Abstract:
A vehicle bumper system is shown to include a vehicle bumper component, a main electrical connector integrated with the vehicle bumper component, a second electrical connector integrated with the vehicle bumper component, and an electrical communication path integrated with the vehicle bumper component. The electrical communication path extends between the first electrical connector and the second electrical connector. The vehicle bumper component is designed to permit mounting of an electrically controlled device at a mounting area. The second electrical connector is at or in close proximity to the mounting area to permit the electrically controlled device to electrically couple therewith when it is mounted at the mounting area of said vehicle bumper component. Another electrical communication path electrically couples the second electrical connector with bumper mounting holes used to permit mounting of the bumper component with a vehicle chassis/frame.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to vehicle bumper systems and, more particularly to vehicle bumper systems having vehicle bumpers with integrated electrical conductors used to energize and communicate electrically with bumper-mounted devices. Still more particularly, the present invention relates to commercial vehicle bumper systems having a vehicle bumper with integrated electrical conductors used to energize and communicate electrically with bumper-mounted devices. 
     It is well known within the art that vehicle bumper systems include a variety of components. One primary component in vehicle bumper systems is the vehicle bumper itself. As known by those skilled in the art, bumpers can be single- or multi-piece components. Additionally, bumpers can consist of a back mounting plate with a cosmetic, aesthetically pleasing, visible front plate secured thereto. 
     Vehicle bumper systems further include mounting attachments, which permit devices to be mounted to the bumper. Examples of such attachments are brackets, bolts, hangers and the like. 
     Vehicle bumper systems also include electrically controlled devices that can be secured to the bumper or positioned in close proximity therewith. Examples of such devices include but are not limited to headlights and other lighting systems, lamps and indicators, antennae, various sensors, and sight sticks that function as corner locators. 
     In addition, vehicle bumper systems include wiring harnesses that electrically couple the forgoing devices to an electrical energy source and/or electronic control circuitry. When incorporated for use with a particular vehicle, all of the foregoing comprise a vehicle bumper system. 
     It is well known that bumper systems are incorporated in virtually every land vehicle, including trucks and automobiles. As such, bumper systems are incorporated in commercial vehicles, including those commercial vehicles classified in classes five through eight. 
     FIG. 2 illustrates a conventional bumper system  20  incorporated in a standard commercial vehicle having a chassis  22  and wheel  24 . The conventional vehicle bumper system  20  shown in FIG. 2 includes a bumper-mounted device showing in the form of a headlight  26  mounted to a hanger  28  extending from the rear of the conventional vehicle bumper  30 . The conventional vehicle bumper system  20  further includes a wiring harness  32  extending from chassis  22  to provide electrical energy to the circuitry incorporated within the housing of device  26 . 
     As will be appreciated by those skilled in the art, in conventional vehicle bumper systems, at least one wiring harness is used for bumper-mounted electrically controlled devices, and at least one electrical conductor extends to each electrically controlled device, typically hanging loosely between the vehicle chassis and/or wiring harness and the electrically controlled device. Each wiring harness typically includes copper wiring, crimp connectors, wire ties, wire clamps and the like. 
     The use of wiring harnesses and other loosely hanging electrical conductors as components of a vehicle bumper system presents several potential problems. Their installation is particularly complex and laborious. 
     It will also be appreciated by those skilled in the art that the wiring harnesses and other loosely hanging electrical conductors tend to wear more rapidly when subjected to inclement weather and increased road debris. 
     They also wear during ordinary vehicle operation, as they are subjected to forces in a variety of directions to the point where they often ultimately come disconnected at their weakened connections, causing failure of the electrically controlled devices in the bumper system. 
     Another deficiency of conventional vehicle bumper systems is that redundant lamps must be used, even in the case of common-switched lighting and indicators. One wiring harness is typically required for each lamp. 
     Another deficiency of conventional vehicle bumper systems is that electrical shorts and open circuits can and do occur as wiring harnesses and other loosely hanging electrical conductors wear with extended vehicle operation. 
