Folded Vehicle Bumper Panel With Interlocking Bend-Line Assembly
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Solution Overview
Problem
Existing fabricated metal bumpers require significant labor for fixturing and use of heavy machinery for bending, are prone to heat distortion, and have insecure tab and slot arrangements, leading to quality variations and material inefficiencies.
Innovation Solution
A single-piece, foldable metal panel design with perforations and slots along bend lines, incorporating interlocking dovetail shapes and bolt holes for secure assembly without the need for multiple components or heavy machinery, reducing bending force and enhancing structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple sheet metal segments are used and welded together, then the bumper can achieve the desired structural shape, but significant fabrication labor is required for fixturing and alignment
Solution Approach 1:
The patent combines multiple separate sheet metal segments into a single integrated panel with interconnected sections. The first, second, and third sections are formed from one continuous piece of sheet metal, eliminating the need for separate fixturing and alignment operations during assembly.
Solution Approach 2:
While using a single piece of metal, the panel is designed with distinct interconnected sections that can be independently formed and positioned. These sections are connected through folded edges and slots, allowing modular assembly without traditional welding fixturing.
2Manufacturing precision
If heavy duty machinery is used to bend folded components, then the correct position and angle can be achieved, but the equipment cost and complexity increase
Solution Approach 1:
The patent introduces slots and perforations at specific locations along the bend lines to locally reduce material continuity. This allows hand bending to achieve precise angles without requiring heavy machinery, as the slots create natural hinge points that facilitate controlled folding.
Solution Approach 2:
The design changes the physical parameters of the sheet metal by adding slots and perforations, which alter the bending characteristics. These modifications enable manual bending operations to achieve the same precision previously requiring heavy duty equipment.
3Ease of operation
If tabs and slots are used for aligning folded panels, then assembly is simplified, but the arrangement does not securely engage panels on similar planes and may allow separation during welding
Solution Approach 1:
The patent employs dovetail-shaped interlocking features with tapered geometry. The dovetail tabs and recesses create a wedge-like engagement that prevents separation in multiple directions, providing secure mechanical interlocking that is more reliable than simple tab-and-slot arrangements.
Solution Approach 2:
The design combines multiple joining mechanisms: folded edges for initial alignment, dovetail interlocking for mechanical engagement, and slot-based connections for positional stability. This composite approach to joint design ensures panels remain securely engaged throughout the welding process.
4Strength
If welded joints are used at structural joints, then strong connections are achieved, but quality variation occurs due to material and process differences
Solution Approach 1:
The patent performs preliminary mechanical joining through folded edges, slot insertions, and dovetail interlocking before welding is applied. This pre-alignment and mechanical securing ensures consistent joint positioning and reduces variability in the final weld quality.
Solution Approach 2:
The folded edges and interlocking features are self-forming during the assembly process, creating inherent alignment and positioning without requiring external fixturing or complex welding procedures. The structure self-aligns through its geometric features.
5Force
If a single piece of sheet metal is used with perforations and slots, then bending force is reduced enabling manual operation, but the amount of material is reduced
Solution Approach 1:
The patent extracts minimal amounts of material through strategically placed slots and perforations along the bend lines. These removed portions are sufficient to reduce bending resistance and enable manual operation, while the majority of the sheet metal remains intact to maintain structural integrity.
Data Source
AI summary
A panel configured to convert from a flat configuration to a folded configuration includes a central section, a first intermediate section, a second intermediate section, a first outer section, and a second outer section. The first intermediate section and the second intermediate section are formed on opposite sides of the central section and are foldable relative to the central section. The first outer section is formed on a side of the first intermediate section opposite the central section and is foldable relative to the first intermediate section. The second outer section is formed on a side of the second intermediate section opposite the central section and is foldable relative to the second intermediate section. The panel can be folded along a plurality of intended bend lines to be converted to the folded configuration and includes a slot or a perforation line defined therein along one or more of the intended bend lines.