ONE-PIECE BUMPER BEAM ASSEMBLY FOR VEHICLE

Claims

1. A method for manufacturing a one-piece unit (100) of a vehicle bumper beam, comprising: providing multiple blanks (1, 2, 3); joining the blanks to obtain a combined blank (4); deforming the combined blank (4) to obtain a solid bumper beam assembly (100), wherein the solid bumper beam assembly (100) comprises a bumper beam (10), a pedestrian beam (20) and at least one crossbar (30) connecting the bumper beam to the pedestrian beam, wherein the plurality of blanks comprises a blank (1) of a bumper beam and a blank (2) of a pedestrian beam, and wherein the joining of the blanks includes the formation of one or more overlapping zones formed by partially overlapping the blanks with each other.

2. A method for manufacturing a one-piece bumper beam assembly (100) according to claim 1, characterized in that the plurality of blanks comprises a bumper beam blank (1), a crossbar blank (3), and a pedestrian beam blank (2).

3. A method for manufacturing a one-piece bumper beam assembly (100) according to claim 1 or 2, characterized in that one or more overlapping zones are formed by partially overlapping the crossbar blank (3) with the bumper beam blank (1) and / or with the pedestrian beam blank (2).

4. A method for manufacturing a one-piece bumper beam assembly (100) according to any of paragraphs 1-3, characterized in that the connection of the blanks includes welding the blanks together.

5. A method for manufacturing a one-piece bumper beam assembly (100) according to paragraph 4, characterized in that the welding includes spot welding and / or laser welding.

6. A method for manufacturing a one-piece bumper beam assembly (100) according to any one of paragraphs 1-5, characterized in that the deformation of the combined blank (4) to obtain the one-piece bumper beam assembly (100) includes hot stamping of the combined blank (4).

7. A method for manufacturing a one-piece bumper beam assembly (100) according to any of paragraphs 1-6, characterized in that the deformation is performed during one separate operation.

8. A method for manufacturing a one-piece bumper beam assembly (100) according to any one of paragraphs 1-7, characterized in that the one-piece bumper beam assembly (100) contains two or more crossbars (30) connecting the bumper beam (10) to the pedestrian beam (20).

9. The method according to any one of paragraphs 1-8, characterized in that at least part of the blank (2) of the pedestrian beam is made of a more plastic material than the blank (1) of the bumper beam.

10. The method according to any one of paragraphs 1-9, characterized in that the bumper beam blank (1) is made of ultra-high-strength steel.

11. The method according to any one of paragraphs 1-10, characterized in that the integral unit (100) of the bumper beam comprises a support (60) for the auxiliary system, and optionally the auxiliary system comprises one or more sensors.

12. The method according to any one of paragraphs 1-11, characterized in that the deformation of the combined blank (4) to obtain a solid bumper beam unit (100) includes providing the bumper beam (10) and the pedestrian beam (20) with a hat-shaped cross-section.

13. The method according to claim 12, characterized in that the hat-shaped cross-section of the beam (20) for a pedestrian is open on the first side, and the hat-shaped cross-section of the beam (10) of the bumper is open on the second side and at least one cross-member connects the beam (10) of the bumper to the beam (20) for a pedestrian.

14. A solid bumper beam assembly obtained by the method according to any of paragraphs 1-13.

15. A vehicle comprising a one-piece bumper beam assembly according to paragraph 14.