Vehicle Under-Protector Mounting Structure Without Exposed Bolts
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Solution Overview
Problem
Existing under-protector fastening structures for vehicles are inefficient due to exposed fastening bolts that can corrode and cause musculoskeletal issues for workers, while also compromising appearance and marketability by increasing the cross-sectional area and requiring separate assembly, which complicates the production process.
Innovation Solution
The under-protector is integrated with the bumper, eliminating exposed bolts by weld-coupling the under-protector fixing bracket to the under-protector panel, allowing for installation within the package approach angle, reducing production costs, and enhancing marketability through improved ground clearance and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the under-protector panel is fastened to the under-protector mounting assembly by a fastening bolt, then the under-protector can be assembled, but the externally protruding fastening bolt deteriorates appearance quality and may be corroded and damaged
Solution Approach 1:
The under-protector panel and under-protector mounting assembly are merged into a single integrally formed component. This eliminates the need for separate fastening bolts and their associated recesses, thereby removing the harmful effects of exposed bolts (corrosion and appearance deterioration) while maintaining assembly capability. The integral structure ensures the under-protector functions as a unified protective element without requiring additional fastening hardware.
Solution Approach 2:
The fastening bolt and its recess structure are extracted (removed) from the design. By eliminating these separate fastening elements, the patent avoids the problems of exposed bolts deteriorating appearance and being susceptible to corrosion. The under-protector panel is directly formed as part of the mounting assembly, removing the need for separate fastening components entirely.
2Ease of manufacture
If a cross-section area increases to implement a shape of a fastening bolt recessed structure, then the fastening function is achieved, but the marketability deteriorates due to the invasion of a package approach angle
Solution Approach 1:
The under-protector panel and mounting assembly are combined into a single integrated component. This eliminates the need for separate fastening bolt recesses that would increase the cross-sectional area and invade the package approach angle. The integral structure maintains the necessary fastening function through direct formation while preserving the sleek external profile required for marketability.
3Ease of manufacture
If a worker enters the lower portion of the vehicle and fastens the under-protector panel to the under-protector mounting assembly while looking up, then the fastening operation can be performed, but foreign material may enter eyes of the worker or a musculoskeletal disease of the worker may occur, and thus workability is reduced
Solution Approach 1:
The under-protector panel and mounting assembly are merged into an integral structure that is pre-assembled or designed as a single unit. This eliminates the need for workers to perform fastening operations in the difficult lower vehicle portion, thereby preventing foreign material from entering workers' eyes and avoiding musculoskeletal diseases. The integrated design maintains fastening functionality while improving worker safety and comfort.
4Ease of manufacture
If the under-protector is integrated with the bumper, then production costs are reduced and marketability is improved, but the structural complexity of the fastening system changes
Solution Approach 1:
The under-protector and bumper are merged into an integrated assembly, reducing production costs by eliminating separate fastening components and simplifying the manufacturing process. While the fastening system structure changes, the integration reduces overall complexity by removing multiple separate parts (fastening bolts, recesses, mounting assemblies) and replacing them with a unified structure that achieves the same functional goals.
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 solution reduces production costs, improves marketability, prevents musculoskeletal diseases, and enhances the structural strength of the under-protector by eliminating exposed bolts and sagging, while ensuring high ground clearance and corrosion resistance.
Implementation Method 1
weld-coupling an under-protector fixing bracket to an under-protector panel
Data Source
AI summary
An under-protector fastening structure includes a bumper assembly coupled to a chassis frame, wherein the bumper assembly includes a bumper inner member and a bumper cover coupled to an outer side of the bumper inner member, and an under-protector coupled to the bumper inner member of the bumper assembly in a direction vertical to a length direction of a vehicle body, wherein the under-protector includes an under-protector mounting assembly coupled to the bumper inner member and an under-protector panel coupled to the under-protector mounting assembly, and wherein the under-protector mounting assembly includes a pipe member extending in the direction vertical to the length direction of the vehicle body, a mounting bracket coupled to the pipe member and the bumper inner member, and an under-protector fixing bracket having a first side coupled to the mounting bracket and a second side coupled to the under-protector panel.