Front-end module

The present application claims priority 35 U.S.C. §119 to German Patent Publication No. DE 102014214561.9 (filed on Jul. 24, 2014), which is hereby incorporated by reference in its entirety.

Embodiments relate to a front-end module at least comprising a cross-member with crash boxes attached thereto and a mounting support arranged spaced apart therefrom and above said cross-member, wherein the mounting support is attached by way of support elements to the cross-member or the crash boxes.

Front-end modules for motor vehicles are known. A front-end module on a vehicle generally forms the front part of the body framework. The front-end module has upper and lower elements, which in each case are arranged horizontally on the upper end and the lower end, and at least one vertical element which vertically connects both the upper and the lower elements.

Thus a front-end module for a motor vehicle comprising a frame-shaped mounting support, a bumper cross-member arranged approximately in the central vertical region of the mounting support and connected thereto, an outer skin element and at least one impact absorption element between the mounting support and the outer skin element is disclosed in DE 100 42 037 A1.

A front-end module for a vehicle body having an additional element, which extends upwardly from the bumper cross-member, is disclosed in DE 10237454B3. (The directional information “upwardly” refers, as in the directional information used hereinafter, to the installed position of the front-end module in a motor vehicle.) The bumper cover is attached to the additional element.

FR 2935934 A1 discloses a mounting support to which support elements are attached, said support elements being supported on a bumper support. Said support elements are fixedly connected to the mounting support. A connecting element serves for this purpose, said connecting element being pushed through bores at the top of the support element and through bores on the mounting support.

A crash box is fastened to a mounting support in DE 102012019092 A1. The fastening takes place by way of retaining devices which are configured as T-pieces or bayonet closures.

DE 102012021746 A1 discloses a mounting support for a front-end module in a modular system which is designed for a vertical adaptation of the mounting support relative to the vehicle cross-member. In this case, support elements having different overall heights are used and connected to the mounting support.

Proceeding from such a modular principle for the adaptation of the overall heights of the mounting support above the cross-member, the object of embodiments is to produce a connection between different support elements and the mounting support which is simple to mount.

The object is achieved by a front-end module at least comprising a cross-member with crash boxes attached thereto and a mounting support arranged spaced apart therefrom and above said cross-member, wherein the mounting support is attached by way of support elements to the cross-member or to the crash boxes and the support elements having different overall heights are connected by clip connections to the mounting support.

In accordance with embodiments, a front-end module for a vehicle may include at least one of the following: a cross-member with crash boxes attached thereto; a mounting support arranged spaced apart therefrom and above said cross-member; and support elements to attach the mounting support to the cross-member or the crash boxes, wherein the support elements have different overall heights; and clip connections to connect the support elements to the mounting support.

In accordance with embodiments, a front-end module for a vehicle may include at least one of the following: a cross-member having crash boxes; a mounting support arranged spaced apart therefrom and above said cross-member, the mounting support including a mounting support body, an upper part and an upper flange; and support elements to attach the mounting support to the crash boxes, wherein the support elements are latched via a clip connection to the upper part, and includes an upper support which is supported on the upper part and a lower support which is supported on the crash boxes.

The support elements may be easily exchanged with one another by way of the clip connections between the mounting support and the support elements. Support elements having different heights may be used in order to adapt to the respective overall heights of the vehicle. Different types of support elements may also be used. The mounting is simplified by the clip connections.

In an advantageous embodiment of the front-end module the mounting support is made up of an upper mounting support flange and an upper mounting support part. Advantageously, the upper flange comprises metal.

It is also advantageous if the upper part comprises plastics. This hybrid structure of the mounting support permits a flexible production of the support, whilst optimizing the weight and the stability.

Advantageously, the mounting support is also produced entirely from plastics or from an assembly consisting of an organometallic sheet with metal or lightweight metal.

The mounting support may also be optimally produced entirely from plastics for the respective requirements, or from an organometallic sheet which is optionally reinforced with metal or lightweight metal components. The mounting support has to be at least partially sufficiently flexible for the clip connections so that a clip connection is maintained.

It is advantageous, therefore, that the upper mounting support part or the mounting support comprises a clip or recess for receiving a mating part on the support element in the form of an edge.