     Another deficiency of conventional vehicle bumper systems is that the wiring harnesses and loosely hanging electrical conductors extending to bumper-mounted devices mounted closest to the opposite ends of the bumper, such as is the case with headlights, are often subjected to the greatest forces during vehicle operation, and tend to wear faster than those extending to bumper-mounted devices mounted in a central portion of the bumper. 
     In light of the foregoing, it is desirable to develop a vehicle bumper system that has a reduced number of vehicle bumper system component parts. 
     It is further desirable to develop a vehicle bumper system that has reduced installation complexity. 
     It is further desirable to develop a vehicle bumper system that requires less labor in order to install the system on a particular vehicle, translating into less costs associated with the system. 
     It is further desirable to develop a vehicle bumper system that requires only a single wiring harness for electrically controlling a plurality of bumper-mounted electrically controlled devices. 
     It is further desirable to develop a vehicle bumper system that eliminates redundant lamps for common switch lighting and indicators. 
     It is further desirable to develop a vehicle bumper system that eliminates flex-induced fiber optic cable and electrical wire breakage, translating into increased useful life for the system. 
     It is further desirable to develop a vehicle bumper system that provides relatively simple self-wiring installation of bumper-mounted, electrically controlled devices, such as electrical and lighting components. 
     It is further desirable to develop a vehicle bumper system that provides design freedom for cosmetic lighting. 
     It is further desirable to develop a vehicle bumper system that accommodates an integrated circuit to reduce the number of electrical conductors required for operation of bumper-mounted, electrically controlled devices. 
     It is further desirable to develop a vehicle bumper system that has faster assembly time. 
     It is further desirable to develop a vehicle bumper system that has reduced components. 
     It is further desirable to develop a vehicle bumper system that has a single electrical connector associated with the bumper to which a single connector extending from the vehicle chassis is mated. 
     It is further desirable to develop a vehicle bumper system that reduces the possibility of connection failure. 
     It is further desirable to develop a vehicle bumper system that is adaptable to accommodate various bumper-mounted, electrically controlled devices without requiring modifications to the integrated electrical connections. 
     It is further desirable to develop a vehicle bumper system that provides for guaranteed grounding to the grounded vehicle frame through the bumper mounting features. 
     It is further desirable to develop a vehicle bumper system that reduces the potential for electrical short and open circuits. 
     These and other desired benefits of the preferred forms of the invention will become apparent from the following description. It will be understood, however, that a system or method could still appropriate the claimed invention without accomplishing each and every one of these desired benefits, including those gleaned from the following description. The appended claims, not these desired benefits, define the subject matter of the invention. Any and all benefits are derived from the preferred forms of the invention, not necessarily the invention in general. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed to a vehicle bumper system. Preferably, the vehicle bumper system includes a vehicle bumper component. It further preferably includes a first electrical connector integrated with the vehicle bumper component. Still further, it preferably includes a second electrical connector integrated with the vehicle bumper component. Even further, it preferably includes an electrical communication path integrated with the vehicle bumper component. This electrical communication path preferably extends between the first electrical connector and the second electrical connector. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     Throughout this description, reference has been and will be made to the accompanying views of the drawing wherein like subject matter has like reference numerals, and wherein: 
     FIG. 1 is a rear view of a fiber-reinforced composite vehicle bumper used in a vehicle bumper system constructed in accordance with the principles of the present invention; 
     FIG. 2 is a rear perspective view of a prior art vehicle bumper system installed on a commercial vehicle; 
     FIG. 3 is a fragmentary view of the fiber-reinforced composite bumper shown in FIG. 1 having a bumper-mounted, electrically controlled device shown in exploded form from its mounting position; 
     FIG. 3A is a fragmentary view of a different embodiment of the fiber-reinforced composite bumper shown in FIG. 1 having a bumper-mounted, electrically controlled device shown in exploded form from its mounting position; mounted electrically controlled device shown in exploded form from its mounting position; 
     FIG. 4 is a diagrammatic view of an exemplary weave formed during manufacture of fiber-reinforced composite bumpers constructed in accordance with the principles of the present invention, such as the one shown in FIG. 1; 
     FIG. 5 is an end view of the diagrammatic view shown in FIG. 4; 
     FIG. 6 is a fragmentary end view of a toe of fibers used in fiber-reinforced composite bumpers constructed in accordance with the principles of the present invention; 
     FIG. 7 is a rear view of a metal vehicle bumper used in a vehicle bumper system constructed in accordance with the principles of the present invention; 
     FIG. 8 is an enlarged fragmentary view of a portion of the vehicle bumpers shown in FIGS. 1 and 7; 
     FIG. 9 is an enlarged fragmentary view of another portion of the bumpers shown in FIGS. 1 and 7; and 
     FIG. 10 is an enlarged fragmentary view of yet another portion of the bumpers shown in FIGS.  1  and  7 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates a fiber-reinforced composite vehicle bumper  40  designed to be used in vehicle bumper systems constructed in accordance with the principles of the present invention. Fiber-reinforced composite vehicle bumper  40  is of a type known in the art. It will be appreciated, however, that the principles of the present inventIon are not limited to fiber-reinforced composite bumpers, but certain aspects of the present invention apply to vehicle bumpers generally. 
