DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to a bumper assembly in vehicles and more particularly, but not exclusively to a bumper assembly having integrated lower stiffener to reduce injury to a pedestrian.

BACKGROUND
[002] Automotive vehicle bumper systems have long been designed primarily to absorb impact forces generated during collisions with other vehicles and/or with fixed objects. Bumper systems are typically constructed of a high strength plastic mounted to a metal bumper beam and/or frame. This bumper system typically extends across the front and rear of the vehicle and serves as an absorber and deflector upon impact.
[003] Previous bumper designs have been effective in vehicle-to-vehicle collisions, but limitations in the design are realized during pedestrian impacts. In some vehicle collisions with upright (standing, walking, or running) pedestrians, the bumper makes contact with the pedestrian's leg in the vicinity of the knee and there is a tendency for the pedestrian's foot to remain planted on the ground. As the vehicle continues to move forward, the bumper forces the pedestrian's lower leg to rotate about the foot or ankle and the bumper overrides the lower leg, resulting in potentially severe knee injury and/or the pedestrian being drawn under the vehicle.
[004] Conventional bumper systems use a metallic or plastic lower stiffener that is connected to a bumper beam to prevent the pedestrian from sliding under the vehicle in the event of collision. The lower stiffener of the bumper system provides rebound force requirements to the pedestrian’s lower leg thereby minimizing the bending of the pedestrian’s leg that result in reducing the possibility of pedestrian sliding under the vehicle and end up in a more critical state. The aforementioned bumper system incurs high investment and manufacturing costs due to assembly of the lower stiffener as a separate unit. Further, the aforementioned bumper system has increased total act completion time (TACT) and increases weight of the vehicle thereby resulting in increased fuel consumption of the vehicle.
[005] Therefore, there exists a need for a simple and cost-effective bumper assembly having integrated lower stiffener that meet pedestrian norms. Further, there exists a need for a bumper assembly having compact and integrated lower stiffener that obviates the aforementioned drawbacks of the conventional bumper system.

