Integrated Bumper Grille and Energy Absorber

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Solution Overview

Problem

Current front bumper systems in motor vehicles often suffer damage during low-speed impacts, and lack a debris grille to protect the radiator or front end module from debris, leading to costly repairs.

Innovation Solution

A front bumper system with an integrated energy absorbing cover and debris grille that couples to the bumper beam, featuring a screen assembly with a honeycomb pattern to restrict debris from reaching the front end module and absorb collision forces, thereby protecting the radiator and reducing damage to the bumper fascia and beam.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional bumper beam and fascia system is used, then the structure is simple, but the bumper fascia becomes damaged during low-speed impacts and debris can contact the front end module

Engineering Contradiction:

Improveprotection of front end module and bumper fasciaVSAvoidstructure of bumper system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the debris grille and energy absorber into a single integrated cover assembly that attaches to the bumper beam. This merging of functions (debris protection and impact energy absorption) into one component provides enhanced protection for the front end module and bumper fascia while avoiding the need for multiple separate parts, thus improving reliability without proportionally increasing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover assembly serves multiple functions simultaneously: it acts as a debris grille to prevent objects from contacting the front end module, an energy absorber to mitigate low-speed impact forces, and a protective shield for the bumper fascia. This multi-functionality addresses multiple protection needs with a single integrated solution

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If no debris grille is provided, then the device complexity is low, but debris damages the radiator or front end module causing costly repairs

Engineering Contradiction:

Improveprotection of radiator and front end moduleVSAvoidaddition of debris grille

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The debris grille is merged with the energy absorber in a single integrated cover assembly. This combination means the debris protection function is added without requiring a completely separate grille structure, reducing the overall complexity increase while still providing effective debris protection for the radiator and front end module

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a separate debris grille and energy absorber are used, then the protection function is comprehensive, but the device complexity and number of parts increase

Engineering Contradiction:

Improveprotection functionVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the debris grille, energy absorber, and cover into a single unified assembly that attaches to the bumper beam as one unit. This merging eliminates the need for multiple separate parts while maintaining comprehensive protection functions, directly reducing the number of components and simplifying assembly

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cover assembly performs multiple protective functions simultaneously - debris exclusion, impact energy absorption, and bumper fascia protection - all within a single multi-functional component. This approach provides comprehensive protection without requiring multiple specialized parts

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 debris grille effectively prevents debris from contacting the radiator and absorbs collision forces, reducing damage to the front bumper system components and minimizing repair costs by acting as a buffer between the bumper fascia and beam during low-speed collisions.

Implementation Method 1

an energy absorbing cover coupled to the beam... absorbs collision forces... acting as a buffer between the bumper fascia and beam during low-speed collisions

Methodology Applied

Scientific EffectEnergy absorption: Deformation

Implementation Method 2

The grille defines a plurality of openings sized to at least partially restrict objects from contacting the front end module

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS7540543B2Front bumper energy absorber with integrated debris grille

Publication Date: 2009.06.02 FCA US LLC

AI summary

A front bumper system for a motor vehicle including a body and a front end module includes a beam coupled to the body and an energy absorbing cover coupled to the beam. The front bumper system also includes a grille coupled to the cover and covering at least a portion of the front end module. The grille can define a plurality of openings sized to at least partially restrict objects from contacting the front end module.