Front bumper and headlamp matching structure and assembling method

Abstract

The invention belongs to the technical field of automobile body assembling, and particularly discloses a front bumper and headlamp matching structure and an assembling method. The front bumper assembly comprises a front bumper upper body and a bumper welding support which are fixed through puncture welding, positioning structures matched with each other are arranged between the bumper welding support and the front bumper upper body, and an assembly gap is formed between the positioning structures. A matching space is formed between the front bumper upper body and the headlamp shell; a support soft rubber belt is integrally formed on the bumper welding support and extends to the matching space in the direction from the bumper welding support to the front headlamp. The extending tail end of the support soft rubber belt abuts against the headlamp shell and generates elastic deformation. The elastic deformation of the positioning structure, the assembling gap and the bracket flexible adhesive tape is matched; the method has the following advantages that the assembly precision is improved, flexible fitting is achieved, and vibration abnormal sound is restrained.

Description

Technical Field

[0001] This invention relates to the field of automotive body assembly technology, and more specifically, to a front bumper and headlight assembly structure and method. Background Technology

[0002] In existing automotive front-end structures, the front bumper and headlights are typically fitted together using snap-fit ​​structures, bolt connections, or pre-installed fixed gaps. Positioning and assembly are mostly achieved through rigid contact or simple gap control. In practical applications, due to the cumulative effects of component manufacturing tolerances and assembly errors, uneven gaps or localized interference can easily occur between the front bumper and headlights, affecting the overall consistency and perceived quality of the vehicle's appearance. During vehicle operation, road surface excitation and vehicle body vibrations can cause relative displacement at the rigid mating interface, leading to vibration and abnormal noise. Furthermore, traditional mating structures lack effective buffering and compensation mechanisms, making it difficult to balance assembly smoothness and fit stability. Long-term use may also lead to loosening of the connection points or a decline in sealing performance.

[0003] To address this issue, a front bumper and headlight assembly structure and method are proposed to solve the problems mentioned above. Summary of the Invention

[0004] The present invention aims to provide a front bumper and headlight mating structure to solve or improve the problem that the existing front bumper and headlight mating structures are difficult to simultaneously achieve assembly precision control, uniform gap fitting and vibration and noise suppression.

[0005] In view of this, a first aspect of the present invention is to provide a front bumper and headlight mating structure.

[0006] A second aspect of the present invention is to provide an assembly method.

[0007] A first aspect of the present invention provides a front bumper and headlight mating structure, including a front headlight and a front bumper assembly; the front headlight includes a headlight housing; the front bumper assembly includes a front bumper upper body and a bumper welding bracket fixed by piercing welding, wherein a mutually cooperating positioning structure is provided between the bumper welding bracket and the front bumper upper body, and an assembly gap is formed between the positioning structures; a mating space is formed between the front bumper upper body and the headlight housing; a bracket soft rubber strip is integrally formed on the bumper welding bracket, the bracket soft rubber strip extending from the bumper welding bracket toward the front headlight to the mating space; wherein the extended end of the bracket soft rubber strip abuts against the headlight housing and undergoes elastic deformation; the positioning structure, the assembly gap, and the elastic deformation of the bracket soft rubber strip cooperate to keep the front bumper assembly and the front headlight in a close fit after assembly.

[0008] A second aspect of the present invention provides an assembly method comprising the following steps: S101, positioning and fixing the upper body of the front bumper; S102, docking the bumper welding bracket with the upper body of the front bumper, such that the positioning structures cooperate with each other to form the assembly gap, and placing the bumper welding bracket in a pre-positioned state; S103, in the pre-positioned state, piercing and welding the bumper welding bracket with the upper body of the front bumper to fix them; S104, extending the bracket soft rubber strip integrally formed on the bumper welding bracket from the bumper welding bracket toward the headlight to the mating space; S105, assembling the headlight to the corresponding position on the front bumper assembly, such that the extended end of the bracket soft rubber strip abuts against the headlight housing and undergoes elastic deformation, and the front bumper assembly and the headlight form a fitted state.

