Bumper Retainer Structure With Separated Sensor and Connection Parts
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Solution Overview
Problem
Existing bumper retainers with integrated sensor attachment parts face an increase in size due to mold interference, necessitating changes in connection part positions which are constrained by sensor attachment positions.
Innovation Solution
The bumper retainer design includes a separate connection part protruding orthogonally from the retainer main body, allowing it to be positioned on a straight line through the sensor attachment part without integrally molding, thus avoiding mold interference and optimizing attachment directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the connection part is positioned directly above the sensor attachment part in the thickness direction, then the attachment structure is optimized, but mold interference occurs when integrally molding the retainer main body, sensor attachment part, and connection part
Solution Approach 1:
The retainer is divided into separate components: the retainer main body, the sensor attachment part, and the connection part. This segmentation allows each component to be manufactured independently without mold interference, while still achieving the optimized attachment structure where the connection part is positioned directly above the sensor attachment part.
Solution Approach 2:
The connection part is extracted from the integrally molded structure and made separable. This extraction resolves the mold interference issue by allowing the connection part to be manufactured and attached separately, while maintaining its optimal position directly above the sensor attachment part for improved attachment structure.
2Ease of manufacture
If the connection part position is changed to avoid mold interference, then manufacturing becomes easier, but the retainer increases in size
Solution Approach 1:
By segmenting the retainer into separate components, the connection part can be positioned optimally directly above the sensor attachment part without requiring additional space that would increase overall retainer size. The separate manufacturing process eliminates the need for offset positioning that would occur with integral molding.
Solution Approach 2:
The solution transitions from trying to position components in the planar dimensions to utilizing the thickness direction dimension. The connection part is positioned directly above the sensor attachment part in the thickness direction, achieving optimal attachment structure without increasing the retainer's planar dimensions.
3Ease of manufacture
If the sensor attachment part and connection part are integrally molded, then manufacturing is simplified, but the retainer main body increases in size
Solution Approach 1:
The sensor attachment part and connection part are segmented into separate components that can be manufactured independently. This segmentation eliminates the need for additional material and space required for integral molding, thereby suppressing the increase in retainer main body size while still allowing for simplified assembly processes.
Solution Approach 2:
The connection part is extracted from the integral molding process and manufactured separately. This extraction reduces the volume of the retainer main body by eliminating the material and space required for the integrally molded connection part, while maintaining the functional integration through separate attachment.
Data Source
AI summary
A bumper retainer includes a retainer main body for attaching a bumper to a vehicle body, the retainer main body being made of resin; a sensor attachment part provided on a side in a thickness direction of the retainer main body, the sensor attachment part being integral with or separate from the retainer main body, the sensor attachment part enabling a sensor to be attached to the sensor attachment part; and a connection part protruding from the retainer main body in a direction orthogonal to the thickness direction, the connection part being located on a straight line extending in the thickness direction through the sensor attachment part as viewed counter to the direction in which the connection part protrudes, the connection part being separate from the sensor attachment part, and connectable to an exterior component.