Integrated Bumper Energy Absorber and Air Shutter Assembly
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Solution Overview
Problem
Existing vehicle front end components lack an integrated solution for energy absorption and air flow management, with separate systems for bumper energy absorption and air flow control being complex, space-intensive, and not adaptable to mechanical failures, and there is a need for a durable, robust, and aesthetically pleasing solution that maintains vehicle operation even in the event of air flow control mechanism failure.
Innovation Solution
An integrated assembly that combines a bumper energy absorber with an air flow management system, featuring a shutter section with active shutter members and an actuator mechanism, allowing for energy absorption and air flow control in a single component, with shutter members designed to default to an open position in case of mechanical failure to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate systems are used for bumper energy absorption and air flow control, then each system can be optimized independently, but the overall device complexity and space requirements increase
Solution Approach 1:
The patent combines the bumper energy absorber and air flow control system into a single integrated assembly. The air flow control system is mounted directly on the bumper assembly, allowing both energy absorption and air management functions to be performed by one unified structure rather than separate systems, thereby reducing overall complexity while maintaining independent optimization of each function.
Solution Approach 2:
The integrated bumper assembly serves multiple functions simultaneously: it provides energy absorption during impacts through the crushable bumper material, controls air flow to the engine through adjustable shutters, and manages aerodynamic forces. This multi-functional design eliminates the need for separate dedicated components for each function.
2Reliability
If separate systems are used for bumper energy absorption and air flow control, then each system can be optimized independently, but the space requirements in front of the engine increase
Solution Approach 1:
The air flow control system is integrated into the bumper assembly structure itself, utilizing the existing space and structural elements of the bumper. The shutters and actuator mechanism are mounted within or on the bumper components, eliminating the need for additional separate space allocations for air flow control hardware in front of the engine.
3Adaptability or versatility
If active air flow control mechanisms are added to the bumper system, then air flow management capability is improved, but the assembly complexity increases
Solution Approach 1:
The patent incorporates adjustable shutters that can dynamically change their position to control air flow. The shutters are connected to an actuator mechanism that allows them to move between different positions (open, closed, and intermediate positions), enabling active air flow management in response to varying engine conditions and environmental factors.
Solution Approach 2:
The actuator mechanism is designed to be integrated with the existing bumper assembly structure, utilizing available structural elements for mounting and support. The system leverages the vehicle's existing control systems or simple mechanical actuators to operate the shutters, minimizing the need for additional complex control infrastructure.
4Device complexity
If integrated assembly is used for energy absorption and air flow control, then space efficiency and assembly simplicity are improved, but the reliability upon mechanism failure may worsen
Solution Approach 1:
The patent designs the shutter mechanism with a fail-safe feature where the shutters are biased toward an open position. In the event of actuator failure or mechanical decoupling, spring forces or aerodynamic pressures automatically push the shutters to the open position, ensuring that air flow is not blocked and the engine does not overheat. This prior cushioning approach prepares the system in advance for potential failures.
Solution Approach 2:
Instead of designing the shutter system to default to a closed position (which would block air flow upon failure), the patent inverts the default state so that failures naturally result in an open shutter position. This inversion ensures that the failure mode is benign and does not compromise engine operation.
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
The integrated assembly provides efficient energy absorption and air flow management, ensuring vehicle operation even if the air flow control mechanism fails, while maintaining vehicle appearance and aerodynamics, and reducing the complexity of assembly and warranty costs.
Implementation Method 1
The energy absorbing section includes at least one crush section configured to absorb energy when crushed against the bumper reinforcement beam
Implementation Method 2
The shutter section includes active shutter members movable between a closed position to block air flow through the shutter section, an open position to allow air flow through the shutter section
Data Source
AI summary
An integrated assembly includes a bumper energy absorber section with crush lobes for abutting a bumper beam, an upper air shutter section with subassembled shutter members movable between closed and open positions, a first actuator mechanism for moving the shutter members between positions, an upper fascia support section with upper leg crush lobe therein above the upper air shutter section, a lower air shutter section with subassembled lower shutter members movable between closed and open positions, a second actuator mechanism for moving the lower shutter members between the positions; and a lower leg energy absorber section attached below the lower air shutter section and configured to abut (or replace) a face of a secondary pedestrian impact bar. The shutter members may be molded to a shutter frame using over molding technology rather than separately, manually assembled.