[0009] The beneficial effects of this invention compared to the prior art are as follows: By setting a mutually cooperating positioning structure between the front bumper upper body and the bumper welding bracket in the front bumper assembly, and forming an assembly gap between the positioning structures, the bumper welding bracket can first establish a controlled relative positional relationship when assembled with the front bumper upper body. Then, the assembly gap is used to release and compensate for the machining tolerances and assembly errors of the parts. The technical effects obtained are: on the one hand, it can improve the assembly positioning accuracy of the bumper welding bracket relative to the front bumper upper body, and reduce the risk of misalignment assembly caused by positional offset; on the other hand, it can avoid local interference, assembly stagnation or assembly stress concentration caused by excessively tight rigid fit, thus simultaneously ensuring assembly smoothness and assembly consistency.

[0010] The bracket soft tape is no longer a separate additional component, but relies on the bumper welding bracket to obtain a stable and accurate installation benchmark, so that its extension direction, end position and effective area can be stably controlled; at the same time, after the bracket soft tape enters the mating space, it can form a flexible transition interface between the front bumper assembly and the headlight housing, thereby compensating for the residual local gaps after assembly, making it easier for the front bumper assembly and the front headlight to maintain a continuous and uniform fit in appearance.

[0011] When a vehicle is subjected to road surface excitation or body vibration, the elastic deformation of the bracket soft rubber strip can buffer and absorb the relative displacement trend between the front bumper assembly and the front headlights, thereby reducing the possibility of rigid collisions and frictional contact, weakening vibration transmission, and suppressing vibration noise.

[0012] Additional aspects and advantages of embodiments of the invention will become apparent in the following description or may be learned by practice of embodiments of the invention. Attached Figure Description

[0013] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a side view of the front bumper and headlights working together according to the present invention. Figure 2 This is a frontal schematic diagram of the front bumper and front headlights of the present invention. Figure 3 This is a cross-sectional view of the front bumper and headlights of the present invention. Figure 4 This is an inner side view of the bumper welding bracket of the present invention cooperating with the upper body of the front bumper; Figure 5 This is a flowchart of the method steps of the present invention.

[0014] in, Figures 1-5 The correspondence between the reference numerals and component names in the attached drawings is as follows: 1. Front headlights, 2. Front bumper assembly, 3. Front bumper upper body, 4. Headlight housing, 5. Bracket soft tape, 6. Bumper welding bracket, 7. Recessed hole, 8. Raised platform, 9. Positioning pin, 10. Welding point. Detailed Implementation

[0015] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0016] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0017] Please see Figures 1-5 The following describes a front bumper and headlight assembly structure and assembly method according to some embodiments of the present invention.

[0018] An embodiment of the first aspect of the present invention provides a front bumper and headlight mating structure. In some embodiments of the present invention, such as... Figures 1-4 As shown, the front bumper and headlight assembly includes a front headlight 1 and a front bumper assembly 2.

[0019] The front headlight 1 includes a headlight housing 4.

[0020] The front bumper assembly 2 includes a front bumper upper body 3 and a bumper welding bracket 6 fixed by piercing welding. The bumper welding bracket 6 and the front bumper upper body 3 are provided with mutually cooperating positioning structures, and an assembly gap is formed between the positioning structures.

[0021] There is a mating space between the main body 3 of the front bumper and the headlight housing 4; a bracket soft rubber strip 5 is integrally formed on the bumper welding bracket 6, and the bracket soft rubber strip 5 extends from the bumper welding bracket 6 toward the front headlight 1 to the mating space.

[0022] The extended end of the bracket soft rubber strip 5 abuts against the headlight housing 4 and undergoes elastic deformation; the positioning structure, assembly gap and elastic deformation of the bracket soft rubber strip 5 cooperate to keep the front bumper assembly 2 and the front headlight 1 in a close fit after assembly.