OBJECTS
[006] The principal object of an embodiment of this invention is to provide a bumper assembly for an automotive vehicle to reduce injury to a pedestrian.
[007] Another object of an embodiment of this invention is to provide the bumper assembly having integrated lower stiffener that meets pedestrian lower leg requirements of pedestrian norms.
[008] Yet another object of an embodiment of this invention is to provide a simple and cost-effective bumper assembly that meets pedestrian norms.
[009] Still another object of an embodiment of this invention is to provide a method of mounting a bumper assembly in an automotive vehicle.
[0010] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0012] FIG. 1 depicts a perspective view of a bumper assembly, according to an embodiment of the invention as disclosed herein;
[0013] FIG. 2 depicts the perspective view of a bumper beam of a vehicle, according to an embodiment of the invention as disclosed herein;
[0014] FIG. 3 depicts a schematic view of a bumper cover mounted to the bumper beam of the vehicle, according to an embodiment of the invention as disclosed herein;
[0015] FIG. 4 depicts a graph indicating CAE stimulation versus physical test of the bumper assembly, according to an embodiment of the invention as disclosed herein; and
[0016] FIG. 5 depicts a flowchart of a method of mounting a bumper assembly in an automotive vehicle, according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0017] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0018] The embodiments herein achieve a simple and cost-effective front bumper assembly that meets pedestrian norms. Further, embodiments herein achieve a bumper assembly having integrated lower stiffener that meets pedestrian lower leg requirements of pedestrian norms. Referring now to the drawings, and more particularly to FIGS. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0019] FIG. 1 depicts a perspective view of a bumper assembly 100, according to an embodiment of the invention as disclosed herein. In an embodiment, the bumper assembly 100 includes a bumper beam 102, an energy absorber 104, a first mounting bracket 106, a second mounting bracket 108, a bumper cover 110, a chin member 112 and a connecting section 114.
[0020] FIG. 2 depicts the perspective view of a bumper beam 102 of the vehicle, according to an embodiment of the invention as disclosed herein. In an embodiment, the bumper beam 102 is provided in the front portion of the vehicle. The bumper beam 102 is made up of steel which is mounted to the vehicle's frame rails. However, it is also within the scope of the invention to provide any type of material for manufacturing bumper beam without otherwise deterring the intended function of providing rigidity as can be deduced from this description and corresponding drawings. In an embodiment, the bumper beam 102 is used to provide stiffness to the bumper assembly 100. In an embodiment, the bumper beam includes a front surface (not shown) and a rear surface (not shown). The bumper beam 102 further includes the first mounting bracket 106 to affix the bumper cover 110.
[0021] In an embodiment, the energy absorber 104 is provided at the front surface of the bumper beam 102. In an embodiment, the energy absorber 104 of the bumper assembly 100 is used to absorb impact energy as well as distribute the impact energy in event of collision. In an embodiment, the energy absorber 104 is made up of at least one of high-density foam, a multiple density foam absorber, and an injection molded plastic absorber. However, it is also within the scope of the invention to provide any type of material for absorbing collision energy without otherwise deterring the intended function of the absorbing as can be deduced from this description and corresponding drawings.
[0022] FIG. 3 depicts a schematic view of a bumper cover 110 mounted to the bumper beam 102 of the vehicle, according to an embodiment of the invention as disclosed herein. In an embodiment, the bumper assembly 100 includes the bumper cover 110 which is affixed to the bumper beam 102 at the first mounting bracket using a bolt and nut assembly. However, it is also within the scope of the invention to provide any type of attachment between the bumper cover 110 and the bumper beam 102 without otherwise deterring the intended function of coupling the bumper cover 110 with the bumper beam 102 as can be deduced from this description and corresponding drawings. In an embodiment, the bumper cover 110 is coupled to the bumper beam 102 by at least one of bolts, screws, riveting, clinching, welding and interlocking joints.
[0023] In an embodiment, the bumper cover 110 includes an upper portion (not shown), a lower portion (not shown) and a connecting section 114. The connecting section 114 of the bumper cover 110 is connected to the second mounting bracket 108 provided at a predetermined position in the vehicle. In an embodiment, the bumper cover 110 is configured to have an aerodynamic fascia profile formed of a plastic material. However, it is also within the scope of the invention to provide any type of fascia made of any material without otherwise deterring the intended function of providing front face on the bumper cover 110 as can be deduced from this description and corresponding drawings. In an embodiment, the fascia comprises a grille and may be fabricated in a single piece or in multiple pieces as necessary for manufacturing and assembly purposes.
[0024] In an embodiment, the bumper cover 110 provides rebound force to a pedestrian’s lower leg in event of collision. In an embodiment, the bumper cover 110 defines a C-shaped profile. However, it is also within the scope of the invention to provide the bumper cover 110 with O- shaped profile or any other shape without otherwise deterring the intended function of the rebounding force as can be deduced from the description.
[0025] In an embodiment, the bottom chin member 112 is configured to provide stiffness to the bumper assembly 100. The bottom chin member 112 is affixed to the bumper cover 110 at lower portion of the bumper cover 110.
[0026] FIG. 4 depicts a graph indicating CAE stimulation versus physical test of the bumper assembly 100, according to an embodiment of the invention as disclosed herein. In an embodiment, the bumper assembly 100 is tested for parameters such as acceleration and knee bending angle. In an embodiment, the simulation test is marked through A and the physical test is marked through B. In the graph, 0-1 corresponds to fascia and chin crush, 1-2 corresponds to energy absorber crush, 3-4 corresponds to contact of the pedestrian to hood, and 5 corresponds to stack up. From the graph it is evident that the physical test of the bumper assembly 100 achieved lower values than the predetermined acceleration and knee bending angle values of the pedestrian norms. The table below provides the values of acceleration and knee bending angle tested using the bumper assembly 100.
S.No Parameter CAE target CAE Test % Correlation
1 Acceleration 136 g (Regulation target < 170g) 124 121.1 97.7
2 Knee bending angle 15.2 deg (Regulation target < 19 deg) 7.79 7.94 98.1

