Vehicle Bodywork Fastening Structure for Hidden Lighting Module Mounting

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Solution Overview

Problem

Existing methods for attaching lighting modules to vehicle bumpers require complex assembly, additional material, and increased cost due to the need for cavities and visible screws, limiting manufacturing efficiency and aesthetics.

Innovation Solution

A molded plastic bodywork element with an external groove and internal fixing barrels allows for secure attachment of lighting modules without visible fasteners, reducing material usage and enabling easy production of both open and closed versions from the same part.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If a cavity with bottom wall is created to hide the lighting module and its fastening, then the fixing becomes invisible from the outside, but the material consumption and manufacturing complexity increase significantly

Engineering Contradiction:

Improvevisibility of fixingVSAvoidassembly complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The harmful effect (visible fixing) is eliminated by extracting the fastening elements to the rear side of the bumper, where they are hidden from external view. The fixing barrels are positioned on the internal face, and screws are inserted from the rear, completely removing the visual impact of the fastening system while maintaining secure attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating a cavity to hide the fixing (conventional approach), the invention inverts the approach by positioning the fixing barrels on the internal face and inserting screws from the rear. This reverses the traditional cavity-based solution, achieving invisibility without the associated complexity and material consumption.

Inventive Principle:

Principle #13The other way round (Inversion)

2Object-generated harmful factors

If a deep cavity with bottom wall is created to accommodate the lighting module, then the module can be hidden, but the quantity of material used increases

Engineering Contradiction:

Improvevisibility of moduleVSAvoidmaterial consumption

Core Design Contradiction:

Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The lighting module is extracted from the bumper structure itself, eliminating the need for a deep cavity. The module is mounted on the rear side using fixing barrels that protrude from the internal face, allowing the module to be positioned without displacing external bumper material.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of building a cavity to house the module (conventional approach), the invention inverts by mounting the module on the rear side with fixing barrels on the internal face. This achieves module concealment without the material consumption associated with deep cavity construction.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If fixing barrels are created on the internal face, then surface imperfections from molding are hidden in the groove, but additional material is required for the barrels and groove

Engineering Contradiction:

Improvesurface qualityVSAvoidmaterial consumption

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The surface imperfections created by the fixing barrels are converted from a harmful effect into a beneficial one by positioning them at the bottom of the groove. The groove acts as a concealing feature, transforming the visual defect into an aesthetic element that is difficult to perceive from the outside.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The groove is positioned specifically to conceal the surface imperfections generated by the fixing barrels. This local quality adjustment ensures that the problematic areas (barrel imprints) are hidden in the groove, while the rest of the external face maintains high aesthetic quality.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4090556B1Bodywork element comprising simplified equipment fastening means, and vehicle comprising such a bodywork element

Publication Date: 2023.12.27 STELLANTIS AUTO SAS

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AI summary

Disclosed is a bodywork element (1) made from moulded plastic material, preferably for the front or rear face of a vehicle, comprising an inner face (10) turned towards the inside of the vehicle, and an outer face, the bodywork element (1) comprising an opening (12) intended to receive a piece of equipment (2) and fastening means (13) arranged around the opening (12) and on the inner face (10), intended to fasten the equipment (2), characterised in that the bodywork element (1) comprises a groove (14) on its outer face (11) arranged to either side of the opening (12), the fastening means (13) being fastening shafts protruding from the inner face (10) and arranged opposite the groove (14).