A light-up bumper and its manufacturing process

Abstract

This invention relates to the field of automotive parts technology, and more particularly to a luminous bumper and its manufacturing process. The luminous bumper includes: a mounting bracket, a bumper body, and decorative lights; the mounting bracket includes a load-bearing bracket and a light bracket, with upper brackets on both sides of the load-bearing bracket, and the upper side of the light bracket is snapped onto the upper bracket; the bumper body includes end covers located on both sides, the end covers being mounted on the light brackets, and the end covers having luminous and non-luminous areas, the luminous areas being located outside the side impact area of ​​the bumper, avoiding the frontal and side impact areas of the bumper, and the luminous areas having laser-engraved patterns formed by fitting multiple dots and holes; the decorative lights are mounted inside the end covers. Optimizing the arrangement of the luminous areas of the bumper improves pedestrian safety, reduces production costs, and increases the yield rate.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile parts, in particular to a luminous bumper and a preparation process thereof. BACKGROUND

[0002] The luminous bumper is an automobile exterior part integrating lighting, signal prompting and decoration functions, mainly applied to the front or rear of the vehicle, and realizes the luminous effect through the combination of the built-in light source and the light-transmitting structure. The traditional luminous bumper usually adopts the way of installing independent light sources (such as fog lamps) by opening holes on the skin, and its working principle is to guide the light outward through the light-transmitting through hole or light-transmitting material. With the development of automobile intelligence, the luminous bumper is gradually endowed with functions such as welcome interaction, charging state display and music rhythm, but the existing technology has significant defects in structural safety, process complexity and cost control.

[0003] The existing technology is a hole type luminous bumper, and its typical structure includes a bumper skin, a light-transmitting blocking decoration part and a luminous assembly (such as 202210166520.4). The light-transmitting through hole is opened on the bumper skin, the light-transmitting blocking decoration part is located behind the skin, and the luminous assembly is arranged behind the decoration part, and the light is transmitted through the through hole. Another type of scheme (such as 202321978649.1) connects the bumper skin and the lamp shell with a lamp bracket, and a plurality of light-transmitting holes are opened on the skin, and the light is transmitted through the lamp shade. In addition, some technologies attempt to use conductive light-transmitting primer (such as 202410133392.2) to realize luminous, but there are problems of high material cost and complex process. In the existing paint spraying process, the laser engraving paint spraying process adopts sheet-shaped laser engraving to ensure the paint adhesion, and adopts secondary online spraying, which has low pass rate and high cost. Especially, the secondary online and secondary baking products are prone to deformation, and there is no secondary paint spraying in the laser engraving area, and the thick paint film reduces the paint adhesion of the ordinary area. This contradiction makes it difficult to mass-produce and implement the process. Another type of scheme (such as 202220374679.0) luminous bumper adopts bumper skin, which is connected with the vehicle body framework; the luminous assembly is connected with the bumper skin on one side through the connecting assembly, and is connected with the vehicle body framework on the other side. This installation structure is installed at the front end of the front bumper beam, and from the perspective of the whole vehicle, the skin is very strong due to the structure behind it, which increases the safety risk of pedestrian protection. In the event of an accident, the high stiffness cannot absorb energy, which will cause great harm.

[0004] Therefore, the existing technology has the following technical problems:

[0005] ①The bumper skin is connected with the vehicle body framework, and is installed at the front end of the front bumper beam. This structure cannot effectively absorb energy when the vehicle collides, which increases the risk of serious injury to pedestrians.

[0006] ② The process of using conductive and transparent primer is expensive and complex, and cannot be mass-produced; the laser engraving and painting process requires secondary online spraying and secondary baking, which not only increases production costs, but also easily leads to product deformation. At the same time, secondary painting of non-laser engraved areas will make the paint film too thick, reducing the paint adhesion of ordinary areas, further affecting product quality and pass rate. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the purpose of this invention is to provide a light-emitting bumper that optimizes the arrangement of the light-emitting areas, avoids a decrease in collision energy absorption capacity, and improves pedestrian safety. It employs a light-shielding primer combined with a single-stage laser engraving solution to eliminate the need for secondary coating, reduce production costs, and improve the yield rate. Under the premise of ensuring safety and reliability, it provides a functional and economical intelligent light-emitting solution for automotive bumpers.