[0023] This invention provides a front bumper and headlight assembly structure. The front bumper upper body 3 and the bumper welding bracket 6 in the front bumper assembly 2 are fixedly connected by piercing welding, thereby forming a stable support relationship in the structure. The positioning structure between the two provides guidance and position constraint in the initial stage of assembly, so that the bumper welding bracket 6 can quickly enter the preset position during the assembly process. The assembly gap formed between the positioning structures is used to absorb and compensate for the machining tolerances and assembly errors of the parts, ensuring smooth assembly while avoiding assembly difficulties caused by interference or overfitting.

[0024] Furthermore, the mating space formed between the front bumper body 3 and the headlight housing 4 provides the necessary arrangement area for the extension and function of the bracket soft rubber strip 5. The bracket soft rubber strip 5, integrally formed on the bumper welding bracket 6, extends from the bumper welding bracket 6 toward the front headlight 1 to the mating space, so that it can directly act on the corresponding surface of the headlight housing 4 after assembly. The extended end of the bracket soft rubber strip 5 abuts against the headlight housing 4 and undergoes elastic deformation, thereby forming a flexible contact between the two. This flexible contact surface can fill the residual gap after assembly and provide continuous contact pressure.

[0025] Thus, through the synergistic cooperation of the initial positioning function provided by the positioning structure, the error compensation capability provided by the assembly gap, and the flexible fitting effect formed by the elastic deformation of the bracket soft tape 5, the front bumper assembly 2 and the front headlight 1 can achieve stable fitting and effectively suppress vibration and abnormal noise after assembly, while ensuring the overall assembly accuracy and appearance consistency.

[0026] In any of the above embodiments, the positioning structure includes a raised platform 8 disposed on the main body 3 of the front bumper and a recessed hole 7 disposed on the welding bracket 6 of the bumper, with the raised platform 8 and the recessed hole 7 cooperating with each other.

[0027] In this embodiment, the raised platform 8 serves as an active guide part. During the process of the bumper welding bracket 6 approaching the front bumper body 3, it can first establish a positional correspondence with the corresponding recess 7 and guide the movement direction of the bumper welding bracket 6 during the process of entering the recess 7. This ensures that the bumper welding bracket 6 does not rest against the front bumper body 3 without constraint, but gradually approaches the target installation position along the predetermined assembly path defined by the raised platform 8 and the recess 7.

[0028] In any of the above embodiments, an assembly gap is formed between the protrusion 8 and the recess 7, and the single-sided allowance value of the assembly gap is 0.03mm~0.07mm; preferably, the single-sided allowance value is 0.05mm.

[0029] In this embodiment, by pre-reserving the aforementioned assembly gap between the raised platform 8 and the recessed hole 7, the raised platform 8 can guide and pre-position the position of the bumper welding bracket 6 relative to the front bumper upper body 3 by means of the cooperation between the two during the process of entering the recessed hole 7. It can also provide space to release the dimensional deviations generated during the processing and assembly of the front bumper upper body 3 and the bumper welding bracket 6, thereby avoiding the problems of insertion difficulties, local interference or assembly obstruction caused by the excessive tightness between the raised platform 8 and the recessed hole 7.

[0030] In any of the above embodiments, the bracket soft tape 5 and the bumper welding bracket 6 are formed into an integral structure by two-color injection molding.

[0031] In this embodiment, the bracket soft adhesive tape 5 is directly molded onto the predetermined position of the bumper welding bracket 6 using a two-color injection molding process, thus establishing a fixed relative positional relationship between the bracket soft adhesive tape 5 and the bumper welding bracket 6. By using two-color injection molding to form an integral structure, the bracket soft adhesive tape 5 can be integrated with the bumper welding bracket 6 during the molding stage, thereby avoiding the risks of positional deviation, unstable connection, or detachment caused by subsequent separate assembly, bonding, or splicing. Furthermore, the extension direction, extension length, and end position of the bracket soft adhesive tape 5 can be determined according to the installation position of the bumper welding bracket 6, ensuring that the bracket soft adhesive tape 5 is in a predetermined arrangement state within the mating space between the front bumper body 3 and the headlight housing 4.

[0032] In any of the above embodiments, a plurality of positioning pins 9 are provided on the main body 3 of the front bumper, and the positioning pins 9 are used to position the bumper welding bracket 6.

