Detachable Bumper Light Bar Mounting for Single-Worker Assembly
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Solution Overview
Problem
Customizing vehicle bumpers to meet specific user needs is time-consuming, material-intensive, and often non-compliant with safety standards, and existing detachable components require a two-worker procedure for alignment and attachment, which is cumbersome.
Innovation Solution
A vehicle bumper design featuring a mounting plate with integrally formed mounting flanges and light bars, allowing for detachable engagement and disengagement, and a support member that simplifies alignment and attachment with a single worker, while accommodating customizable lights and accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom components are fabricated to meet specific user needs, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The bumper system is divided into modular components: a base bumper assembly and separately attachable light bar assemblies. Each light bar assembly includes its own mounting flange with pre-drilled holes, allowing independent fabrication or replacement without customizing the entire bumper. This segmentation enables users to customize specific functional elements while keeping the main structure standardized.
Solution Approach 2:
The mounting flanges are designed with universal features including multiple mounting holes arranged in standard patterns, compatibility with various light bar configurations, and integration with the base bumper structure. This universal design allows the same mounting mechanism to serve multiple customization needs across different applications.
2Manufacturing precision
If two workers are used for alignment and bolt insertion, then manufacturing precision is improved, but labor requirements and operation complexity increase
Solution Approach 1:
The mounting flanges are pre-formed with precisely positioned mounting holes during the manufacturing process. This preliminary action ensures that when assembly occurs, the alignment holes are already in the correct positions, eliminating the need for one worker to hold and align components while another inserts bolts. The precision is achieved during manufacturing rather than during assembly operation.
3Ease of manufacture
If standard factory components are used, then manufacturing cost is reduced, but adaptability to specific user needs deteriorates
Solution Approach 1:
The system separates the standardized base bumper (produced at low cost through standard manufacturing) from the customizable light bar assemblies. Users can select from pre-fabricated light bar options or attach their own custom light bars using the standardized mounting flanges, achieving customization without requiring custom manufacturing of the entire bumper assembly.
Data Source
AI summary
Provided in this disclosure is a vehicle bumper having a mounting plate extending between first end and second ends and a first mounting flange formed integrally with the first end of the mounting plate. A second mounting flange is formed integrally with the second end of the mounting plate. A first light bar and a second light bar are provided. A first mating mounting flange is formed integrally with the first light bar, and a second mating mounting flange formed integrally with the second light bar. The mounting plate has a planar mounting surface. The first mating mounting flange is configured for detachable engagement with the first mounting flange. The second mating mounting flange is configured for detachable engagement with the second mounting flange.