[0008] To achieve the above objectives, the embodiments of the present invention provide the following technical solutions:

[0009] A luminous bumper includes: a mounting bracket, a bumper body, and a decorative light; the mounting bracket includes a load-bearing bracket and a light bracket, the load-bearing bracket has upper brackets on both sides, and the upper side of the light bracket is snapped onto the upper bracket; the bumper body includes end covers located on both sides, the end covers are mounted on the light brackets, the end covers have luminous areas and non-luminous areas, the luminous areas are located outside the side impact area of ​​the bumper, avoiding the front impact area and side impact area of ​​the bumper, the luminous areas have laser-engraved patterns, the laser-engraved patterns are formed by fitting multiple dots and holes; the decorative light is mounted inside the end covers.

[0010] Optionally, a first load-bearing seat is provided on the top of the inner side of the lamp bracket, and a first slot and a second slot are provided on the upper bracket. The second slot is located above the first slot, the first load-bearing seat is inserted into the first slot, and the upper side of the end cover is bent and embedded into the second slot.

[0011] Optionally, the lamp holder is provided with multiple welding points distributed on the outer surface of the lamp holder, and the end cover is welded to the lamp holder by piercing through the welding points.

[0012] Optionally, the lamp holder is provided with multiple limiting grooves, which are distributed on the corners of the lamp holder and have different arrangement directions. The inner side of the end cover is provided with multiple limiting pieces, the positions of which correspond to the positions of the limiting grooves, and the limiting pieces are inserted into the limiting grooves.

[0013] Optionally, a fixing plate is provided on one side of the lamp bracket, and a first screw is installed on the fixing plate, with the inner end of the first screw installed on the end face cover.

[0014] Optionally, the mounting plate is arranged around the decorative lamp, a second screw is mounted on the mounting plate, and an inner end of the second screw is mounted on the lamp support.

[0015] Optionally, the decorative lamp has a PCB board, and an end of the PCB board has a light isolation structure.

[0016] Optionally, the decorative lamp has a double-layer sealed foamed rubber pad.

[0017] Optionally, the bumper body material comprises 70-90 parts of polypropylene, 5-15 parts of ethylene-propylene rubber, and 5-15 parts of calcium silicate.

[0018] The embodiment of the application also provides a preparation process of the light-emitting bumper as described above, comprising the following steps:

[0019] The end face cover is successively sprayed with light-shielding primer, color paint and varnish, and after drying, laser-engraved dot holes are formed to form a laser-engraved pattern.

[0020] The laser-engraved end face cover is puncture-welded on the outer side of the lamp support.

[0021] The decorative lamp is mounted on the inner side of the end face cover.

[0022] The one or more technical solutions provided in the embodiment of the application have at least the following technical effects or advantages:

[0023] 1. The light-emitting bumper comprises a mounting support, a bumper body and a decorative lamp, the mounting support comprises a load-bearing support and a lamp support, the upper supports on both sides of the load-bearing support provide clamping positions for the lamp support, so that the lamp support can be stably mounted on the load-bearing support. The bumper body is split into left and right end face covers, which reduces the volume of the bumper and facilitates the back-and-forth carrying during the laser-engraving process. The end face covers are mounted on the lamp support, and the light-emitting area is located on the outer side of the side impact area of the bumper, thereby avoiding the front impact area and the side impact area and reducing the safety hazard. The laser-engraved pattern of the light-emitting area is fitted by a plurality of dot holes, and such a dot structure effectively solves the paint adhesion problem while ensuring the pattern, avoids the problem of twice online, twice primer spraying and twice varnish spraying of the painted part caused by the difference in paint adhesion between the laser-engraved area and the non-laser-engraved area in the traditional process, reduces the production cost, and improves the product qualification rate. The decorative lamp is mounted on the inner side of the end face cover and cooperates with the laser-engraved pattern to realize the shape display and interaction function of the light.