[0033] In this embodiment, multiple positioning pins 9 are distributed within the installation areas corresponding to the front bumper upper body 3 and the bumper welding bracket 6. This allows the bumper welding bracket 6 to establish a predetermined positional relationship relative to the front bumper upper body 3 during assembly, thanks to the corresponding limiting effect of the multiple positioning pins 9. By setting multiple positioning pins 9, the assembly direction, assembly position, and fitting posture of the bumper welding bracket 6 can be guided and constrained when it approaches the front bumper upper body 3. This ensures that the bumper welding bracket 6 is under control from the initial assembly stage, avoiding problems such as skewed assembly, local misalignment, or installation position deviation.

[0034] In any of the above embodiments, a reserved gap is formed on the positioning side between the positioning pin 9 and the bumper welding bracket 6.

[0035] The clearance value is 0.07mm~0.13mm, preferably 0.1mm; the diameter tolerance of the locating pin 9 is ±0.05mm.

[0036] In this embodiment, by providing a reserved gap on the positioning side between the positioning pin 9 and the bumper welding bracket 6, the bumper welding bracket 6, during assembly and positioning with the help of the positioning pin 9, can establish a predetermined positional relationship with the front bumper upper body 3 based on the positioning pin 9, and also provide space for the release of dimensional deviations between the positioning pin 9 and the bumper welding bracket 6. This avoids situations such as insertion obstruction, local interference, or assembly stress concentration caused by excessive tightness. Simultaneously, the gap value of the reserved gap is controlled within the range of 0.07mm to 0.13mm, ensuring that the positioning pin 9 can still provide effective positional constraint on the bumper welding bracket 6 after being inserted into the corresponding positioning part, preventing loose positioning, assembly misalignment, or a decrease in overall installation accuracy due to excessive gap. Thus, the positioning pin 9 and the reserved gap together form a cooperative relationship that takes into account guiding, tolerance compensation, and positioning functions.

[0037] In any of the above embodiments, an inner space for accommodating the bracket soft rubber strip 5 is formed between the bumper welding bracket 6 and the front bumper upper body 3, and the end of the bracket soft rubber strip 5 is formed with a bent portion that abuts against the headlight housing 4.

[0038] In this embodiment, the inner space is located in the corresponding area between the bumper welding bracket 6 and the upper body 3 of the front bumper, providing a transition area for the bracket soft tape 5 to extend from the bumper welding bracket 6 towards the front headlight 1. By providing the inner space, the bracket soft tape 5, after being integrally formed into the bumper welding bracket 6, can be at least partially located between the bumper welding bracket 6 and the upper body 3 of the front bumper. This allows the bracket soft tape 5 to obtain appropriate accommodation and guiding conditions as it extends outward from the bumper welding bracket 6, preventing excessive compression, interference, or positional displacement of the bracket soft tape 5 in the assembled state.

[0039] A bend is provided at the end of the bracket soft tape 5 away from the bumper welding bracket 6, to increase the contact adaptability between the end of the bracket soft tape 5 and the headlight housing 4. By providing a bend at the end of the bracket soft tape 5, after the bracket soft tape 5 extends into the mating space, its end can be arranged towards the headlight housing 4 in a bent transition form, thereby making it easier to establish an abutment relationship with the corresponding surface of the headlight housing 4, and to produce elastic deformation at the abutment position after assembly.

[0040] In any of the above embodiments, the end of the front bumper upper body 3 is located between the bumper welding bracket 6 and the headlight housing 4.

[0041] A platform is provided on the side of the bumper welding bracket 6 near the headlight housing 4, and a central space is formed between the platform and the end of the front bumper upper body 3; the central space is used to connect the inner space and the mating space.

[0042] In this embodiment, by arranging the end of the upper body 3 of the front bumper between the bumper welding bracket 6 and the headlight housing 4, the upper body 3 of the front bumper can form an adjacent boundary corresponding to the headlight housing 4 on the exterior side, while the bumper welding bracket 6 is located in the inner support position of the upper body 3 of the front bumper, thereby forming a structural arrangement relationship that gradually transitions from the inside to the outside.

