Over Slam Bumper Buffer Unit Mounting Mechanism
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Solution Overview
Problem
Existing over slam bumpers for vehicles, made entirely of rubber, suffer from permanent deformation and wear, leading to separation from the penetration aperture due to frequent elastic deformation and abrasion, compromising their damping function and requiring premature replacement, especially on uneven road surfaces.
Innovation Solution
An over slam bumper design featuring a buffer unit made of thermo plastic elastomer (TPE) and a mounting unit made of poly oxy methylene (POM), with a locking mechanism using insert flanges, support flanges, clips, and support protrusions to securely attach the buffer unit to the inner panel, preventing separation and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the over slam bumper is made entirely of rubber material, then it can absorb shock through elastic deformation, but it becomes permanently deformed and separated due to frequent elastic deformation and abrasion over time
Solution Approach 1:
The over slam bumper is divided into two distinct parts: a buffer unit made of rubber material for shock absorption and a mounting unit made of wear-resistant synthetic resin for secure attachment. This segmentation allows each part to be optimized for its specific function, with the buffer unit handling elastic deformation and the mounting unit providing durable mounting, thereby resolving the contradiction between maintaining damping function and extending service life.
Solution Approach 2:
The invention uses composite construction by combining rubber material for the buffer unit with synthetic resin for the mounting unit. This composite approach leverages the elastic properties of rubber for shock absorption while utilizing the wear and deformation resistance of synthetic resin for the mounting components, thus preventing permanent deformation and separation while maintaining the damping function throughout the service life.
2Reliability
If the mounting unit is forcibly pressed and fitted into the penetration aperture, then it can be securely mounted, but workability deteriorates
Solution Approach 1:
The mounting unit incorporates an elastic body that can be elastically deformed during the mounting process to facilitate insertion into the penetration aperture. After mounting, the elastic body returns to its original shape, providing secure fixation. This dynamic elasticity allows for easy installation without requiring excessive force, thereby improving workability while maintaining mounting security.
Solution Approach 2:
The mounting unit utilizes changes in elastic deformation parameters during mounting. The elastic body is temporarily deformed beyond its normal range to enable insertion, then returns to its elastic limit, creating a secure fit. This parameter change approach allows for simple snap-fit mounting without complex tools or excessive force, resolving the contradiction between secure mounting and ease of manufacture.
3Reliability
If the over slam bumper is made entirely of rubber material, then it can provide cushioning effect, but it requires replacement after predetermined time due to abrasion and deformation
Solution Approach 1:
The over slam bumper is segmented into a buffer unit and a mounting unit, allowing the buffer unit to be replaced independently when worn. This segmentation enables cost-effective maintenance where only the rubber buffer unit needs replacement rather than the entire assembly, maintaining the cushioning effect over time while reducing replacement costs and improving marketability.
Solution Approach 2:
The buffer unit made of rubber material is designed as a replaceable component with a limited service life due to its elastic deformation and abrasion characteristics. By making this unit replaceable and relatively simple in construction, the invention allows for economical replacement rather than replacing expensive integrated assemblies, thus maintaining productivity and marketability while ensuring continuous cushioning performance.
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
The solution effectively absorbs shock and noise, enhances mounting workability, and extends the lifespan of the over slam bumper by preventing permanent deformation and separation, while allowing for cost-effective replacement of the buffer unit when worn, thus improving marketability and durability.
Implementation Method 1
the over slam bumper is made entirely of the rubber material and therefore may be permanently deformed due to the frequency elastic deformation and abrasion occurrence when it is used for a substantial period of time
Data Source
AI summary
An over slam bumper for a vehicle is provided and includes a buffer unit having one end protruding from an inner panel of the door toward a vehicle body and absorbing shock power between the vehicle body and the door. A mounting unit has one end fixed to another end of the buffer unit and another end thereof is inserted into a penetration aperture to fix the buffer unit to the inner panel. The mounting unit includes an insert flange inserted into the buffer unit and a support flange interconnected to the insert flange. An insert having one end integrally protrudes from a center of the support flange toward the penetration aperture and clips are integrally formed at the protruding end of the insert and are fixed while being locked to an inner circumferential surface of the penetration aperture when a predetermined portion thereof is inserted into the penetration aperture.