Description:FIELD OF INVENTION

The present invention relates to front-bumpers in automotive vehicles and top-grill profiles therein. In particular, the present invention relates to obtaining an improved stiffness of the front-bumper and top-grill profiles joined to the air-intake spaces between the top-grill and upper facia of the front-bumper. More particularly, the present invention relates to reducing the possibility of waviness in the front-bumper profiles and enhancing the stiffness of the top-grill at the air duct area.

BACKGROUND OF THE INVENTION

In the early 20th century, the stiff metal bumpers on automotive vehicles had merely an ornamental function. However, continuous improvements in materials and production technologies, and also with the emphasis on their main functions to protect the vehicle components and to enhance the safety of automobiles have brought a vast improvement in bumpers over time.

Automotive front-bumpers should ideally minimize the height mismatches between the vehicles to protect the pedestrians from any substantial injury. The stringent regulatory compliances also necessitate that after unavoidable accidents, the vehicle repair costs should be reduced and the impact on pedestrians should be minimized.

The latest bumper covers are made of flexible materials. In particular, the front bumpers are low in weight and made of softer materials, like foams and crushable plastics to reduce the severity of the impact on pedestrian’s legs. Automotive bumpers predominantly play a safety function by being fixed at the front and back of the vehicles.
The bumpers are configured to absorb a predetermined impact from the collision by functioning as dampers therefor. In addition, the modern day bumpers are configured to be aerodynamic and cost-effective to improve the efficiency and performance of the vehicles. Moreover, by providing air-intake spaces or channels in the bumper, air entering from the front of the vehicle is used to have a better grip and stability for a safer drive while operating automotive vehicles.

The primary issue faced in the air-intake spaces or air duct areas of the front bumper grill is the warpage occurring due to lower stiffness on thin sections of the bumper profiles. This warpage defect during the injection molding process occurs when the intended shape of the molded component is distorted during the cooling process. The mold warping can cause the component to fold, bend, twist, or bow. The occurrence of this defect is a chronic issue, when plastic components have open edges. The air-cooling system serves three important functions in automobiles.

First, the air-cooling system removes excess heat from the engine.

Second, it maintains the engine operating temperature for the engine to function most efficiently.
Finally, this air-cooling system brings the engine up to the right operating temperature as quickly as possible.

The automobile grill is a component that facilitates the air-circulation within the engine room, and air enters through the holes or air-intake spaces/air-duct areas for adequately maintaining the engine room temperature. The grill and air-guides also help the engine-cooling process by using a radiator to impart a proper direction to the incoming air flow.
PRIOR ART

US20070182173A1 titled: “Radiator Grill Attachment” discloses a side attachment for attaching a grill to a front bumper of a vehicle that allows the grill to pivot independently relative to the front bumper. The grill also includes tabs that locate the bottom edge of the grill to the front bumper and release the grill to allow rotation during a frontal impact of the vehicle, thereby minimizing damage to the grill. However, the object of this invention is to pivotally couple the grill to the front bumper for rotation about a substantially horizontal pivot axis relative to the front bumper.

DESCRIPTION OF THE INVENTION

In accordance with the present invention, a middle bracket support system is configured for strengthening the top grill profiles joined to the air-intake spaces between the top-grill and front-bumper facia. This middle bracket support system reduces the possibility of waviness in the front-bumper profiles and adds stiffness to the top-grill at the air-duct area.

The direction of air-flow is defined precisely through the component geometry to eliminate additional parts such as air-flow guide used conventionally. The structure for the front portion of a vehicle acting as the front bumper includes a rectangular opening after connecting the top grill with the upper fascia.

An identically structured member is formed along this rectangular opening to provide more rigidity for imparting an enhanced stiffness between the top grill and the fascia of the bumper.

A locking mechanism is also provided on the top-grill to support the fascia for controlling the deflection by including an additional support and offers an additional advantage of achieving a gap as per the design condition. This gap also acts as an air-guide to the radiator. Thereby, the conventionally used air-guides are eliminated.

The following are the advantages of the front bumper top-grill cutout with a middle bracket support system configured in accordance with the present invention:

• More rigid due to enhanced stiffness between the top grill and bumper upper facia.

• Cut out deflection is eliminated.

• Cut-out boundary gap is achieved as per the design conditions.

• Add-on advantage as the air guide to the radiator.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide a front bumper top-grill cutout with a middle bracket support system, which prevents the waviness of the flanges of the front bumper grill at the air-duct areas.

Another object of the present invention is to provide a front bumper top-grill cutout with a middle bracket support system, which maintains the shape of the component without any deflection thereof.

