Modular Push Bumper Assembly for Protected Accessory Mounting

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Solution Overview

Problem

Welded push bumpers are labor-intensive to manufacture, prone to rust, costly to ship and store, difficult to customize, and expose mounted accessories to damage, requiring complete replacement or repair.

Innovation Solution

A modular push bumper assembly that can be assembled and customized by the end user, with accessories protected from the elements and vandalism, and allowing individual parts to be replaced or repaired without removing the entire assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welded push bumpers are used, then structural strength is improved, but manufacturing complexity and labor intensity increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The push bumper is divided into multiple separate modules (crossbar module, upright modules) that can be manufactured independently and assembled later using fasteners, eliminating the need for complex welding operations while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular design with standardized fastening interfaces allows the same modules to be used across different bumper configurations and applications, simplifying manufacturing processes and reducing the need for custom welding for each variant

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If welded push bumpers are used, then structural integrity is improved, but adaptability and customization options decrease

Engineering Contradiction:

Improvestructural integrityVSAvoidcustomization options

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The bumper system is segmented into interchangeable modules that can be mixed and matched to create customized configurations while maintaining structural integrity through standardized fastening interfaces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular design allows the bumper configuration to be dynamically adjusted and reconfigured based on specific application requirements, enabling customization without compromising structural strength

Inventive Principle:

Principle #15Dynamics

3Reliability

If welded push bumpers are used, then durability is improved, but ease of repair and replacement decreases

Engineering Contradiction:

ImprovedurabilityVSAvoidease of repair

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The bumper is segmented into replaceable modules that can be individually removed and replaced without affecting the entire structure, significantly easing repair and maintenance operations while maintaining overall durability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Damaged modules can be easily removed and replaced with new or refurbished modules, allowing for efficient repair and recovery of functional components without replacing the entire bumper assembly

Inventive Principle:

Principle #34Discarding and recovering

4Adaptability or versatility

If accessories are mounted on push bumpers, then vehicle functionality is improved, but exposure to damage from elements and vandalism increases

Engineering Contradiction:

Improvevehicle functionalityVSAvoidexposure to damage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Accessories are nested within the bumper structure itself, with the bumper members forming protective enclosures that shield mounted accessories from environmental elements and potential vandalism while maintaining functionality

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12612002B2Modular push bumper

Publication Date: 2026.04.28 FEDERAL SIGNAL CORPORATION

AI summary

A modular push bumper that mounts directly to a chassis or frame of a vehicle. Members of the push bumper are fastened together with fasteners, rather than welded together. The modular push bumper can include a channel member defining a channel for mounting accessories to the modular push bumper. The channel member is configured to block access to the accessory.