Single-Piece Bracket for Bumper Accessories

Solution Overview

Problem

The use of multiple brackets for attaching accessories like fog lamps and active air dams to vehicle bumpers increases assembly time, cost, and weight, due to the complexity and massiveness of the mounting systems.

Innovation Solution

A single-piece multi-accessory bracket with integrated mount interfaces for both fog lamps and active air dam actuators, featuring a screw jack mechanism and trolley system, which reduces the number of components and enhances structural rigidity and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple brackets are used to attach fog lamps and air dams to the bumper, then the mounting system provides adequate structural support and stability, but the assembly time increases and the overall weight and cost increase

Engineering Contradiction:

Improvestructural supportVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent combines multiple separate mounting brackets into a single integrated bracket assembly that simultaneously mounts both the fog lamp and the active air dam to the bumper. This merging of functions reduces the number of separate components needed, thereby decreasing assembly time while maintaining the required structural support through the integrated design of the bracket.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single bracket assembly is designed to perform multiple mounting functions - it securely attaches both the fog lamp and the active air dam to the bumper. This multi-functional bracket eliminates the need for separate mounting brackets for each accessory, reducing assembly complexity and time while providing adequate structural support for both components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If multiple brackets are used to attach fog lamps and air dams to the bumper, then the mounting system provides adequate structural support and stability, but the overall weight increases

Engineering Contradiction:

Improvestructural supportVSAvoidoverall weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent combines multiple separate mounting brackets into a single integrated bracket assembly that simultaneously mounts both the fog lamp and the active air dam to the bumper. This merging of functions reduces the number of separate components needed, thereby decreasing assembly time while maintaining the required structural support through the integrated design of the bracket.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single bracket assembly is designed to perform multiple mounting functions - it securely attaches both the fog lamp and the active air dam to the bumper. This multi-functional bracket eliminates the need for separate mounting brackets for each accessory, reducing assembly complexity and time while providing adequate structural support for both components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If multiple brackets are used to attach fog lamps and air dams to the bumper, then the mounting system provides adequate structural support and stability, but the cost increases

Engineering Contradiction:

Improvestructural supportVSAvoidcost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate mounting brackets into a single integrated bracket assembly that simultaneously mounts both the fog lamp and the active air dam to the bumper. This merging of functions reduces the number of separate components needed, thereby decreasing assembly time while maintaining the required structural support through the integrated design of the bracket.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single bracket assembly is designed to perform multiple mounting functions - it securely attaches both the fog lamp and the active air dam to the bumper. This multi-functional bracket eliminates the need for separate mounting brackets for each accessory, reducing assembly complexity and time while providing adequate structural support for both components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 simplifies assembly, reduces weight and cost, and improves the robustness and efficiency of the bumper system by integrating mounting points for both fog lamps and air dams, while maintaining structural integrity and reducing noise, vibration, and harshness (NVH) performance.

Implementation Method 1

The actuator comprises a screw jack

Methodology Applied

Scientific EffectScrew mechanism: Screw

Data Source

PatentUS11325521B2Multi-accessory bracket for bumper mounted accessories

Publication Date: 2022.05.10 FORD GLOBAL TECH LLC

AI summary

An apparatus, according to an exemplary embodiment includes, among other things, a single-piece bracket having a first mount interface configured to receive a fog lamp and a second mount interface configured to receive an actuator for an active air dam. A method according to an exemplary aspect of the present disclosure includes, among other things, injection molding a single-piece bracket from a plastic material to include a first mount interface configured to receive a fog lamp and a second mount interface configured to receive an actuator for an active air dam.