Still another object of the present invention is to provide a front bumper top-grill cutout with a middle bracket support system, which suitably directs the air-flow by providing a predefined direction thereto through the air-duct areas provided on the front bumper grill to the radiator.

Yet another object of the present invention is to provide a front bumper top-grill cutout with a middle bracket support system, which optimally achieves the cutout boundary gap as per the design condition thereof.

These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a front bumper assembly including a middle bracket support system comprising:

- a front-bumper top-grill bracket;
- a front-bumper upper facia;
- a top-grill;
- a plurality of chrome bezels with company logo;
- a tow-hook;
- an air-intake-grill for cooling air;
- a front-bumper lower-facia; and
- a pair of fog-lamp bezels;

characterized in that a middle bracket support system is configured to hold the front bumper upper facia and front bumper lower facia together for eliminating the warping thereof, to enhance the rigidity and stiffness between the front-bumper top-grill and front bumper upper facia by means of a plurality of snap attachments/mountings and profiled ribs, and to act as air-guide to radiator.

Typically, the front bumper assembly middle bracket support system comprises a plurality of mounting points, 2-way locator slots, snap attachments, and snap mountings provided for holding the front bumper upper and lower facia together.

Typically, the middle bracket support system comprises seven mounting points with a respective hole therein.

Typically, the mounting points have a 2-way locator slot with a hole of a predefined diameter, preferably 6 mm diameter; and an oval hole or slot with a predefined dimension, preferably 6 mm diameter and 8 mm length.

Typically, the middle bracket support system comprises six snap attachments and five snap-mountings.

Typically, the snap attachments are configured for attachment of the middle bracket support system with the front-bumper upper facia.

Typically, the snap mountings are configured for attachment of the middle bracket support system with the front-bumper lower facia.

Typically, the profiled ribs are as a plurality of triangular reinforcement ribs configured on left-hand side and right-hand side of the middle bracket support system.

Typically, the middle bracket support system comprises six triangular reinforcement ribs configured on the left-hand side and six triangular reinforcement ribs configured on the right-hand side thereof.

Typically, the middle bracket support system comprises:

• seven mounting points with respective holes therein, the mounting points having a 2-way locator slot with a hole of 6 mm diameter; and an oval hole/slot with 6 mm diameter and 8 mm length;

• six snap attachments for connecting the middle bracket support system to the front-bumper upper facia;

• five snap-mountings for connecting the middle bracket support system to the front-bumper lower facia; and

• six triangular reinforcement ribs configured on the left-hand side and six triangular reinforcement ribs configured on the right-hand side thereof;

wherein the middle bracket support system is made of polycarbonate/acrylonitrile styrene acrylate (PC/ASA) for internal and external application, e.g. for styling in automotive vehicles, and to hide the internal components thereof.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described in the following with reference to the accompanying drawings.

Figure 1 shows an exploded view of the front bumper assembly including a top-grill cutout with a bracket support system configured in accordance with the present invention.
Figure 2 shows a typical bumper top-grill support bracket for the front bumper assembly configured in accordance with the present invention.

Figure 3 shows the bumper top-grill support bracket positioned in the front bumper assembly configured in accordance with the present invention when seen from outside the vehicle.

Figure 4 shows a bumper top-grill support bracket positioned in the front bumper assembly configured in accordance with the present invention when seen from inside the engine compartment of the vehicle.

Figure 5 shows a perspective view of the bumper top-grill support bracket positioned in the front bumper assembly configured in accordance with the present invention when seen from inside the engine compartment of vehicle.

Figure 6a shows a top view of the bumper middle-grill support bracket for positioning in the front bumper assembly configured in accordance with the present invention.

Figure 6b shows a detailed view of the bumper middle-grill support bracket of Figure 6a across section line A-A.

Figure 6c shows a detailed view of the bumper middle-grill support bracket of Figure 6a across section line B-B.

Figure 7a shows a perspective view of the bumper middle-grill support bracket of Figure 6a.

Figure 7b shows another view of the bumper middle-grill support bracket when viewed in the direction of arrow ‘P’ in Figure 7a.
Figure 7c shows a detailed view of the bumper middle-grill support bracket of Figure 7b, across section C-C.

Figure 7d shows a detailed view of the bumper middle-grill support bracket of Figure 7b, across section D-D.

DETAILED DESCRIPTION OF THE INVENTION

In the following, the front bumper assembly including a top-grill cutout with a bracket support system configured in accordance with the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention.