[0027] Therefore, the bumper assembly 100 satisfies the pedestrian lower leg requirements of pedestrian norms thereby preventing the pedestrian from sliding under the vehicle.
[0028] In an embodiment, a method 200 for mounting a bumper assembly 100 for a vehicle is shown in FIG. 5. The method includes providing a bumper beam 102 having a front surface at a front portion of the vehicle (step 201). Further, the method includes providing at least one energy absorber 104 on the front surface of the bumper beam 102 (step 203). The energy absorber 104 is provided in a front impact direction to absorb collision energy. Furthermore, the method includes providing at least one first mounting bracket 106 in the bumper beam 102 (step 205). In addition, the method includes coupling a bumper cover 110 to the bumper beam 102 (step 207). The bumper cover 110 is configured to rebound a force in an event of a collision between the vehicle and the pedestrian.
[0029] 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 understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Referral Numerals
Bumper assembly 100
Bumper beam 102
Energy absorber 104
First mounting bracket 106
Second mounting bracket 108
Bumper cover 110
Chin member 112
Connecting section 114
,CLAIMS:STATEMENT OF CLAIMS
We claim,
1. A bumper assembly 100 for an automotive vehicle to reduce injury to a pedestrian, the bumper assembly 100 comprising:
a bumper beam 102 having a front surface provided at a front portion of the vehicle;
at least one energy absorber 104 disposed on the front surface of the bumper beam 102;
at least one first mounting bracket 106 provided in the bumper beam 102; and
a bumper cover 110 coupled to the bumper beam 102;
wherein
the energy absorber 104 is provided in a front impact direction to absorb collision energy;
the bumper cover 110 is configured to rebound a force in an event of a collision between the vehicle and the pedestrian.

2. The bumper assembly 100 as claimed in claim 1, wherein the bumper cover 110 includes:
an upper portion;
a lower portion; and
a connecting section 114 formed on the lower portion of the bumper cover 110 for connecting the bumper cover 110 to a second mounting bracket 108 provided at a predetermined position in the vehicle.

3. The bumper assembly 100 as claimed in claim 1, wherein the bumper assembly 100 includes a chin member 112 connected to the lower portion of the bumper cover 110 to provide stiffness to the bumper assembly 100.

4. The bumper assembly 100 as claimed in claim 1, wherein the bumper cover 110 has a profile which is C-shaped in cross section.

5. The bumper assembly 100 as claimed in claim 1, wherein the bumper cover110 is configured to be an aerodynamic fascia profile.

6. The bumper assembly as 100 claimed in claim 1, wherein the bumper cover 110 comprises a grille.

7. The bumper assembly 100 as claimed in claim 1, wherein the bumper cover 110 is coupled to the bumper beam 102 by at least one of bolts, screws, riveting, clinching, welding and interlocking joints.

8. A method 200 of mounting a bumper assembly 100 for an automotive vehicle to reduce injury to a pedestrian, the method comprising steps of:
providing a bumper beam 102 having a front surface at a front portion of the vehicle;
providing at least one energy absorber 104 on the front surface of the bumper beam 102;
providing at least one first mounting bracket 106 in the bumper beam 102; and
coupling a bumper cover 110 to the bumper beam 102;
wherein
the energy absorber 104 is provided in a front impact direction to absorb collision energy;
the bumper cover 110 is configured to rebound a force in an event of a collision between the vehicle and the pedestrian.

9. The method as claimed in claim 8, wherein the bumper cover 110 includes:
an upper portion;
a lower portion; and
a connecting section 114 formed on the lower portion of the bumper cover 110 for connecting the bumper cover 110 to a second mounting bracket 108 provided at a predetermined position in the vehicle.

10. The method as claimed in claim 8, wherein the bumper assembly 100 includes a chin member 112 connected to the lower portion of the bumper cover 110 to provide stiffness to the bumper assembly 100.