     Fiber-reinforced composite vehicle bumper  40  includes air ducts  42 , central bumper-mounted device bore  44 , and two end bumper-mounted bores  46 . Further included for fiber-reinforced composite vehicle bumper  40  are bumper mounting bores  48  to permit the bumper to be mounted to a vehicle frame/chassis or the like. 
     Fiber-reinforced composite vehicle bumper  40  includes a main electrical connector  50  designed to receive and accommodate a connector coupled to a single wiring harness extending from the vehicle frame. Advantageously, this preferred.embodiment of the bumper forming a component of the preferred vehicle bumper system requires that only a single wiring harness be used for providing electrical energy and communication to bumper-mounted, electrically controlled devices. Further advantageously, main electrical connector  50  is positioned generally in close proximity to the vehicle centerline such that the single wiring harness extending from the vehicle chassis will be subjected to minimal vibration and other forces during vehicle operation. As such, the useful life of the vehicle bumper system will be maximized. 
     Main electrical connector  50  is electrically coupled to an integrated circuit  52  that is integrated with fiber-reinforced composite vehicle bumper  40  in order to facilitate switching control for the electrical circuitry integrated with the bumper. Integrated circuit  52  therefore reduces the number of electrical connections required, yet maintains the switching control required for communication with bumper-mounted, electrically controlled devices. 
     Main signal conductors  54  extend from integrated circuit  52  to electrical connectors  56 ,  5 B,  60 . As explained above, bumper-mounted, electrically controlled devices will typically be mounted to fiber-reinforced composite bumper  40  at central bumper-mounted device bore  44  and end bumper-mounted device bores  46 . Electrical connector  56  positioned in close proximity to one of the end bumper-mounted device bores  46  is illustrated as a two-pin electrical connector. Referring briefly to FIG. 3, a bumper-mounted, electrically controlled device  62  is illustrated in the form of a headlight having an electrical lead  64  coupled to a two-pin electrical connector shown in the form of an electrical plug  66 . While not shown, it will be appreciated by those skilled in the art that headlight  62  is mounted to fiber-reinforced composite vehicle bumper  40  by mounting attachments similar to attachment  28  shown in FIG.  2 . When mounted accordingly, the pins associated with two-pin electrical plug  66  are inserted into and received by the two bores included within electrical connector  56 . 
     FIG. 3A illustrates a different embodiment for fiber-reinforced composite bumper  40 . A bumper-mounted, electrically controlled device  262  is illustrated in the form of a headlight having a two-pin electrical connector shown in the form of an electrical plug  266  integrally connected to the back of the housing thereof. Fiber-reinforced composite bumper  40  includes a cavity-like mounting portion  268  that includes a forward facing electrical connector  270  designed to receive plug  266 . When mounted properly, the pins associated with two-pin electrical plug  266  are inserted into and received by the two bores included within electrical connector  270 . 
     Referring back to FIG. 1, it is seen that one pin attachment for electrical connector  56  is coupled to one of the main signal conductors  54 , while the other pin is electrically coupled to tap line  68 A extending from a ground bus line  69 . Through this electrical coupling, headlight  62  car be caused to operate, as desired. 
