Vehicle rear bumper assembly

A vehicle rear bumper assembly includes a vehicle body structure, an exhaust system and a rear bumper fascia. The exhaust system is attached to the vehicle body structure and has an exhaust pipe. The rear bumper fascia has a main body and a finisher extension. The main body is attached to the vehicle body structure and has a recessed area shaped and dimensioned to complement the shape of the exhaust pipe. The finisher extension extends away from the main body proximate the recessed area. The main body and the finisher extension are formed with a living hinge therebetween such that the finisher extension is pivotable about the living hinge from an extending orientation to a finishing orientation. In the extending orientation, the finisher extension is spaced apart from the recessed area. In the finishing orientation, the finisher extension is located within the recessed area adjacent to the exhaust pipe.

BACKGROUND

Field of the Invention

The present invention generally relates to vehicle rear bumper assembly. More specifically, the present invention relates to rear bumper assembly that includes a finisher extension that pivots into a recessed area dimensioned to complement the appearance of an adjacent an exhaust pipe.

Background Information

Exhaust finisher structures are typically trim elements that are added to a bumper fascia requiring human operators to assembly such trim elements.

SUMMARY

It has been discovered that in order to reduce manufacturing costs and improve the appearance of a rear bumper fascia and an adjacent exhaust pipe, that a rear bumper fascia can be formed with a finisher extension that pivots about a living hinge to provide a finished look or appearance to the rear bumper fascia in a recessed area adjacent to an exhaust pipe.

In view of the state of the known technology, one aspect of the present disclosure is to provide a vehicle rear bumper assembly with a vehicle body structure, an exhaust system and a rear bumper fascia. The exhaust system is attached to the vehicle body structure and has an exhaust pipe. The rear bumper fascia has a main body and a finisher extension. The main body is attached to the vehicle body structure and has a recessed area shaped and dimensioned to complement the shape of the exhaust pipe. The finisher extension extends away from the main body proximate the recessed area. The main body and the finisher extension are formed with a living hinge therebetween such that the finisher extension is pivotable about the living hinge from an extending orientation to a finishing orientation. In the extending orientation, a distal end of the finisher extension is spaced apart from the recessed area. In the finishing orientation, the distal end of the finisher extension and the finisher extension are located within at least a portion of the recessed area and are positioned adjacent to the exhaust pipe.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring initially toFIG. 1, a vehicle10having a vehicle body structure12that includes a rear bumper assembly14is illustrated in accordance with a first embodiment.

In the depicted embodiment the vehicle is a sedan or coupe with two or four doors. Since coupe and sedan body designs are convention designs, further description is omitted for the sake of brevity.

The vehicle body structure12includes many structural elements. Since most elements of vehicle body structures are conventional and well known, further description thereof is omitted for the sake of brevity, except where such structures or features are necessary for understanding the rear bumper assembly14(also referred to as a vehicle rear bumper assembly14).

The vehicle10and rear bumper assembly14define a widthwise direction DWand outboard directions DO, as shown inFIG. 1and rearward direction DR, as shown inFIGS. 3-5. The widthwise direction DWcorresponds to a lateral direction of the vehicle10that is perpendicular to a centerline (not shown) of the vehicle10, where the centerline extends from the front of the vehicle10to the rear of the vehicle10. The centerline (not shown) is also centered between the two lateral sides of the vehicle10. The outboard directions DOare defined as directions from the centerline of the vehicle10that extend laterally outboard from the center of the vehicle perpendicular to the centerline of the vehicle10. Since a centerline, widthwise direction, and outboard directions are conventional characteristics of a vehicle, further description is omitted for the sake of brevity.

The rear bumper assembly14includes a support beam (not shown) that is fixed to the vehicle body structure12in a conventional manner, an energy absorbing member (not shown) that is fixed to at least the support beam and a rear bumper fascia18that covers and conceals both the support beam and the energy absorbing member. The rear bumper fascia18is attached to at least fenders and structural portions (not shown) of the vehicle body structure12. The rear bumper fascia18can also optionally be attached to the energy absorbing member (not shown) in a conventional manner. Since energy absorbing members and support beams of a bumper assembly are conventional vehicle features, further description of energy absorbing members and support beams is omitted for the sake of brevity. A description of the rear bumper fascia18is proved hereinbelow.

As shown inFIGS. 1 and 13-15, the vehicle10also includes an exhaust system20with an exhaust pipe22that extends rearward from the remainder of the exhaust system20below and adjacent to the rear bumper fascia18, as described further below.

