Vehicle Bumper Cover Coupling for Impact Absorption
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Solution Overview
Problem
Conventional bumper cover attachments to trim elements, such as radiator shells, often result in misalignment due to the structural arrangement, which is aesthetically undesirable and increases the risk of damage during low-speed collisions, as the impact force is not effectively absorbed, potentially harming more expensive and delicate components.
Innovation Solution
The implementation of releasable couplings that detach the bumper cover from the trim element upon absorbing a predetermined impact force, allowing the bumper cover to displace and absorb the force without transferring it to the trim element, thus maintaining alignment and reducing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bumper cover is rigidly attached to trim element using conventional bolts, then structural strength is improved, but alignment precision deteriorates and damage risk increases during impact
Solution Approach 1:
The coupling device is segmented into distinct functional components: a fastening mechanism (clips or bolts) for structural attachment, and separate alignment features (alignment pins or guide rails) for precise positioning. This segmentation allows each component to perform its specialized function optimally without compromising the other.
Solution Approach 2:
The patent introduces alignment pins or guide rails as intermediary elements between the bumper cover and trim element. These intermediaries facilitate precise alignment during assembly and maintain it throughout the service life, eliminating the misalignment problems associated with direct rigid attachment.
2Manufacturing precision
If bumper cover is rigidly attached to trim element, then alignment is maintained, but impact force is not absorbed effectively causing damage to trim element
Solution Approach 1:
The coupling device incorporates dynamic characteristics by allowing controlled movement or deformation during impact. The fastening mechanism can temporarily disengage or the coupling can flex, enabling the bumper cover to move independently during collision to absorb impact energy, while maintaining alignment during normal operation.
Solution Approach 2:
The coupling device is designed with built-in cushioning features such as energy-absorbing elements or controlled deformation zones that activate during impact. These features are pre-configured to absorb impact forces before they can be transmitted to the trim element, protecting it from damage while maintaining alignment.
3Shape
If bumper cover is attached closely to trim element for aesthetic alignment, then appearance is improved, but risk of damage to expensive components increases during collision
Solution Approach 1:
The coupling device enables the bumper cover to maintain close aesthetic alignment with the trim element during normal conditions, while allowing controlled dynamic separation or movement during impact. This dynamic behavior protects expensive trim elements from damage while preserving the desired aesthetic appearance.
Solution Approach 2:
The coupling system separates the aesthetic alignment function from the impact protection function into distinct components. Alignment features ensure close visual positioning for aesthetic purposes, while separate fastening and energy-absorbing mechanisms provide impact protection, allowing both requirements to be satisfied simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures the trim element remains undamaged, reduces repair costs, and enhances safety by absorbing impact forces, preventing damage to the trim element and minimizing pedestrian injuries during collisions, while maintaining an aesthetically pleasing alignment.
Implementation Method 1
A coupling (9) comprises a body (10) and a substantially U-shaped mouth (23) for engaging with a slot (15) on the radiator shell base (7). The mouth (23) comprises a recess (20) formed within a lower support surface (22). The coupling (9) further comprises a tooth (21) that sits in the mouth (23) between two projections (17). The tooth (21) is attached to the lower support surface (22) of the mouth (23) at only at one end such that its free end may flex in a vertical direction about the attached end.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A vehicle comprises a trim element (2), such as a radiator shell 3, a bumper cover (4) and one or more couplings (9). Each coupling (9) releasably couples the bumper cover (4) to the trim element (2). Each coupling (9) is arranged to release the bumper cover (4) from the trim element (2) when the bumper cover (4) receives an impact force above a predetermined level, such as after a collision with an object.