[0024] 2、Compared with the prior art, the application optimizes the arrangement of the bumper light-emitting area, skillfully avoids the head-on and side collision points of the vehicle, reduces the risk of causing serious injury to pedestrians in a collision accident, and at the same time ensures that the bumper can effectively absorb energy when colliding, reducing the impact force on pedestrians. A new type of light-shielding primer, color paint, varnish spraying process and laser engraving process are adopted to avoid secondary online spraying and secondary baking, reduce product deformation and paint adhesion problems, thereby reducing production costs, improving product qualification rate, realizing mass production of body same color spraying and laser engraving process transparent substrate combination. Reasonably plan the light-emitting area of the bumper, so that it can meet the aesthetic and functional requirements, and not affect the safety performance of the vehicle, provide more creative space for modeling design, and at the same time realize the interaction function of light and the owner through intelligent control, such as intelligent welcome, music rhythm, charging display, etc., improve the use experience of the owner and the intelligent level of the vehicle.

[0025] The advantages of the additional aspects of the application will be given in the following description, some of which will become apparent from the following description, or will be understood through practice of the application. BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only illustrate some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0027] Figure 1 is a front view of the bumper provided by the embodiment of the present application;

[0028] Figure 2 is a schematic view of the mounting bracket provided by the embodiment of the present application;

[0029] Figure 3 is a schematic view of the left and right end cover provided by the embodiment of the present application;

[0030] Figure 4 is a schematic view of the laser-engraved pattern on the end cover provided by the embodiment of the present application;

[0031] Figure 5 is a schematic view of the laser-engraved pattern provided by the embodiment of the present application;

[0032] Figure 6 is a schematic view of the lamp bracket provided by the embodiment of the present application;

[0033] Figure 7 is a schematic view of the bumper inner side provided by the embodiment of the present application;

[0034] Figure 8 is Figure 7 A1 cross-sectional view in the middle;

[0035] Figure 9 is Figure 7 B1 cross-sectional view in the middle;

[0036] Figure 10 is Figure 7 C1 cross-sectional view in the middle;

[0037] Figure 11 is the bumper and upper side light installation schematic diagram provided by the embodiment of the present application;

[0038] Figure 12 is the lamp support and end cap cover cooperation schematic diagram provided by the embodiment of the present application;

[0039] Figure 13 is the lamp support and decorative lamp cooperation schematic diagram provided by the embodiment of the present application;

[0040] Figure 14 is the spraying process schematic diagram in the prior art;

[0041] Figure 15 is the spraying process schematic diagram provided by the embodiment of the present application;

[0042] In the figure: 1, bumper body; 11, frontal collision area; 12, side collision area; 13, end cap cover; 131, non-lighting area; 132, lighting area; 133, laser-engraved pattern; 134, point hole; 135, limiting sheet; 136, first screw; 2, bearing support; 21, upper support; 3, lamp support; 31, welding point; 32, limiting groove; 33, first bearing seat; 34, second screw; 35, positioning pin; 36, boss column; 4, decorative lamp; 41, light isolation structure; 42, PCB board; 43, sealing foaming rubber pad; 5, lifting point; DETAILED DESCRIPTION

[0043] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the present application. Unless otherwise indicated, all technical and scientific terms used in the present application have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. In addition, it should be understood that when the terms "comprise" and / or "include" are used in the present specification, they indicate the presence of a feature, step, operation, device, component and / or their combinations.

[0044] Embodiment 1

[0045] As shown in Figure 1 , Figure 2 , the present embodiment proposes a light-emitting bumper, which comprises a mounting support, a bumper body 1 and a decorative lamp 4 (as shown inFigure 6 The mounting bracket includes a load-bearing bracket 2 having upper brackets 21 on both sides and a lamp bracket 3, the upper side of which is clamped on the upper brackets 21; as Figure 3 、 Figure 4 The bumper body 1 includes end face covers 13 on both sides, which are installed on the lamp bracket 3, and the end face cover 13 has a light-emitting area 132 and a non-light-emitting area 131, the light-emitting area 132 is located on the outer side of the bumper side impact area 12, avoiding the bumper frontal impact area 11 and the side impact area 12, and the light-emitting area 132 has a laser-engraved pattern 133 fitted by a plurality of point holes 134; the decorative lamp 4 is installed on the inner side of the end face cover 13.

