Secondary Bumper Assembly With Heel Block Mounting
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Solution Overview
Problem
Traditional secondary bumpers for vehicles used in loading and unloading processes at docks are prone to rapid wear and damage due to high friction and abrasion, leading to frequent replacements and potential damage to both the vehicle and loading docks.
Innovation Solution
The secondary bumper assembly eliminates horizontal mounting holes, featuring a base plate with groove hold-down heel blocks and a compressible secondary bumper made of durable materials like EPDM rubber, which is designed to absorb impacts and resist shredding, with a rigid clamping structure to maintain placement during bumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional secondary bumpers with horizontal mounting holes are used, then installation is simple, but they wear down quickly and bolt heads hit the loading dock causing damage
Solution Approach 1:
The bumper is divided into multiple segments including a main body, base segments, and heel blocks that can be independently positioned and secured. This segmentation allows the bumper to distribute wear across multiple components rather than a single continuous structure, extending service life while maintaining ease of installation through modular assembly
Solution Approach 2:
The mounting system transitions from horizontal mounting holes to a vertical/diagonal orientation using heel blocks that engage with the loading dock at an angle. This dimensional change prevents bolt heads from contacting the dock surface during oblique impacts, eliminating the damage mechanism while preserving installation simplicity through the heel block interface
2Strength
If rubber material is used for secondary bumpers, then impact absorption is good, but friction and abrasion resistance is limited
Solution Approach 1:
The bumper employs a composite construction combining rubber material for the main body with harder base segments and heel blocks. The rubber provides impact absorption while the harder materials resist friction and abrasion from contact with the loading dock, creating a multi-material system that addresses both requirements simultaneously
Solution Approach 2:
Different regions of the bumper have different material properties optimized for their specific functions: the main body uses soft rubber for impact absorption, while the base segments and heel blocks use harder materials for abrasion resistance at contact points. This local differentiation of material quality resolves the contradiction between impact absorption and friction resistance
3Object-affected harmful factors
If UHMW polyethylene is used for secondary bumpers, then protection against shredding is improved, but ability to be compressed is limited
Solution Approach 1:
The bumper combines UHMW polyethylene for the main body structure and heel blocks with compressible rubber material. The UHMW provides shredding resistance and structural integrity, while the rubber components provide the necessary compressibility for impact absorption, creating a composite system that delivers both properties
Solution Approach 2:
The bumper structure features local differentiation where UHMW polyethylene is used in regions requiring shredding resistance and structural stability, while rubber material is used in regions requiring compressibility for impact absorption. This localized material assignment allows each material to perform its optimal function without compromising the other
4Ease of operation
If secondary bumpers are mounted with horizontal holes, then mounting is straightforward, but they wear down to bolt heads hitting the loading dock
Solution Approach 1:
Instead of mounting the bumper horizontally with holes through the main body, the design inverts the mounting approach by using heel blocks that engage vertically/diagonally with the loading dock. This inversion changes the contact geometry so that bolt heads are positioned away from the dock surface, preventing damage while maintaining straightforward mounting through the heel block interface
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 significantly increases the service life of secondary bumpers by preventing wear and damage, allowing them to withstand abrasion-prone loading and unloading processes without the need for frequent replacements.
Implementation Method 1
The hardness level of the base segments is greater than a predetermined level to prevent flexing of the base segments in a direction away from portions of the main body opposite the base segments
Implementation Method 2
The rubber of the secondary bumpers absorbs impacts
Implementation Method 3
The secondary bumper includes a main body and a base. A first groove and a second groove exist between portions of the main body and the base
Implementation Method 4
The first pair of heel blocks includes flanges and are configured to at least one of maintain contact between or at least partially prevent movement between the secondary bumper and the base plate
Data Source
AI summary
A secondary bumper assembly is provided and includes a base plate, a secondary bumper, and heel blocks. The base plate includes holes for mounting the secondary bumper assembly to a primary bumper. The secondary bumper is disposed on the base plate. The secondary bumper includes a main body and a base. First and second grooves exist between portions of the main body and the base, which has base segments. The heel blocks include flanges and maintain contact between or at least partially prevent movement between the secondary bumper and the base plate. The base segments slide into gaps between the base plate and the heel blocks. A hardness level of the base segments is greater than a predetermined level to prevent flexing of the base segments in a direction away from portions of the main body opposite the base segments. The flanges slide respectively into the first and second grooves.