Adhesive Interface Module for Crash Box Attachment
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Solution Overview
Problem
The automotive industry faces challenges in creating a lightweight, stable, and cost-effective crash management system for vehicles, as mechanical fastening methods for composite bumper systems often lead to early detachment due to brittle failure modes and stress concentrations, and traditional welding has limited application with composites.
Innovation Solution
An interface module comprising a foam core support structure and a carbon fibre covering layer, which is securely enclosed between the bumper beam and the covering layer, eliminating the need for mechanical fasteners and providing stable support for crash boxes through form-fitting and adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fastening methods (welding, bolting) are used to attach bumper beam and crash box, then connection strength is improved, but weight increases and composite material failure occurs due to stress concentrations
Solution Approach 1:
The patent replaces mechanical fastening methods (welding, bolting) with an adhesive bonding system. The adhesive layer bonds the crash box directly to the bumper beam surface, eliminating the need for mechanical fasteners. This substitution reduces weight while maintaining connection strength, and avoids stress concentrations that cause composite material failure.
Solution Approach 2:
The patent employs composite material structure where the adhesive layer acts as an intermediate bonding material between the crash box and bumper beam. This composite approach allows for distributed stress transfer across the bonding interface, preventing the stress concentrations that occur with mechanical fasteners while maintaining strong attachment.
2Reliability
If mechanical fastening methods are used to attach bumper beam and crash box, then connection stability is improved, but weight increases
Solution Approach 1:
The patent replaces mechanical fastening systems with adhesive bonding, eliminating heavy fasteners while maintaining connection stability. The adhesive creates a continuous bonding interface that distributes loads evenly, providing reliable attachment without the weight penalty of mechanical fasteners.
3Weight of moving object
If adhesive bonding is used to attach crash box to bumper beam, then weight is reduced and stress concentrations are avoided, but bonding strength must be sufficient to prevent detachment
Solution Approach 1:
The patent uses adhesive bonding to replace mechanical fasteners, achieving weight reduction while maintaining sufficient bonding strength. The adhesive creates a continuous bonding interface that distributes stresses evenly across the attachment area, preventing the stress concentrations that lead to composite failure while providing adequate strength to prevent detachment during vehicle operation and minor impacts.
Data Source
AI summary
An interface module for a vehicle crash management system wherein the interface module includes a support structure and a covering layer, and the interface module is adapted for attaching a crash box to a bumper beam. A first section of the support structure is adapted for being placed in direct contact with the bumper beam. A second section of the support structure comprises a recess adapted for receiving one end of the crash box, and the second section is further adapted for being covered by the covering layer. The covering layer is adapted for being arranged on the second surface, such that the support structure is completely enclosed between the bumper beam and the covering layer. Also disclosed are a crash management system and a method for assembling such a system.