Automotive Bumper Optical Unit with Localized Fracture Zone
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Solution Overview
Problem
Existing motor vehicle front face designs face challenges in managing clearances and aesthetics between light units and the bumper skin while also ensuring energy absorption during low-speed impacts, as the addition of supports for the bumper skin compromises the energy absorption capabilities of the optical units.
Innovation Solution
Incorporating a projecting element on the internal face of the bumper skin to break a localized zone of the concealed glass part before contact, which is designed to facilitate fracture and weaken the optical unit during impacts, thereby improving energy absorption and reducing damage to surrounding parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supports are arranged directly on the crystal of the optical unit to support the bumper skin, then the positioning and aesthetics of the front face are improved, but the energy absorption capability during impacts deteriorates
Solution Approach 1:
The patent applies preliminary action by creating localized weakened zones (thinner lines) in the glass of the optical unit before impact occurs. These pre-defined fracture lines are positioned strategically so that during low-speed impacts, the glass breaks along these predetermined paths, allowing the optical unit to absorb energy through controlled fracture rather than creating hard support points that would prevent energy absorption.
2Reliability
If the glass of the optical unit is strengthened to maintain structural integrity, then the reliability is improved, but the energy absorption during low-speed impacts deteriorates
Solution Approach 1:
The patent applies local quality by creating localized weakened zones (thinner lines) in specific areas of the glass while maintaining the overall structural integrity of the optical unit. The glass has different thicknesses in different locations: thinner in the localized zones for energy absorption, and normal thickness in other areas for maintaining strength and reliability. This allows the glass to break easily at predetermined locations during low-speed impacts while maintaining overall structural soundness.
3Device complexity
If supports are added to the optical unit for bumper skin positioning, then the device complexity increases, but the ease of manufacture deteriorates
Solution Approach 1:
The patent merges the positioning function with the existing support structure by integrating the support directly into the optical unit housing rather than adding separate positioning components. The support is formed as part of the optical unit assembly, and the bumper skin positioning is achieved through the interaction between this integrated support and the localized weakened zones in the glass, eliminating the need for additional complex positioning mechanisms.
Data Source
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AI summary
The face has an optical unit (2) with a lens (4) having a disassembled part (4a) behind skin of a bumper (6). A support is arranged on the part, and supports the skin of the bumper. The skin of the bumper has a projection element (10) on its internal face (6a), where the element breaks a localized zone (A) of the part during the impact. The zone is located in the part at a level of the support. The element is formed by a rib (11) and a terminal molded on the internal face of the skin of the bumper.