     As further shown in FIG. 1, electrical connector  58  is a four-pin electrical connector positioned in close proximity to central bumper-mounted device bore  44 . As such, central bumper-mounting device bore  44  is able to permit mounting of a bumper-mounted device such as an antenna or other device requiring additional control circuitry. Electrical connector  58  has three of its bores electrically coupled to integrated circuit  52 , while its fourth bore is electrically coupled to a tap line  68 B for ground bus line  69 . 
     Electrical connector  60  resembles electrical connector  56 . In that regard, electrical connector  60  is positioned in close proximity to end bumper-mounted device bore  46  at the other end of fiber-reinforced composite vehicle bumper  40 . As such, electrical connector  60  is suited to permit operation of a bumper-mounted, electrically controlled device such as headlight  62  shown in FIG.  3 . 
     Regarding the grounding for circuitry integrated with fiber-reinforced composite vehicle bumper  40 , ground bus line  69  is electrically connected to certain of the bumper mounting bores  48 . In this arrangement, the ground bus line  69  is electrically connected to the vehicle chassis/frame when the vehicle bumper is installed on a vehicle. In an alternative arrangement, the main electrical connector  50  can include a pin that is electrically connected to ground bus line  69 . Under such circumstances, a ground conductor will extend in the wiring harness and be electrically coupled to a pin for the electrical connector that is designed to mate with main electrical connector  50 . 
     The electrical circuitry integrated in the fiber-reinforced composite vehicle bumper  40  illustrated in FIG. 1 is constructed by weaving a solid conductor or toe of conductive fibers into the fiber fabric of the bumper. The bumper can then be molded by conventional vehicle bumper manufacturing processes. As will be appreciated by those skilled in the art, fiber-reinforced composite bumpers and the methods of making same are well known in the art. However, methods of making the fiber-reinforced composite vehicle bumper with integrated electrical circuitry to communicate with bumper-mounted, electrically controlled devices as described above are unique. Such methods are described below in further detail. 
     FIGS. 4 and 5 illustrate a plurality of longitudinally extending toes of fiber  70  positioned relative to a plurality of laterally extending toes of fiber  72  in such a manner that they form a weave pattern. Each toe of fiber  70  preferably alternates its position relative to adjacent toes of fiber  72 . In that regard, as shown, each toe of fiber  70  alternates from extending under one toe  72 , over the next toe  72 , back under the following toe  72 , and so forth. Similarly, each toe of fiber  72  preferably alternates its position relative to adjacent toes of fiber  70 . 
     FIGS. 4 and 5 illustrate a longitudinally extending toe of fiber designated  74  that forms a conductor of the electrical circuit integrated with the fiber-reinforced composite vehicle bumper  40  shown in FIG.  1 . In that regard, conductor  74  is integrated directly into the vehicle bumper material, specifically its fiber material. 
     FIG. 6 illustrates an enlarged end view of conductor  74 . As shown, conductor  74  is a toe of fibers constructed from a plurality of small fibers extending in a generally uniform direction. Preferably, each fiber is made of carbon and plated with a material exhibiting conductive properties. Examples of suitable conductive materials include gold, copper, aluminum, etc. 
     In order to manufacture the fiber-reinforced composite bumper  40  illustrated in FIG. 1, the following processes are preferably carried out. First, a lay up process is performed wherein the fibers are positioned and oriented into the preferred shape of the final product. During this process, any desired conductors can be introduced either in the woven fabric, or can be added by manually weaving same into the fabric at desired locations. 
     In a preferred manner, a woven fabric would have a predetermined number of conductors serving as bus conductors woven into it. These bus conductors would act as signal and/or ground busses. This fabric would be stamped to the general shape of the final product in that peripheral edges and bores would be cut away. 
     Conductors that connect from the bus conductors at one end to other bumper system components at their other end, as desired, could then be manually woven into the fabric. The connections at the bus conductors would need to be sufficient. At the opposite end of the manually woven conductors, electrical connectors, integrated circuits or other desired components would then be attached onto the fabric. 