[0046] The upper bracket 21 absorbs the weight of the front protection system to prevent sinking, the bumper body 1 is split into left and right end face covers 13, reducing the volume of the bumper and facilitating the back-and-forth handling of the bumper during laser engraving.

[0047] The decorative lamp 4 uses a white and black double-color cover with a built-in shading structure, and the light-emitting area 132 of the bumper has Figure 4 As shown in

[0048] As shown in Figure 5 The diameter of the point hole 134 is 0.3mm, and the distance between every two centers is 1mm, the laser-engraved pattern 133 is fitted by the point hole 134, which can prevent the decrease in paint adhesion and prevent the paint from falling off, avoiding the problems of secondary online spraying, secondary spraying of primer and varnish, reducing costs and improving the pass rate.

[0049] As shown in Figure 7 、 Figure 8 、 Figure 10 The inner side of the lamp bracket 3 is provided with a first load-bearing seat 33, the upper bracket 21 is provided with a first clamping groove and a second clamping groove, the second clamping groove is located on the upper side of the first clamping groove, the first load-bearing seat 33 is inserted into the first clamping groove, and the upper side of the end face cover 13 is bent and embedded into the second clamping groove. The lamp bracket 3 and the upper bracket 21 unload part of the weight of the decorative lamp 4 through the load-bearing seat; at the same time, as shown in Figure 11 The front headlamp cover has three high-strength lifting points 5, which provide strong support and ensure the stability of the overall structure of the bumper.

[0050] As shown in Figure 6As shown, the lamp holder 3 is provided with a plurality of welding points 31 distributed on the outer side of the lamp holder 3, and the end cap cover 13 is puncture welded on the lamp holder 3 through the welding points 31. The puncture welding provides sufficient mechanical strength, and the distribution of the plurality of welding points 31 makes the welding more uniform, avoiding local stress concentration and improving the durability of the bumper. The end cap cover 13 adopts a variable thickness of 3.-2.8mm, which ensures that the puncture welding process does not have appearance defects when welding the lamp holder 3.

[0051] As shown in Figure 6 , Figure 12 , a plurality of limiting grooves 32 are formed on the lamp holder 3, the plurality of limiting grooves 32 are distributed on the corners of the lamp holder 3 and the arrangement direction of each limiting groove 32 is different, the inner side of the end cap cover 13 is provided with a plurality of limiting pieces 135, the positions of the limiting pieces 135 correspond to the positions of the limiting grooves 32, and the limiting pieces 135 are inserted into the limiting grooves 32. This design enables the end cap cover 13 to be accurately positioned by the cooperation of the limiting pieces 135 and the limiting grooves 32 during installation, and the limiting grooves 32 in different directions can limit the end cap cover 13 from multiple angles, effectively preventing the end cap cover 13 from shaking and mispositioning on the lamp holder 3, and improving the assembly precision and reliability.

[0052] One side of the lamp holder 3 is provided with a fixing plate, a first screw 136 is installed on the fixing plate, and the inner end of the first screw 136 is installed on the end cap cover 13, realizing pre-assembly of the lamp holder 3 and the end cap cover 13 and enhancing the connection strength between the end cap cover 13 and the lamp holder 3.

[0053] As shown in Figure 13 , the mounting plate is provided around the decorative lamp 4, the second screw 34 is installed on the mounting plate, the inner end of the second screw 34 is installed on the boss column 36 of the lamp holder 3, so that the decorative lamp 4 can be quickly and accurately installed on the lamp holder 3, and part of the mounting plate is also provided with a positioning pin 35 for positioning with the lamp holder 3. The use of the positioning pin 35 ensures the positional accuracy of the decorative lamp 4 during installation, avoiding problems such as poor optical effect or difficult assembly caused by positional deviation. At the same time, the tightening action of the second screw 34 ensures the stability of the decorative lamp 4 during use, preventing the decorative lamp 4 from loosening or shifting due to vibration during vehicle driving, which affects the light effect and service life.