Figure 1 shows an exploded view of the front bumper assembly 100 including a top-grill bracket 1 with a middle bracket support system 10 configured in accordance with the present invention. The front bumper assembly 100 includes a front-bumper top-grill bracket 1, a front-bumper upper facia 2, a top-grill 3, a plurality of chrome bezels 4 with company logo, a tow-hook 5, an intake-grill 6 for cooling air-intake, a front-bumper lower-facia 7 and a pair of fog-lamp bezels 8. Top-grill bracket 1 with middle bracket support system 10 (Figures 6a, 7a) is placed on front bumper lower fascia 7 for holding top-grill bracket 1 at the air-duct/intake area.

Figure 2 shows a typical bumper top-grill bracket 1 with a middle bracket support system 10 for the front bumper assembly 100 configured in accordance with the present invention. There are 7 mounting points (S1, S2, S3, S4, S5, S6, S7), out of which 2 mounting points (S5, S7) have 2-way locator slots, and 11 snap attachments (S1, S2, S3, S4, A1, A2, A3, S6, A4, A5, A6) for the middle bracket support system 10 to hold front-bumper fascia 2, 7 together.

Figure 3 shows the bumper top-grill 3 with the middle bracket support system 10 positioned in the front bumper assembly 100 configured in accordance with the present invention when seen from outside the vehicle.

Figure 4 shows the bumper top-grill 3 with the middle bracket support system 10 positioned in the front bumper assembly 100 configured in accordance with the present invention when seen from inside the engine compartment of the vehicle. The middle bracket support system 10 is configured to eliminate the warping of the front bumper grill fascia 2, 7.

Figure 5 shows a perspective view of the middle bracket support system 10 positioned in the front bumper assembly 100 configured in accordance with the present invention when seen from inside the engine compartment 20 of the vehicle.

Figure 6a shows a top view of the middle bracket support system 10 for positioning in the front bumper assembly 100 configured in accordance with the present invention. The seven (7) mounting points (S1, S2, S3, S4, S5, S6, S7) with holes (e.g., 6-8 mm diameter) are visible along with six (6) snap attachments (SA) SA1-SA6 with front-bumper upper facia 2. Here, each of two (2) mounting points (S5, S7) have 2-way locator slots of a hole (C) with a predefined diameter, e.g., 6-8 mm and an oval hole or slot (SL) with 6-8 mm diameter and 6-8 mm length. Section-lines A-A and B-B are also marked to be described further in details. The snap mountings (M1, M2, M3, M4, M5) are also shown in this figure. A plurality of left-side LR and right-side RR substantially triangular ribs (e.g., 6 nos. each) are provided for reinforcement of the front-bumper top-grill bracket 1. The middle bracket support system 10 connects the air-passage to radiator (not shown) to improve the air-flow thereto. This middle bracket support system 10 is made of polycarbonate/acrylonitrile styrene acrylate (PC/ASA) for internal and external application, e.g., for styling in automotive vehicles, and to hide the internal components.

Figure 6b shows a detailed view of the middle bracket support system 10 of Figure 6a to indicate the cross-section at the mounting points (S1, S2, S3, S4, S5, S6, S7) across the section line A-A marked therein.

Figure 6c shows a detailed view of the middle bracket support system 10 of Figure 6a to indicate the cross-section at the snap-attachments (SA1, SA2, SA3, SA4, SA5, SA6) across the section line B-B marked therein.

Figure 7a shows a perspective view of the middle bracket support system 10 of Figure 6a. The mounting points (S1, S2, S3, S4, S5, S6, S7), holes (C), slot (SL) and snap mountings (M1, M2, M3, M4, M5) are visible here. For example, substantially triangular reinforcement ribs are provided on the left-side (LR1, LR2, LR3, LR4, LR5, LR6) and right-side (RR1, RR2, RR3, RR4, RR5, RR6) for reinforcing the middle bracket support system 10.

Figure 7b shows another view of the middle bracket support system 10 when viewed in the direction of arrow ‘P’ in Figure 7a and indicating the positions of all mounting points (S1, S2, S3, S4, S5, S6, S7), snap attachments (SA1, SA2, SA3, SA4, SA5, SA6), slot (SL), left-side (LR) and right-side (RR) reinforcement ribs and snap mountings (M1, M2, M3, M4, M5) are also visible. The section lines C-C and D-D are marked to be described further in details.

Figure 7c shows a detailed view of the middle bracket support system 10 of Figure 7b to indicate the cross-section at the snap mountings (M1, M2, M3, M4, M5) across the section C-C.

Figure 7d shows a detailed view of the middle bracket support system 10 of Figure 7b to indicate the cross-section at the snap mountings (M1, M2, M3, M4, M5) across the section D-D.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The front bumper assembly including a middle bracket support system configured in accordance with the present invention offers the following advantages:

• Provides more rigidity and stiffness between the top grill and bumper upper facia.

