Motor Vehicle Bumper Panel Burr-Free Joint Design
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Solution Overview
Problem
Corrosion issues arise when exterior trim components made of plastic are connected to metal sheets in motor vehicles, particularly due to burrs from tool separation, which can damage paintwork and create contact problems.
Innovation Solution
The exterior trim component design features a burr-free surface geometry where the tool separation is relocated inward, creating a clearance and using a cam to maintain a defined zero joint, preventing chafing and ensuring the burr does not contact the sheet metal, thus avoiding damage to the paintwork and stabilizing the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the exterior trim component is connected directly to the body at the outermost position, then a zero joint is achieved for aesthetic purposes, but burrs from tool separation cause corrosion and damage to paintwork
Solution Approach 1:
The invention relocates the tool separation from the outer surface to the inner side of the component by creating a stepped geometry. The first area maintains parallel surfaces for zero joint appearance, while the second area steps inward to position the parting line away from the contact surface with the body, thus separating the aesthetic requirement from the harmful burr location.
Solution Approach 2:
The component is divided into distinct areas: a first area with parallel surfaces for aesthetic contact, and a second area with stepped-back surfaces containing the tool separation. This segmentation allows the harmful burrs to be isolated in a separate zone that does not contact the body or paintwork.
2Object-affected harmful factors
If the tool separation is relocated inward to prevent corrosion, then paintwork protection is improved, but the connection geometry becomes more complex
Solution Approach 1:
The stepped geometry is applied locally only where the tool separation occurs, rather than throughout the entire component. The first area maintains simple parallel surfaces for aesthetic contact, while the complexity is confined to the second area where the parting line is positioned, minimizing overall geometric complexity.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Exterior trim component (10) of a motor vehicle, in particular a bumper for connection to a sheet metal part of the exterior trim of a motor vehicle, the body (20) of which has a shoulder (21) for connection of the exterior trim component, wherein the shoulder (21) extends from the outside (A) of the motor vehicle to the inside (I) and a leg (11) of the exterior trim component (10) also extending inwards (I) roughly parallel to the shoulder (21), wherein the shoulder (21) and an adjacent surface (12) of the leg (11) facing the shoulder (21) extend almost parallel to each other in a first area (31) extending from the outside (A) to the inside (I) from the perspective of a section through the motor vehicle, wherein the adjacent surface (12) is free of burrs, for example caused by tool parting (W), from the outside (A) to at least the inner end of the first area (31).and that the adjacent area (12) following the first area (31), in a second area (32), taking up an increasing distance to the sales area (21), slopes down with a free passage (33) to a separation area (34).