Integrated Vehicle Bumper Reinforcement for Simpler Assembly
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Solution Overview
Problem
Recent vehicle bumpers manufactured through long fiber injection (LFI) processes face high post-processing costs and increased difficulty in manufacturing and assembling due to the combination of panel units with reinforcing parts, necessitating improved rigidity reinforcement and connection methods.
Innovation Solution
A vehicle bumper design comprising multiple panel units connected by a single reinforcing part, coated with a mixture of polyurethane and long glass fibers, which is then foamed and shaped to enhance rigidity and reduce weight, using a blocking member to prevent material flow and improve assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple panel units are connected through separate reinforcing parts, then the rigidity of each panel is improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate reinforcing parts into a single integrated reinforcing panel that simultaneously connects multiple panel units. This reinforcing panel includes a first reinforcing part for the first panel, a second reinforcing part for the second panel, and a connecting part that links them together, thereby reducing assembly complexity while maintaining rigidity enhancement.
Solution Approach 2:
The reinforcing panel serves multiple functions simultaneously: it reinforces the rigidity of the first panel, reinforces the rigidity of the second panel, and connects both panels together. This multi-functional design eliminates the need for separate components for each function, simplifying the overall assembly process.
2Ease of manufacture
If separate panel units and reinforcing parts are manufactured independently, then manufacturing flexibility is improved, but post-processing costs and assembly difficulty increase
Solution Approach 1:
The reinforcing panel is designed with pre-formed connecting parts that are integrated during the reinforcing panel manufacturing process. The connecting part is preliminarily shaped to match the coupling parts of the panel units, enabling direct connection without additional processing or adjustment during assembly, thereby improving assembly efficiency.
3Device complexity
If a single reinforcing part connects multiple panel units, then assembly is simplified, but the reinforcing capability for each panel may be insufficient
Solution Approach 1:
The reinforcing panel combines multiple reinforcing functions into a single component. The first reinforcing part is disposed on the non-exposed surface of the first panel, the second reinforcing part is disposed on the non-exposed surface of the second panel, and the connecting part links them, ensuring each panel receives adequate reinforcement while maintaining assembly simplicity.
Solution Approach 2:
The reinforcing panel extends in multiple spatial dimensions to simultaneously contact and reinforce multiple panel units. By distributing the reinforcing parts across different panels and connecting them through a multi-dimensional structure, the design maintains sufficient reinforcing capability for each panel while achieving assembly simplification.
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 design reduces manufacturing costs and time, enhances rigidity and heat resistance, and improves design freedom by simplifying the assembly process while maintaining aesthetic integrity.
Implementation Method 1
The non-exposed surfaces of the first panel and the second panel may be coated with the reinforcing panel in a form of a mixture of polyurethane and long glass fibers and then foamed and shaped in spaces between the first panel, the second panel, and a mold
Data Source
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AI summary
The present invention relates to an improved vehicle bumper in which a plurality of panel units are connectable through one reinforcing part and a method of manufacturing the same. The vehicle bumper includes a panel unit including a first panel forming a main protection area and a second panel coupled to the first panel and forming an additional protection area at one side of the main protection area, and a reinforcing panel disposed on non-exposed surfaces of the first panel and the second panel and fixing the first panel and the second panel to each other.