Integrated Rear Fascia Bracket for Flush Tail Lamp Assembly
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Solution Overview
Problem
The existing bracket systems require multiple individual tooling and installation steps to attach a rear fascia to a vehicle body-side sheet metal and a rear panel sheet metal, which complicates the assembly process and affects the flushness and margin between adjacent components.
Innovation Solution
A single bracket with a flexible portion that connects two elongated and enlarged body portions, allowing attachment of the rear fascia to both the vehicle body-side sheet metal and the rear panel sheet metal underneath the tail lamp, facilitating easier installation and reducing the number of parts and tooling required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple brackets are used to attach the rear fascia to the vehicle body-side sheet metal and rear panel sheet metal, then the attachment function is achieved, but the assembly process becomes complicated and requires individual tooling for each bracket
Solution Approach 1:
The patent combines multiple separate brackets into a single integrated bracket assembly that performs the functions of attaching the rear fascia to both the vehicle body-side sheet metal and the rear panel sheet metal. This merging eliminates the need for individual tooling for each bracket and simplifies the assembly process while maintaining all necessary attachment functions.
Solution Approach 2:
The single bracket assembly is designed to perform multiple functions: it attaches the rear fascia to the vehicle body-side sheet metal, attaches to the rear panel sheet metal, and provides structural support. This multi-functional design replaces multiple specialized brackets, reducing complexity and tooling requirements.
2Reliability
If multiple brackets are used, then the attachment points are secured, but the number of installation steps increases for each bracket on the assembly line
Solution Approach 1:
By merging multiple bracket functions into a single integrated assembly, the number of installation steps is reduced. The single bracket can be installed in one operation rather than requiring sequential installation of multiple separate brackets, thereby improving assembly line efficiency while maintaining secure attachment at all necessary points.
3Manufacturing precision
If multiple brackets are used, then the attachment coverage is sufficient, but the flushness and margin between adjacent components are compromised
Solution Approach 1:
The integrated single bracket assembly provides better control over flushness and margin between adjacent components compared to multiple separate brackets. The unified structure ensures consistent positioning and alignment, eliminating variations that may occur with multiple independent brackets, thereby improving manufacturing precision.
Data Source
AI summary
A method and an apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a single bracket that has a first portion that attaches a rear fascia to a vehicle body-side sheet metal and a second portion that attaches the rear fascia to a rear panel sheet metal that extends underneath a tail lamp to support the tail lamp.