     In view of the foregoing, a woven fabric assembly would be formed, which would serve as a flexible circuit board supporting all conductors, integrated circuits, electrical connectors, fiber optics, communication lines and other components for the circuitry integrated with the vehicle bumper. This woven fabric assembly is then used in the lay up process for manufacturing the vehicle bumper having integrated circuitry. 
     After the lay up process, a molding process is performed wherein the fibers are infused with a resin matrix in such a manner that all fibers are uniformly made wet. During this process, the fibers will be caused to maintain their intended position. Once the resin is cured, the part is removed with all of its integrated circuitry intact. This process can be carried out using any conventional molding process well known in the art. 
     Finally, a finishing process is performed, which will include the post-molding operations to achieve the final product. These post-molding operations include deflashing, polishing, cutting, drilling, piercing, sanding, grinding, painting, and coating. Those skilled in the art will recognize that these operations are performed to finish the manufacturing process for the final product. 
     FIG. 7 illustrates a metal vehicle bumper  140  for use in a vehicle bumper system constructed in accordance with the principles of the present invention. While bumper  40  in FIG. 1 is a fiber-reinforced composite bumper, bumper  140  in FIG. 7 is a metal bumper. In that regard, metal bumper  140  can be constructed from aluminum, an alloy thereof, steel, an alloy thereof, or any other metal or metal alloy known to be suitable by those skilled in the art. 
     The electrical circuit layout shown for metal bumper  140  in FIG. 7 is identical to that shown in fiber-reinforced composite vehicle bumper  40  of FIG.  1 . In the case of the metal bumper  140  shown in FIG. 7, however, the circuitry does not form part of the metal bumper, but rather the conductors, the electrical connectors and the integrated circuit are integrated with the metal vehicle bumper by being secured thereto, preferably by an adhesive bonding or the like. With an adhesive bonding, the conductors, integrated circuits and electrical connectors are permanently affixed to the rear of the metal bumper  140 . The adhesive bonding acts as a structural support for the circuit as it is affixed to the metal bumper, and the bonding serves-to protect the circuitry from the environment. 
     FIG. 8 illustrates a detailed view of the main electrical connector  50  and integrated circuit  52  shown in FIGS. 1 and 7 as being integrated with fiber-reinforced composite bumper  40  and metal bumper  140 , respectively. As shown, main electrical connector  50  preferably is an eight pin electrical connector and conductors extend from each pin of the main electrical connector to integrated circuit  52 , thereby electrically coupling them together. 
     As will be appreciated by those skilled in the art, the design and architecture of integrated circuit  52  can preferably be such that the electrical circuitry integrated with fiber-reinforced composite bumper  40  and metal bumper  140  can provide energy, communication and switching control for a variety of bumper-mounted, electrically controlled devices. Alternatively those skilled in the art will appreciate that the design and architecture of integrated circuit  52  can preferably be optimized for specific applications. 
     FIG. 9 illustrates the four pin electrical connector  58  positioned in close proximity to central bumper-mounted device bore  44 . As shown, three pins for electrical connector  58  are preferably coupled to conductors which, in turn, are coupled to integrated circuit  52  (see FIGS.  1  and  7 ). Additionally, the fourth pin for electrical connector  58  is preferably coupled to a tap line coupled to the ground bus line  69  (see FIGS.  1  and  7 ). 
     FIG. 10 illustrates the two pin electrical connector  60  positioned in close proximity to end bumper-mounted device bore  46  positioned at one end of fiber-reinforced composite bumper  40  and metal bumper  140 . It will be appreciated that electrical connector  60  is similar to electrical connector  56  positioned in close proximity to the end bumper-mounted device bore  46  positioned on the opposite end of fiber-reinforced composite bumper  40  and metal bumper  140 . One of the two pins for electrical connector  60  is preferably coupled to a conductor which, in turn, is coupled to integrated circuit  52  (see FIGS.  1  and  7 ). The other pin for electrical connector  60  is preferably coupled to a tap line coupled to the ground bus line  69  (see FIGS.  1  and  7 ). 
     While this invention has been described with reference to certain illustrative aspects, it will be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the illustrative embodiments without departing from the true spirit and scope of the invention, as defined by the following claims. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law.