Bumper component with embedded sensor

• US 9,278,659 B2
• Filed: 04/22/2014
• Issued: 03/08/2016
• Est. Priority Date: 04/22/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Schondorf, Steven Yellin, Philip, Abraham G., Ghannam, Mahmoud Yousef, Hagen, Markus, Arndt, Thomas
• Primary Examiner(s): GOODEN JR, BARRY J
• Application Number:
  US14/258,713
• Publication Number:
  US 20150298635A1
• Time in Patent Office: 686 Days
• US Class Current: 1/1
• CPC Class Codes: B29C 45/14819 the inserts being completely encapsulated
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29L 2031/3044 Bumpers
• CPC Class Codes: B29L 2031/34 Electrical apparatus, e.g. sparking plugs or parts thereof
• CPC Class Codes: B60R 19/023 Details
• CPC Class Codes: B60R 19/18 characterised by the cross-section; Means within the bumper to absorb impact
• CPC Class Codes: B60R 19/483 with obstacle sensors of electric or electronic type
• CPC Class Codes: B60R 2019/1866 Cellular structures
• CPC Class Codes: B60R 2021/0004 Frontal collision
• CPC Class Codes: B60R 2021/0011 Rear collision or recoiling bounce after frontal collision
• CPC Class Codes: B60R 21/0134 responsive to imminent contact with an obstacle , e.g. using radar systems
• CPC Class Codes: B60R 21/0136 responsive to actual contact with an obstacle , e.g. to vehicle deformation, bumper displacement or bumper velocity relative to the vehicle monitoring crash strength in combination with passenger seat detection B60R21/01558
• CPC Class Codes: G01S 2013/93275 in the bumper area

Abstract

Exemplary methods of making a bumper component are disclosed, along with exemplary bumper assemblies and vehicles. An exemplary method may include providing a first mold portion defining at least in part a front surface, and positioning at least one sensor in the first mold portion. Exemplary methods may further include enclosing the at least one sensor within the first mold portion with a second mold portion. The second mold portion may define at least in part a rear surface. The method may further include forming a body within the first and second mold portions, thereby embedding the at least one sensor between the front and rear surfaces, the body extending between the front and rear surfaces.

Claims

1. A bumper assembly, comprising:

a molded body formed from a flow of heated material between a front surface and a rear surface; and

at least one sensor positioned by a netting support structure extending longitudinally within the material flow such that the at least one sensor and the support structure are embedded between the front and rear surfaces and bonded with the material forming the molded body, the support structure configured to provide structural rigidity to the molded body.

2. The bumper assembly of claim 1, further comprising an electrical connector and an electrical lead in communication with the at least one sensor, the electrical lead embedded within the molded body and extending along a longitudinal length thereof and such that the electrical connector is located at one of two ends of the molded body.

3. The bumper assembly of claim 1, wherein the at least one sensor is flush with the front surface of the molded body.

4. The bumper assembly of claim 1, wherein the at least one sensor is a pedestrian sensor configured to sense one of a pedestrian presence adjacent the front surface of the molded body and a pedestrian impact with the front surface of the molded body.

5. The bumper assembly of claim 1, wherein the molded body is one of a bumper fascia defining an outer surface of the bumper assembly, an energy-absorbing structure, and a structural element of the bumper assembly.

6. The bumper assembly of claim 1, wherein the at least one sensor includes a plurality of sensors.

7. The bumper assembly of claim 6, further comprising an electrical lead connecting the plurality of sensors to each other.

8. The bumper assembly of claim 1, further comprising a sensor capsule enclosing the at least one sensor, the sensor capsule embedded within the molded body and positioned between the front and rear surfaces.

9. The bumper assembly of claim 8, wherein the sensor capsule includes a window positioned to allow the at least one sensor a field of view beyond the front surface of the molded body.

10. A vehicle, comprising:

a bumper assembly, including;

a molded body formed from a flow of heated material between a front surface and a rear surface,

a netting support structure longitudinally extending between the front surface and the rear surface and having support members, and

at least one sensor positioned by the support structure in the material flow between the front and rear surfaces and bonded with the material forming the molded body, the support members configured to strengthen a rigidity of the molded body and the at least one sensor configured to sense at least one of an external object presence and an external object impact with the molded body; and

a sensing system in communication with the at least one sensor, the sensing system configured to deploy at least one countermeasure in response to the at least one of the external object presence adjacent the molded body and the external object impact with the molded body.

11. The vehicle of claim 10, further comprising an electrical lead connecting the sensor to an electrical connector, wherein the electrical lead is embedded within the molded body and extends along a longitudinal length of the molded body such that the electrical connector is located at one of two ends of the molded body.

12. The vehicle of claim 10, wherein the bumper assembly is positioned at one of a front end and a rear end of the vehicle.

13. The vehicle of claim 10, further comprising a sensor capsule enclosing the sensor, the sensor capsule embedded within the molded body between the front and rear surfaces.

14. The vehicle of claim 13, wherein the sensor capsule includes a window positioned to allow the at least one sensor a field of view beyond the front surface of the molded body.

15. A method of forming a bumper fascia, comprising:

providing a first mold portion defining at least in part a front surface;

providing a netting support structure longitudinally extending along the first mold portion;

positioning, by the support structure, at least one sensor in the first mold portion, the at least one sensor configured to sense at least one of an external object presence adjacent the fascia and an external object impact with the fascia;

positioning, by the support structure, at least one electrical lead in electrical connection with the at least one sensor and such that the electrical lead extends along a longitudinal length of the first mold portion;

enclosing the at least one sensor and the support structure within the first mold portion with a second mold portion, the second mold portion defining at least in part a rear surface; and

molding a body by flowing a heated material within the first and second mold portions, thereby embedding the at least one sensor and support structure between the front and rear surfaces and bonding the at least one sensor with the heated material, the body extending between the front and rear surfaces and the support structure structurally reinforcing the body.

16. The method of claim 15, further comprising maintaining a position of the at least one sensor within the body with the support structure while the body is formed.

17. The method of claim 15, further comprising supporting the at least one sensor within the first and second mold portions with one of a mechanical and a magnetic force configured to maintain the support structure in a position and to resist the flowing of the heated material to maintain the position of the at least one sensor.

18. The method of claim 15, wherein the at least one sensor is bonded with the body such that the body transfers substantially all of an impact load from the body to the at least one sensor.