[0043] The central space formed between the platform and the end of the main body 3 on the front bumper plays a transitional and connecting role in the overall structure, so that the inner space, the central space and the mating space are connected in sequence in the extension direction, thereby providing a spatial channel for the continuous arrangement of the bracket soft rubber strip 5, and enabling the bracket soft rubber strip 5 to gradually pass through each spatial area from the inside to the outside while maintaining an integral relationship with the welded bracket 6 of the bumper, and finally reach the position that abuts against the headlight housing 4.

[0044] In any of the above embodiments, the inner space, the middle space, and the mating space form a U-shaped inner cavity through which the support soft tape 5 passes.

[0045] In this embodiment, by connecting the inner space, the middle space and the mating space to form a U-shaped inner cavity, the bracket soft tape 5 can be continuously extended along the U-shaped inner cavity from the location of the bumper welding bracket 6 to the headlight housing 4 after being integrally formed with the bumper welding bracket 6. During the extension process, it can obtain corresponding accommodation, guidance and limiting functions, thereby avoiding the bracket soft tape 5 from shifting, twisting or local interference when passing through different spatial areas.

[0046] Furthermore, the U-shaped inner cavity not only provides a continuous passage for the bracket soft tape 5, but also constrains the overall extension path of the bracket soft tape 5, so that the end of the bracket soft tape 5 can reach the mating space in a predetermined direction and form a stable contact with the headlight housing 4.

[0047] Specifically, the bumper welding bracket 6 and the front bumper upper body 3 serve as the basic assembly structure, respectively undertaking the functions of support and appearance decoration. Both are made of high heat-resistant PP+EPDM-T20 material to ensure structural stability and durability under the vehicle's operating environment. The inner plate surface of the front bumper upper body 3 is provided with 13 positioning pins 9, which are used to form a mating positioning relationship with the bumper welding bracket 6. A gap of 0.1mm is reserved between the positioning pins 9 and the effective positioning side of the bumper welding bracket 6 to provide room for dimensional deviations during the assembly process while ensuring positioning accuracy.

[0048] Furthermore, welding points 10 are formed between the recesses of the bumper welding bracket 6 and between the protrusions of the front bumper body 3.

[0049] A second aspect of the present invention provides an assembly method. In some embodiments of the present invention, such as... Figure 5 As shown, the assembly method includes the following steps: S101, Position and fix the main body 3 on the front bumper.

[0050] S102, the bumper welding bracket 6 is docked with the front bumper upper body 3, so that the positioning structures cooperate with each other and form an assembly gap, and the bumper welding bracket 6 is in a pre-positioned state.

[0051] S103, in the pre-positioned state, the bumper welding bracket 6 is fixed to the front bumper upper body 3 by piercing welding.

[0052] S104, the bracket soft rubber strip 5, which is integrally formed on the bumper welding bracket 6, extends from the bumper welding bracket 6 toward the front headlight 1 to the mating space.

[0053] S105, the front headlight 1 is assembled to the corresponding position of the front bumper assembly 2, so that the extended end of the bracket soft rubber strip 5 abuts against the headlight housing 4 and undergoes elastic deformation, and the front bumper assembly 2 and the front headlight 1 are in a fitted state.

[0054] The present invention provides an assembly method in which the upper body 3 of the front bumper is first positioned and fixed, and then the welding bracket 6 of the bumper is docked with the upper body 3 of the front bumper by means of a positioning structure to form an assembly gap. This allows the welding bracket 6 of the bumper to be in a pre-positioned state before formal fixing, which helps to improve the positional accuracy and assembly consistency during the assembly process and reduce assembly errors caused by manual adjustment or component misalignment. By performing piercing welding fixation in the pre-positioned state, the welding bracket 6 of the bumper can be stably fixed on the upper body 3 of the front bumper, providing a reliable foundation for the subsequent extension and arrangement of the bracket soft tape 5.