A description of the rear bumper fascia18is now provided with specific reference toFIGS. 1-12. The rear bumper fascia18(hereinafter referred to as the fascia18) has main body30, a finisher extension32and a living hinge34that connects the finisher extension32to the main body30.

The main body30is attached to the vehicle body structure12in a conventional manner, as mentioned above, via mechanical fasteners or other attachment structures. The main body30has a rearward facing surface36and a lower flange section38. The lower flange section38of the main body30extends in a vehicle forward direction (opposite the rearward direction DR) from a lower area of the rearward facing surface36.

As shown inFIGS. 1-10, the main body30and the lower flange section38are formed with a recessed area40. As viewed from the rear of the fascia18, the recessed area40is partially defined by the living hinge34visible along a portion of the lower edge of the rearward facing surface36, as shown inFIGS. 1, 5-6 and 9-10. The remainder of the recessed area40is defined by opposing edges of the lower flange section38. However, from underneath the vehicle10looking upward at the lower flange section38the recessed area40is an open area or gap bounded at a rearward end thereof by the living hinge34, as shown inFIGS. 5 and 9-10. The recessed area40is dimensioned to receive the finisher extension32in order to accommodate and approximately correspond to the shape of the exhaust pipe22in a manner further described hereinbelow.

It should be understood from the drawings and description herein that the exhaust pipe22is positioned to extend below the recessed area40but preferably does not contact the finisher extension32or the fascia18.

As shown inFIGS. 2-4, the main body30of the fascia18also includes an upper edge42that defines a trunk opening recess44with fender aligning edges46and48at opposite sides thereof. In the depicted first embodiment, the recessed area40, the living hinge34and the finisher extension32are located below a laterally outboard side of the trunk opening recess44but can alternatively be located below the fender aligning edges46or48.

The main body30, the living hinge34and the finisher extension32are formed as a single, unitary, monolithic element. Specifically, when manufactured, formed and/or molded, the main body30, the living hinge34and the finisher extension32are made simultaneously as a single element of the same materials. For example, the fascia18can be made using various resin materials, such as, thermoplastic olefins (TPOs), polycarbonates, polyesters, polypropylene, polyurethanes and/or polyamides, and/or other materials with characteristics such as resiliency, flexibility and that resist deformation in response to low speed impact events.

A description of the finisher extension32is now provided with specific reference toFIGS. 2-10. When the fascia18is manufactured or formed, the main body30and the finisher extension32are formed with the living hinge34therebetween such that the finisher extension32in an extending orientation with a distal end50being spaced apart from the recessed area40(seeFIGS. 2, 6-7 and 9). The finisher extension32is pivotable about the living hinge34from the extending orientation (FIGS. 2, 6-7 and 9) to a finishing orientation (FIGS. 1, 3-5, 8 and 10) with the distal end50of the finisher extension34being located within at least a portion of the recessed area40.

In the extending orientation, the finisher extension32extends approximately perpendicular to the lower flange section38of the fascia18, as shown inFIG. 7. In the finishing orientation, the finisher extension32extends approximately parallel to the lower flange section38within the recessed area40, as shown inFIG. 5.

The finisher extension32is formed with an attachment flange that is defined by attachment flange portions52and54at the distal end50thereof. Between the attachment flange portions52and54and the living hinge34, the finisher extension32includes a conically shaped portion56having a first end56aand a second end56b. The first end56aof the conically shaped portion56is located proximate and adjacent to the living hinge34. The second end56bof the conically shaped portion56is located at the distal end50of the finisher extension32. The first end56aof the truncated conically shaped portion56is narrower than the second end56bof the truncated conically shaped portion56.

The conically shaped portion56of the finisher extension32is shaped and dimensioned to complement the shape of the exhaust pipe22with the finisher extension32in the finishing orientation, as shown inFIGS. 1, 3-5, 8 and 10. In the finishing orientation, the finisher extension32extend away from the rearward facing surface36of main body30and is located within the recessed area40.

As shown inFIGS. 6 and 9, the attachment flange portions52and54are not aligned with one another relative to the widthwise direction DWof the vehicle10and the fascia18. Specifically, the attachment flange portion54extends in a forward direction of the vehicle10more than the attachment flange portion52as shown inFIGS. 8-10. The attachment flange portions52and54(the attachment flange) attach to the lower flange section38at opposite sides of the recessed area40with the finisher projection32in the finishing orientation, as shown inFIGS. 3-5 and 10.