• Eliminates the deflection of the cut-out portions.

• Achieves the cut-out boundary gap as per the designed condition.

• Offers advantage of acting as air-guide to the radiator.

• Eliminates separate air-guide needed in conventional arrangements.

• Eliminates the warping of the front bumper grill fascia.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.

The description of the exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top”, and “bottom” as well as derivatives thereof (e.g. “horizontally”, “inwardly”, “outwardly”; “downwardly”, “upwardly” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion.

These relative terms are for convenience of description and do not require that the corresponding apparatus or device be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected”, refer to a relationship, wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. , Claims:We claim:

1. A vehicle front bumper assembly (100) including a middle bracket support system (10) comprises:

- a front-bumper top-grill bracket (1);

- a front-bumper upper facia (2);

- a top-grill (3);

- a plurality of chrome bezels (4);

- a tow-hook (5);

- an air-intake-grill (6) for cooling air;

- a front-bumper lower-facia (7); and

- a pair of fog-lamp bezels (8);

wherein said middle bracket support system (10) is configured to hold the front bumper upper facia (2) and front bumper lower facia (7) together for eliminating the warping thereof, to enhance the rigidity and stiffness between said front-bumper top-grill (3) and said front bumper upper facia (2) by means of a plurality of snap attachments/mountings and profiled ribs, and also to act as an air-guide to a radiator.

2. The front bumper assembly (100) as claimed in claim 1, wherein said middle bracket support system (10) comprises a plurality of mounting points, 2-way locator slots, snap attachments, and snap mountings provided for holding the front bumper upper and lower facia (2, 7) together.
3. The front bumper assembly (100) as claimed in claim 2, wherein said middle bracket support system (10) comprises seven mounting points (S1, S2, S3, S4, S5, S6, S7) with respective holes therein.

4. The front bumper assembly (100) as claimed in claim 2, wherein said mounting points (S5, S7) have a 2-way locator slot with a hole (C) of 6-8 mm diameter; and an oval hole or slot (SL) with 6-8 mm diameter and 6-8 mm length.

5. The front bumper assembly (100) as claimed in claim 2, wherein said middle bracket support system (10) comprises six snap attachments (SA1, SA2, SA3, SA4, SA5, SA6) and five snap-mountings (M1, M2, M3, M4, M5).

6. The front bumper assembly (100) as claimed in claim 5, wherein said snap attachments (SA1, SA2, SA3, SA4, SA5, SA6) are configured for attachment of said middle bracket support system (10) with said front-bumper upper facia (2).

7. The front bumper assembly (100) as claimed in claim 5, wherein said snap mountings (M1, M2, M3, M4, M5) are configured for attachment of said middle bracket support system (10) with said front-bumper lower facia (7).

8. The front bumper assembly (100) as claimed in claim 1, wherein said profiled ribs are as a plurality of triangular reinforcement ribs configured on left-hand side and right-hand side of said middle bracket support system (10).

9. The front bumper assembly (100) as claimed in claim 8, wherein said middle bracket support system (10) comprises six triangular reinforcement ribs (LR1, LR2. LR3, LR4, LR5, LR6) configured on the left-hand side and six triangular reinforcement ribs (RR1, RR2. RR3, RR4, RR5, RR6) configured on the right-hand side thereof.

10. The front bumper assembly (100) as claimed in claim 8, wherein said middle bracket support system (10) comprises:

• seven mounting points (S1, S2, S3, S4, S5, S6, S7) with respective holes therein, said mounting points (S5, S7) having a 2-way locator slot with a hole (C) of 6-8 mm diameter; and an oval hole/slot (SL) with 6-8 mm diameter and 6-8 mm length;

• six snap attachments (SA1, SA2, SA3, SA4, SA5, SA6) for connecting said middle bracket support system (10) to said front-bumper upper facia (2);

• five snap-mountings (M1, M2, M3, M4, M5) for connecting said middle bracket support system (10) to said front-bumper lower facia (7); and

• six triangular reinforcement ribs (LR1, LR2. LR3, LR4, LR5, LR6) configured on the left-hand side and six triangular reinforcement ribs (RR1, RR2. RR3, RR4, RR5, RR6) configured on the right-hand side thereof;

wherein said middle bracket support system (10) is made of polycarbonate/acrylonitrile styrene acrylate (PC/ASA) for internal and external application in automotive vehicles, and to hide the internal components thereof.

Dated this 26th day of March 2024.

Digitally / e-Signed by:

(SANJAY KESHARWANI)
APPLICANT’S PATENT AGENT
REGN. NO. IN/PA-2043.