Component integration panel system with closed box section

The present invention relates to a component that will complete a vehicle's front end structure while providing component integration and attachment features.

There are many components that are attached to the front end of a motor vehicle. Objects such as headlamps, turn signals, and a grille, are all connected to the front end of a vehicle through various methods. Additionally, there are mechanical components underneath the hood of the vehicle that are also connected to the front end of the vehicle such as the radiator, wiring harnesses, and even a washer fluid or coolant overflow container. Often, these various vehicle devices are connected to a single component which is mounted onto to the vehicle frame. Conventional methods of producing this component utilize stamped steel box sections in conjunction with plastic to complete what is called a steel section or structure. This approach gives greater design flexibility, but lacks structure for high load applications, such as use with body on frame vehicles. The term “body on frame” is defined as the vehicle body and the frame of the vehicle being designed as two separate components which are assembled together during the manufacturing process. The frame of the vehicle is typically very rigid and provides for a solid structure on which various vehicle components, such various body panels, or the engine, can be mounted. Also, the frame often has higher impact requirements, as well as other more stringent design requirements. A second type of frame which is also very common and used in a vehicle is called a “unibody”. This type of frame is an integration of the body and the frame of the vehicle into a single component.

The type of structure utilized for supporting all the components that are attached to the front end of a vehicle often does not meet the desired requirements for vehicles that have a frame which is separate from the body. Accordingly, there exists a need for an improved structure which allows for greater design flexibility when supporting the components that are attached to the front end of a vehicle.

The present invention is directed to a carrier which allows for improved structure and support of the front end of a motor vehicle as well as having the ability to support all the various vehicle components. The present invention is a carrier for improving the strength of the front end of a vehicle having an upper cross member which incorporates a closed box section, a composite integration panel connected to the upper cross member, and a lower cross member which also has a closed box section and is also connected to the composite integration panel. The closed box section of the upper cross member, and the closed box section of the lower cross member allow the component integration panel to be attached to the front end of a motor vehicle for supporting various vehicle components. The carrier improves strength and rigidity, as well as provides support for any particular vehicle component which needs to be attached to the front end.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is an exploded view of the front end of a motor vehicle incorporating a carrier according to the present invention;

FIG. 2 is a first front perspective view of a carrier according to the present invention;

FIG. 3 is a sectional side view of an upper cross member having steel closed box section and a component integration panel according to the present invention;

FIG. 4 is a second front perspective view of a carrier according to the present invention;

FIG. 5 is a third front perspective view of a carrier according to the present invention;

FIG. 6 is a first perspective rear view of a carrier according to the present invention; and

FIG. 7 is a second perspective rear view of a carrier according to the present invention.

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The front end assembly of a motor vehicle incorporating a carrier according to the present invention is shown in FIG. 1 generally at 10 . The carrier 12 is able to support various vehicle components. In FIG. 1 , the carrier 12 is able to support a grille 14 , headlights 16 , turn signal lights 18 , a radiator 20 which has a radiator hose 22 , a radiator fan shroud 24 , washer fluid bottle 26 , a wiring harness 28 , a lower air seal 30 , a hood seal 32 , an upper air seal 34 , a prop rod 36 , a temperature sensor 38 , an airbag sensor 40 , a horn 42 , and a relay 44 .

Referring now to FIG. 2 , the carrier 12 has an upper cross-member 46 having a closed box section 48 . The upper cross-member 46 is connected to a composite integration panel 50 . Also connected to the composite integration panel 50 is a lower cross-member 52 , which also includes a closed box section 54 .

The upper cross-member 46 can be connected to the composite integration panel 50 through the use of conventional fastening methods, such as bonding or riveting. In this embodiment, the upper cross-member 46 is connected to the composite integration panel 50 through the use of bonds and rivets 56 . The upper cross-member 46 is bonded to the composite integration panel 50 first, and the rivets 56 are then used to hold the upper cross-member 46 and the composite integration panel 50 together while the bond cures. The lower cross-member 52 is connected to the composite integration panel 50 through the use of mounting plates 58 . The mounting plates 58 are welded to the lower cross-member 52 , and the mounting plates 58 are connected to the composite integration panel 50 through the use of conventional rivets 60 . Once again, other conventional fastening methods may be used, such as bonding or a nut and bolt, instead of the rivet 60 .

The upper cross-member 46 , the lower cross-member 52 , and the composite integration panel 50 all have various apertures and recesses which can be used to connect the carrier 12 to the front end of a motor vehicle incorporating a “body on frame design.” Vehicles having a body on frame design utilize a frame which is a separate component from the body of the vehicle, as opposed to vehicles incorporating a unibody design in which the body and the frame are incorporated into a single structure. The carrier 12 is connected to the frame of a vehicle, and the closed box section 48 of the upper cross-member 46 and the closed box section 54 of the lower cross-member 52 provide increased strength and rigidity to the carrier 12 , allowing the carrier to support the various components of the vehicle shown in FIG. 1 , as well as increase the overall strength of a vehicle frame.

Also, the upper cross-member 46 and the lower cross-member 52 are manufactured through a forming process. This allows the shape of the upper cross-member 46 and the lower cross-member 52 to be altered to allow both the upper cross-member 46 and the lower cross-member 52 to be connected to any type of vehicle frame.

To also aid in making the carrier 12 adaptable for different types of vehicle frames, the composite integration panel 50 is made of a thermoplastic material, which can be molded to be incorporated with an upper cross-member 46 or lower cross-member 52 of any shape or size. The composite integration panel 50 can also be an open C-section or L-section utilized in conjunction with the upper cross-member 46 and the lower cross-member 52 . Referring to FIG. 3 , the composite integration panel 50 is in the form of a C-section, having a lower panel 64 , an upper panel 66 , and a side panel 68 . The lower panel 64 , upper panel 66 , and side panel 68 generally form the C-section; this C-section is along both sections of the composite integration panel 50 which receive the upper cross-member 46 and lower cross-member 52 . In FIG. 3 , the C-shape of the composite integration panel 50 receives the closed box section 48 of the upper cross-member 46 .

As previously stated, the composite integration panel 50 could also be in the form of an L-section. This L-section is formed in a similar manner to the C-section shown in FIG. 3 , with the exception that the upper panel 66 , or lower panel 64 , is removed, and the lower panel 64 and side panel 68 remain to form the L-section.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.