[0054] The decorative lamp 4 has a PCB board 42, and the end of the PCB board 42 has a light shielding structure 41. The decorative lamp 4 has a double-layer EPDM sealing foam rubber pad 43 (as shown in Figure 9The PCB board 42 is the core component of the decorative lamp 4, which is used to install and connect the LED lamp beads and other electronic components, and realizes the control and display functions of the light. The design of the light isolation structure 41 can effectively prevent the leakage and scattering of light at the end of the PCB board 42, ensure that the light propagates according to the predetermined path and direction, improve the optical performance and display effect of the decorative lamp 4, realize the complex light effects such as flowing water, breathing, music rhythm of the decorative lamp 4, and make the light change clearer and more accurate, and enhance the interactive experience with the vehicle owner. The main function of the double-layer sealing foam rubber pad 43 is dustproof and waterproof, which can effectively prevent dust, moisture and other impurities from entering the interior of the decorative lamp 4, ensure that the optical elements and electronic elements in the interior of the decorative lamp 4 work in a good environment, and prolong the service life of the decorative lamp 4. At the same time, the sealing foam rubber pad 43 also has a certain damping effect, which can reduce the influence of vibration on the decorative lamp 4 during vehicle driving, and protect the structural integrity of the decorative lamp 4.

[0055] The decorative lamp 4 is provided with 20 chips of power supply type, communication type and power type. The light has the functions of flowing water, breathing, music rhythm, charging display, battery storage state passing, host control, intelligent welcome function when opening and closing lock, and whole vehicle music rhythm. At the same time, the opening and closing of the charging display switch is set on the large screen, which can be opened or not opened according to the needs of the vehicle owner. When opened, the light displays the battery capacity and charging state through the light-emitting bumper.

[0056] The bumper body 1 is made of KLUX-6017 (transparent pp brand) polypropylene material, and the specific composition is shown in the following table. On the premise of meeting the safety of pedestrian protection, the material formula and brand of transparent material are locked on the basis of repeated tests of the rigidity and transmittance of transparent material, haze. On the basis of considering cost and simplifying the paint process, through the new laser engraving process and paint process, the film thickness test of the opaque primer and the primer, color paint and varnish is used to determine that the light source no longer leaks light.

[0057] The embodiment (KLUX-6017) is compared with the existing material (KLUX-8018, ABP-2019) composition table

[0058]

[0059] The embodiment (KLUX-6017) is compared with the existing material (KLUX-8018, ABP-2019) physical property comparison table

[0060]

[0061] The KLUX-6017 of the embodiment uses transparent fillers, which ensures the rigidity of the material while also preserving the transmittance of the 3MM thick material. The dimensional stability of the material is also guaranteed, and the flow is good, making the product easy to form.

[0062] The existing material KLUX-8018 removes the filler, improves the light transmittance of the material, but the rigidity and the dimensional stability of the material cannot meet the requirements; meanwhile, the material flowability is poor, the product forming is difficult, and the appearance will produce defects such as welding lines

[0063] The existing material ABP-2019 uses ordinary calcium carbonate filler, has stable size and rigidity, is cheap, has good material flowability, is easy to form, and has good appearance, but the optical function is 0, cannot transmit light, and cannot meet the light transmittance requirement.

[0064] The decorative light of the light-emitting bumper is bound to the main controller of the vehicle, provides an intelligent welcome function, has flowing water and breathing light when the lock is opened and closed, lights up the bumper through the laser-engraved patterns, so that the light has a shape; meanwhile, the light can produce rhythm with the music rhythm of the vehicle, can carry out a small outdoor party, makes the vehicle more energetic, provides a new joy for the driver in addition to driving; meanwhile, when the vehicle is equipped with an oil-electric hybrid power, the driver does not need to enter the vehicle, understands the battery capacity through the light-emitting area of the bumper when the lock is opened and closed, and the intelligent light-emitting area will appear light flickering and flowing water notification when charging, so that the driver understands the charging state. In summary, through the present application, the vehicle and the driver can interact through the light, and a new design concept and scheme are provided for the light of the vehicle.