It is also advantageous if the upper mounting support part or the mounting support comprises a bearing lug for bearing a mating part on the support element in the form of a clip hook.

It is advantageous here if the support element is able to be clipped or received into the upper mounting support part or the mounting support in the y-direction in order to permit in this manner a simple mounting of the support elements.

In order to permit the clipping in a simple manner, the support element and the upper part or the mounting support are constructed so that the clip connection faces in the vehicle longitudinal direction.

Embodiments are described hereinafter by way of example with reference to the accompanying drawings.

FIG. 1 illustrates an exploded view of a front-end module, in accordance with embodiments.

FIG. 2 illustrates an assembled version of the front-end module of FIG. 1 .

FIG. 3 illustrates a support element of the front-end module, in accordance with embodiments.

FIGS. 4( a ) and 4( b ) illustrate sectional views of the front-end module, in accordance with embodiments.

FIG. 1 illustrates in an exploded view how the assembly of a front module of FIG. 2 is constructed. Serving as a basis is a cross-member 2 to which crash boxes 8 are attached to the left and to the right. At the top in the x-direction a mounting support 3 is positioned and fastened by support elements 4 on the crash boxes 8 .

The cross-member 2 is a component made of metal, and which may be produced in any manner known to the person skilled in the art. Fixedly connected to the cross-member 2 are crash boxes 8 which may also be produced from very different materials and in very different embodiments. In the example of FIG. 2 , the crash boxes 8 are connected via screw connections to the cross-member 2 . The mounting support 3 is produced in different ways. In the example of FIG. 1 , the mounting support 3 includes a mounting support body, an upper mounting support flange 6 composed of metal, and an upper mounting support part 7 composed of plastic. A lock support 5 for the engine bonnet is also able to be identified.

In accordance with embodiments, the support elements 4 are latched via clip connections to the upper mounting support part 7 . The upper mounting support flange 6 is produced in one piece from metal, but it is also possible to construct a three-part structure with a central part and two side parts. In a further advantageous embodiment, the upper mounting support flange 6 is constructed from an assembly of an organometallic sheet in the central part with aluminum side parts to the left and right thereof. Here, the assembly of the upper mounting support flange 6 is connected in each case to an upper mounting support part 7 .

In accordance with embodiments, the mounting support 3 is produced entirely from plastics, wherein a closed cross-section is produced using different welding methods. The support elements 4 are clipped in each case into the plastics.

As illustrated in FIG. 3 , the support element 4 is designed to be approximately L-shaped. The support element 4 in this case has an upper support element section 9 so as to be supported on the upper mounting support part 7 . The support element 4 is supported by way of a lower support element section 10 on the crash box 8 . The support element 4 has an upper edge 11 which extends approximately in the vehicle longitudinal axis

The type of clip connection between the two components may be seen from the further sectional views of FIGS. 4( a ) and ( b ) , which show a section through the mounting support and the support element. In FIG. 4( a ) , the upper edge 11 of the support element 4 may be seen, and is encompassed by a clip-like configuration. A recess 12 encompasses the entire length of the upper edge 11 of the support element 4 or even merely partial portions. The connection extends along the upper edge 11 of the support element 4 . In FIG. 4( b ) , it may be seen that the mounting support 3 on its lower face terminates in a bearing lug 13 configured in the vehicle transverse direction. The support element 4 has, on the other hand, a clip hook 14 along the upper edge 11 , said clip hook 14 extending along the edge in the z-direction.

When mounting the support element 4 in the lower face of the mounting support 3 , the support element 4 is inserted approximately in the y-direction as far as the clip connection and latched therein. Subsequently, the mounting support 3 may be connected to the crash box or the longitudinal member via the connections of the support element 4 which may have different configurations. By the use of clip connections the front-end module may be constructed with variants. In this case, different support elements 4 having different overall heights are clipped to the mounting support 3 .

The term “coupled” or “connected” may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms “first,” “second,” etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated.

Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

1 Front-end module

2 Cross-member

3 Mounting support

4 Support element

5 Lock support

6 Upper flange

7 Upper part

8 Crash box

9 Upper support

10 Lower/Crash box support

11 Upper edge

12 Clips

13 Bearing lug

14 Clip hook