[0055] Furthermore, the bracket soft rubber strip 5, integrally formed on the bumper welding bracket 6, extends towards the front headlight 1 into the mating space. After the front headlight 1 is assembled, its extended end abuts against the headlight housing 4 and undergoes elastic deformation, thereby forming a stable fit between the front bumper assembly 2 and the front headlight 1 after assembly. Therefore, this assembly method not only helps to ensure smooth assembly and structural installation accuracy, but also improves the fit effect through the elastic compensation of the bracket soft rubber strip 5, reduces uneven gaps, and reduces the possibility of vibration and abnormal noise.

[0056] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0057] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A front bumper and headlight assembly structure, characterized in that, This includes the headlights and front bumper assembly; The front headlight includes a headlight housing; The front bumper assembly includes a front bumper upper body and a bumper welding bracket fixed by piercing welding. The bumper welding bracket and the front bumper upper body are provided with a mutually cooperating positioning structure, and an assembly gap is formed between the positioning structures. A mating space is formed between the upper body of the front bumper and the headlight housing; a bracket soft rubber strip is integrally formed on the welding bracket of the bumper, and the bracket soft rubber strip extends from the welding bracket of the bumper toward the front headlight to the mating space; The extended end of the bracket soft rubber strip abuts against the headlight housing and undergoes elastic deformation; the positioning structure, the assembly gap, and the elastic deformation of the bracket soft rubber strip cooperate to ensure that the front bumper assembly and the front headlight remain in a close fit after assembly.

2. The front bumper and headlight mating structure according to claim 1, characterized in that, The positioning structure includes a raised platform on the main body of the front bumper and a recessed hole on the welding bracket of the bumper, wherein the raised platform and the recessed hole cooperate with each other.

3. The front bumper and headlight mating structure according to claim 2, characterized in that, The assembly gap is formed between the raised platform and the recessed hole, and the single-sided allowance value of the assembly gap is 0.03mm~0.07mm.

4. The front bumper and headlight mating structure according to claim 1, characterized in that, The bracket soft rubber strip and the bumper welding bracket are formed into an integrated structure by two-color injection molding.

5. The front bumper and headlight mating structure according to claim 1, characterized in that, The front bumper body is provided with multiple positioning pins, which are used to position the bumper welding bracket.

6. The front bumper and headlight mating structure according to claim 5, characterized in that, A reserved gap is formed on the positioning side between the positioning pin and the bumper welding bracket; The reserved gap value is 0.07mm~0.13mm, and / or the diameter tolerance of the positioning pin is ±0.05mm.

7. The front bumper and headlight mating structure according to any one of claims 2-6, characterized in that, An inner space is formed between the bumper welding bracket and the upper body of the front bumper to accommodate the bracket soft rubber strip, and / or the end of the bracket soft rubber strip has a bent portion that abuts against the headlight housing.

8. The front bumper and headlight mating structure according to claim 7, characterized in that, The end of the front bumper body is located between the bumper welding bracket and the headlight housing; A platform is provided on the side of the bumper welding bracket near the headlight housing, and a central space is formed between the platform and the end of the front bumper upper body; the central space is used to connect the inner space and the mating space.

9. The front bumper and headlight mating structure according to claim 8, characterized in that, The inner space, the middle space, and the mating space form a U-shaped inner cavity through which the soft adhesive tape of the bracket passes.

10. An assembly method for the front bumper and headlight mating structure according to any one of claims 1-9, characterized in that, The following steps are required: S101, Position and fix the main body on the front bumper; S102, dock the bumper welding bracket with the front bumper upper body, so that the positioning structures cooperate with each other and form the assembly gap, and put the bumper welding bracket in a pre-positioned state. S103, in the pre-positioned state, the bumper welding bracket is fixed to the front bumper upper body by piercing welding; S104, the bracket soft rubber strip integrally formed on the bumper welding bracket extends from the bumper welding bracket toward the headlight to the mating space; S105, the front headlight is assembled to the corresponding position of the front bumper assembly, so that the extended end of the bracket soft rubber strip abuts against the headlight housing and undergoes elastic deformation, and the front bumper assembly and the front headlight are in a fitted state.

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