges 414a-c are spaced apart from one another. Further, the vehicle crash box <NUM> of <FIG> differs from the vehicle crash box 100a of <FIG> in that the sections 402a, 402b of the tubular member <NUM> are configured and arranged in a different manner. Each section 402a, 402b of the tubular member <NUM> of <FIG> is substantially L-shaped.

With reference to <FIG>, a third embodiment of the vehicle crash box <NUM> according to the first aspect of the invention and a third embodiment of the vehicle bumper structure <NUM> according to the second aspect of the invention are schematically illustrated. Several features of the the vehicle crash box <NUM> of <FIG> may correspond to features of the vehicle crash box <NUM> of <FIG>, and several features of the vehicle bumper structure <NUM> of <FIG> may correspond to features of the vehicle bumper structure <NUM> of <FIG> and are thus not described in further detail here to avoid repetition. The vehicle crash box <NUM> of <FIG> differs from the vehicle crash box <NUM> of <FIG> in that the vehicle crash box <NUM> comprises only one flange 614b integrally formed with one longitudinal wall 608a of the one or more longitudinal walls 608a-d of the tubular member <NUM>. The flange 614b has a longitudinal extension 622b extending in a direction <NUM> transverse to the longitudinal direction <NUM>. The oblong opening 616b of the flange 614b of <FIG> has a longitudinal extension 624b extending in a direction <NUM> transverse to the longitudinal direction <NUM>. The oblong opening 616b of <FIG> has a longitudinal extension 624b extending in a direction <NUM> transverse to the direction <NUM> of the longitudinal extension of the bumper beam <NUM>.

With reference to <FIG>, a fourth embodiment of the vehicle crash box <NUM> according to the first aspect of the invention and a fourth embodiment of the vehicle bumper structure <NUM> according to the second aspect of the invention are schematically illustrated. Several features of the the vehicle crash box <NUM> of <FIG> may correspond to features of the vehicle crash box <NUM> of <FIG>, and several features of the vehicle bumper structure <NUM> of <FIG> may correspond to features of the vehicle bumper structure <NUM> of <FIG> and are thus not described in further detail here to avoid repetition. The vehicle crash box <NUM> of <FIG> differs from the vehicle crash box <NUM> of <FIG> in that the vehicle crash box <NUM> comprises only two flanges 814a, 814c integrally formed with one longitudinal wall 808a of the one or more longitudinal walls 808a-d of the tubular member <NUM>. Each one 814a, 814c of two flanges 814a, 814c has a longitudinal extension 822a extending in the longitudinal direction <NUM> and comprises an oblong opening 816a for one or more welds for the attachment of the flange 814a, 814c to a bumper beam <NUM> (the oblong opening of the lower flange 814c is not shown in <FIG>). The oblong opening 816a of the flange 814a, 814c of <FIG> has a longitudinal extension 824a extending in the longitudinal direction <NUM>. The oblong opening 816a of <FIG> has a longitudinal extension 824a extending in a direction <NUM> transverse to the direction <NUM> of the longitudinal extension of the bumper beam <NUM>.

Each one of the tubular members <NUM>, <NUM>, <NUM>, <NUM> illustrated above have four longitudinal walls. However, for alternative embodiments, the tubular member may comprise any other number of longitudinal walls. For example, the tubular member may have a circular or oval cross-section and may comprise one longitudinal wall. Other tubular members may have two or three longitudinal walls. Other tubular members may have more than four longitudinal walls.

The features of the different embodiments of the vehicle crash box and the vehicle bumper structure disclosed above may be combined in various possible ways providing further advantageous embodiments.

Claim 1:
A vehicle crash box (100a, 100b; <NUM>; <NUM>; <NUM>) for attaching a bumper beam (<NUM>) to a vehicle (<NUM>),
wherein the vehicle crash box (100a) is attachable to the vehicle (<NUM>),
wherein the vehicle crash box (100a) comprises a tubular member (<NUM>) having a longitudinal extension (<NUM>) extending in a longitudinal direction (<NUM>),
wherein the tubular member (<NUM>) comprises one or more longitudinal walls (108a-d) having a longitudinal extension (110a-d) extending in the longitudinal direction (<NUM>),
wherein the vehicle crash box (100a) comprises one or more flanges (<NUM>) integrally formed with one or more longitudinal walls (108a-d) of the one or more longitudinal walls (108a-d) of the tubular member (<NUM>) in that the one or more flanges (<NUM>) and the one or more longitudinal walls (108a-d) are formed from a single piece by way of hot press forming or cold working, and
wherein the flange forms one or more oblong openings (116a-c) for one or more welds for the attachment of the flange (<NUM>) to the bumper beam (<NUM>).