Ultrasonic Welded Headlight Washer Bracket for Flush Bumper Mounting
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Solution Overview
Problem
Conventional headlight washer assemblies protrude fasteners through the bumper's front surface, creating an unsightly aberration and making the bumper cap more susceptible to tampering and damage, especially on newer vehicles with sculpted bumpers.
Innovation Solution
A bracket is ultrasonically welded to the inner surface of a vehicle's body panel, providing a recessed mounting surface for the headlight washer device, allowing the fasteners to be secured without protruding, and a cap that fits flush with the bumper's surface when the device is retracted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners extend through the front surface of the bumper to secure the washer device, then the washer device can be securely mounted, but the bumper surface becomes unsightly and the bumper cap is more susceptible to tampering and damage
Solution Approach 1:
The fasteners are relocated from the front surface dimension to the rear surface dimension of the bumper. The bracket is secured to the rear surface of the bumper, and fasteners extend through the bracket from the rear, allowing secure mounting while keeping the front surface flush and aesthetically pleasing.
Solution Approach 2:
A bracket serves as an intermediary component between the bumper and the washer device. The bracket is secured to the rear surface of the bumper and provides a mounting surface for the washer device, allowing the fasteners to be hidden while still providing secure attachment.
2Shape
If the bumper cap extends from the bumper's outer surface to conceal fasteners, then the fasteners are hidden, but the bumper cap is more susceptible to tampering and damage
Solution Approach 1:
The fasteners are extracted from the front surface mounting approach and relocated to rear surface mounting. This eliminates the need for the bumper cap to extend outward to conceal fasteners, as the fasteners are already hidden at the rear surface, reducing the bumper cap's exposure to tampering and damage.
3Device complexity
If fasteners are visible on the bumper front surface, then the mounting structure is simple, but the aesthetic appeal is compromised
Solution Approach 1:
The mounting structure is modified by moving fastener installation to the rear surface dimension. The bracket is secured to the rear surface with fasteners, creating a simple mounting structure that does not compromise the aesthetic appearance of the front bumper surface.
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 maintains aesthetic appeal by keeping the fasteners hidden and reduces the risk of damage by securing the headlight washer assembly without visible fasteners, enhancing the vehicle's appearance and durability.
Implementation Method 1
A bracket is ultrasonically welded to the inner surface of a vehicle's body panel
Data Source
AI summary
A headlight washer assembly includes a bracket secured to a rear surface of a component of a vehicle adjacent an opening therein through which a headlight washer device is configured to extend and retract. The bracket provides a recessed mounting surface for securing the headlight washer device to the component of the vehicle such that, unlike prior art approaches, the fasteners do not protrude from the front surface of the component of the vehicle. A cap concealing the opening in the component is received within the opening flush with the front surface of the component. In one embodiment, the component is a body panel of a vehicle.