[0065] Example 2

[0066] The present embodiment provides a preparation process of the light-emitting bumper of Example 1, which comprises the following steps:

[0067] Firstly, the end cap cover is sprayed and laser-engraved, as shown in Figure 15 , after the light-blocking primer, color paint and varnish are sprayed in sequence and then dried, the laser-engraved patterns are formed by laser-engraved dot holes. Compared with the traditional spraying process shown in Figure 14 , the present spraying process can ensure the flatness of the surface of the end cap cover and the quality of the paint, and the setting of the laser-engraved dot holes provides a basis for the subsequent light-emitting effect. Through the dot patterns, the adhesion of the laser-engraved area reaches the state of the ordinary non-engraved area, which simplifies the process of secondary online, shortens the time, improves the efficiency and cost. Secondly, the laser-engraved end cap cover is puncture-welded on the outside of the lamp bracket. This welding method not only fixes the end cap cover, but also provides a basis for the installation of the decorative light. Then, the parts are sub-assembled into an assembly. Finally, the decorative light is installed on the inside of the end cap cover through 8 screws with a diameter of 4.8*19 and main and auxiliary positioning pins, and precise and firm installation is realized through the screws and the positioning pins. The whole preparation process is simple and efficient, the steps are closely connected, the quality and performance of the light-emitting bumper are ensured, and large-scale production and assembly are also facilitated.

[0068] The above describes the specific embodiments of the present application in combination with the drawings, but is not a limitation on the protection scope of the present application. Those skilled in the art should understand that various modifications or changes made by those skilled in the art on the basis of the technical solutions of the present application without creative labor are still within the protection scope of the present application.

Claims

1. A lighted bumper, characterized by, The utility model relates to a kind of decorative lamp for bumper, including: Mounting bracket, bumper body and decorative lamp; The mounting bracket includes load-bearing bracket and lamp bracket, the upper side of the lamp bracket is clamped on the upper bracket of the load-bearing bracket; The bumper body can be split into end cap cover located on both sides, the end cap cover is installed on the lamp bracket, end cap cover has light-emitting area and non-light-emitting area, the light-emitting area is located at the outer side of bumper side impact area, avoids the bumper's frontal collision area and side impact area, and the light-emitting area has laser-engraved pattern, the laser-engraved pattern is fitted by a plurality of point holes; The decorative lamp is installed on the inner side of the end cap cover; The top of the inner side of the lamp bracket is provided with a first load-bearing seat, the upper bracket is provided with a first clamping groove and a second clamping groove, the second clamping groove is located on the upper side of the first clamping groove, the first load-bearing seat is inserted into the first clamping groove, and the upper side of the end cap cover is bent and embedded into the second clamping groove.

2. The illuminated bumper of claim 1, wherein, A plurality of welding points are provided on the lamp bracket, and the end cap cover is pierced and welded on the lamp bracket through the welding points.

3. The illuminated bumper of claim 1, wherein, A plurality of limiting grooves are provided on the lamp bracket, and the plurality of limiting grooves are distributed on the corners of the lamp bracket, and the arrangement directions of the limiting grooves are different, the inner side of the end cap cover is provided with a plurality of limiting pieces, the positions of the limiting pieces correspond to the positions of the limiting grooves, and the limiting pieces are inserted into the limiting grooves.

4. The illuminated bumper of claim 1, wherein, One side of the lamp bracket is provided with a fixing plate, a first screw is installed on the fixing plate, and the inner end of the first screw is installed on the end cap cover.

5. The illuminated bumper of claim 1, wherein, The decorative lamp is provided with a mounting plate around, a second screw is installed on the mounting plate, and the inner end of the second screw is installed on the lamp bracket, wherein a positioning pin is further installed on part of the mounting plates for positioning with the lamp bracket.

6. The illuminated bumper of claim 1, wherein, The decorative lamp has a PCB board, and the end of the PCB board has a light-blocking structure.

7. The illuminated bumper of claim 1, wherein, The decorative lamp has double-layer sealing foam rubber pads.

8. The illuminated bumper of claim 1, wherein, The bumper body material includes 70-90 parts of polypropylene, 5-15 parts of ethylene-propylene rubber and 5-15 parts of calcium silicate.

9. Process for the production of a luminous bumper according to any one of claims 1-8, characterized in that, The utility model includes the following steps: The end cap cover is successively sprayed with light-blocking primer, color paint and varnish, and after drying, the point holes are laser-engraved to form the laser-engraved pattern; The end cap cover with laser-engraved pattern is pierced and welded on the outer side of the lamp bracket; The decorative lamp is installed on the inner side of the end cap cover.

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