The living hinge34provides a connection between the finisher extension32to the main body30of the fascia18. As mentioned above, the main body30, the finisher extension32and the living hinge34are all formed unitarily as a single monolithic element. However, as shown inFIGS. 11 and 12, the living hinge34has a first thickness T1and the adjacent area of the lower flange section38of the main body30and the finisher extension32have a second thickness T2. The thickness T2is greater than the thickness T1and can be more than twice the size of the thickness T1.

As shown inFIGS. 8-10, the living hinge34extends in a direction that is not parallel to the widthwise direction DW(lateral direction) of the vehicle10and the fascia18. In the depicted first embodiment, the living hinge34is approximately 10 degrees offset from the widthwise direction DW.

As mentioned above, the finisher extension32is pivotable about the living hinge34from the extending orientation (FIGS. 2, 6-7 and 9) to a finishing orientation (FIGS. 1, 3-5, 8 and 10). During the manufacturing or forming process used to produce the fascia18, the finisher extension32is manufactured in the extending orientation shown inFIGS. 2, 6-7 and 9. In order to produce a more finished appearance, the finisher extension32is bent or pivoted about the living hinge34in a vehicle forward direction such that the conically shaped portion56is located between and slightly above the lower flange section38within the recessed area40to the finishing orientation shown inFIGS. 1, 3-5, 8 and 10. Thereafter, the attachment flange portions52and54are attached via fasteners to their respective adjacent portions of the lower flange section38.

Thereafter as shown inFIG. 13-15, the exhaust system20is installed to the vehicle10with a bracket20abeing attached to a part or frame member60of the vehicle body structure12. The exhaust system20is shaped and dimensioned such that when installed to the vehicle10, the exhaust pipe22is located adjacent to the conically shaped portion56of the finisher extension32. More specifically, the exhaust pipe22extends below the rear bumper fascia18in an area adjacent to and spaced apart from the recessed area40and the finisher projection32with the finisher projection32in the finishing orientation.

The appearance of the rear of the vehicle10is enhanced by the inclusion of the finisher extension32, which is partially visible from the rear of the vehicle, as shown inFIGS. 1 and 13-15.

Second Embodiment

In the second embodiment the main body130includes a rearward facing surface136, a lower flange section138and a finisher extension132. The lower flange section138includes a recessed area140, as shown inFIG. 17. The finisher extension132is connected to the main body130via a living hinge134. As shown inFIGS. 18 and 19, the living hinge134has a thickness T3, while the lower flange section138and the finisher extension132have a thickness T4. The thickness T4is several times larger than the thickness T3.

As shown inFIG. 17, the living hinge134is approximately parallel to the widthwise direction DWof the main body30(and the vehicle10). Further, attachment flanges152and154of the finisher extension132are linearly aligned with one another relative to the widthwise direction DWof the main body130(and the vehicle10).

Third Embodiment

Referring now toFIGS. 20-23, a main body230of a rear bumper fascia in accordance with a third embodiment will now be explained. In view of the similarity between the first and third embodiments, the parts of the third embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the third embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

In the third embodiment the main body230includes a rearward facing surface236, a lower flange section238and a finisher extension232. The lower flange section238includes a recessed area240, as shown inFIG. 21. The finisher extension232is connected to the main body230via a living hinge234. As shown inFIGS. 22 and 23, the living hinge234has a thickness T5, while the lower flange section238and the finisher extension232have a thickness T6. The thickness T6is more than twice the size of the thickness T5, but less than three times the thickness T5.

As shown inFIG. 21, the living hinge234is angularly offset from the widthwise direction DWof the main body30(and the vehicle10). Further, attachment flanges252and254of the finisher extension232are linearly aligned with one another.

Fourth Embodiment

Referring now toFIG. 24, a main body330of a rear bumper fascia in accordance with a fourth embodiment will now be explained. In view of the similarity between the first and fourth embodiments, the parts of the fourth embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the fourth embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

In the fourth embodiment the main body330includes a rearward facing surface336, a lower flange section338and a finisher extension332. The lower flange section338includes a recessed area340. The finisher extension332is connected to the main body330via a living hinge334. The living hinge334is parallel to the widthwise direction DWof the main body30(and the vehicle10). Further, attachment flanges352and354of the finisher extension332are offset from one another relative to the widthwise direction DWof the main body330(and the vehicle10).

The vehicle body structure and other elements of the vehicle10other than the finisher extensions32,132,232and332(and associated features) are conventional components that are well known in the art. Since such structural features are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

GENERAL INTERPRETATION OF TERMS