Integrated Vehicle Bumper Structure for Simpler LFI Assembly
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Solution Overview
Problem
Recent vehicle bumpers manufactured through the long fiber injection (LFI) process face challenges in terms of high post-processing costs and increased difficulty in manufacturing and assembling multiple components, as they require separate panel units and reinforcing parts to be combined.
Innovation Solution
A vehicle bumper design that connects multiple panel units through a single reinforcing part, where the panel units include cover and coupling parts, and the reinforcing panel is applied to non-exposed surfaces in the form of a polyurethane and long glass fibers mixture, foamed and shaped to reinforce the panels without exposing the coupling structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate panel units and reinforcing parts are combined through LFI process, then the bumper can be manufactured with reduced mold costs, but the manufacturing and assembly complexity increases
Solution Approach 1:
The patent merges the panel units and reinforcing parts into a single integrated bumper structure. The reinforcing parts are embedded within the panel units during injection molding, eliminating the need for separate assembly steps. This integration reduces manufacturing and assembly complexity while maintaining the cost benefits of the LFI process.
Solution Approach 2:
The injection molding process is designed to simultaneously perform multiple functions: forming the panel units, embedding the reinforcing parts, and creating the final bumper structure in one operation. This multi-functionality reduces the number of separate manufacturing steps and simplifies the overall production process.
2Reliability
If multiple panel units are connected through separate reinforcing parts, then the bumper structure can be assembled, but the manufacturing difficulty and assembly difficulty increase
Solution Approach 1:
The reinforcing parts are pre-positioned and embedded within the panel units during the injection molding process. This preliminary action ensures that the reinforcing parts are correctly positioned before final assembly, reducing manufacturing difficulty and ensuring structural reliability without requiring complex post-assembly operations.
3Quantity of substance
If a plurality of panel units are connected using reinforcing parts, then the bumper can be assembled, but post-processing costs remain relatively high
Solution Approach 1:
The patent combines multiple panel units and reinforcing parts into a single integrated component through injection molding. This merging eliminates the need for separate post-processing steps such as separate vacuum-forming, foaming, and assembly operations, thereby reducing post-processing costs while maintaining the necessary structural integrity.
4Ease of manufacture
If separate panel units and reinforcing parts are used, then the bumper can be manufactured through LFI process, but the difficulty of assembling each component increases
Solution Approach 1:
The injection molding process is segmented into distinct functional zones: panel unit formation, reinforcing part embedding, and coupling part integration. This segmentation allows each component to be manufactured with optimized processes while being assembled automatically as a single integrated structure, reducing assembly difficulty.
Solution Approach 2:
The injection molding process automatically performs the assembly function by embedding the reinforcing parts and coupling parts within the panel units during a single operation. This self-service approach eliminates the need for separate manual assembly steps, reducing assembly difficulty while maintaining LFI manufacturing capabilities.
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
This design reduces manufacturing costs and complexity by eliminating the need for separate reinforcing parts, while enhancing the rigidity and heat resistance of the bumper, thus improving the vehicle's design flexibility and reducing weight.
Implementation Method 1
coating the first panel and the second panel with a reinforcing panel in the 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
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.