Hybrid Bumper Energy Absorber for Towing Ring Load Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Energy-absorbing devices composed of composite materials in motor vehicles face challenges in providing a solid connection for towing rings, leading to unsatisfactory fastening characteristics, which compromises their reliability during towing operations.
Innovation Solution
An energy-absorbing device with a reinforced material frame and a non-reinforced material overmolded around it, featuring plates with greater hardness than the non-reinforced material, is designed to absorb impact energy while ensuring optimal fastening to towing rings through strategically positioned plates that distribute loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the energy-absorbing device is composed mainly of composite material to improve energy absorption properties, then the absorption of impact energy is improved, but the fastening characteristics to the towing ring deteriorate
Solution Approach 1:
The energy-absorbing device employs different materials with different properties in different regions: composite material in the energy-absorbing zones and thermoplastic material in the fastening zones. This local differentiation allows the device to optimize for both energy absorption and fastening reliability simultaneously.
Solution Approach 2:
The invention uses composite construction by combining thermoplastic material and composite material in a single device. The thermoplastic material provides solid fastening characteristics for the towing ring, while the composite material provides superior energy absorption properties, creating a hybrid structure that achieves both goals.
2Loss of energy
If the energy-absorbing device uses non-reinforced material to improve energy absorption characteristics, then the absorption properties are improved, but the structural integrity for towing operations deteriorates
Solution Approach 1:
The device applies different material properties to different functional zones: non-reinforced composite material in the energy-absorbing portions and thermoplastic material in the structurally critical fastening portions. This ensures each region has the optimal material properties for its specific function.
Solution Approach 2:
The energy-absorbing device is divided into distinct segments with different material compositions: energy-absorbing zones made of composite material and fastening zones made of thermoplastic material. This segmentation allows independent optimization of each zone's properties.
3Loss of energy
If the energy-absorbing device is made entirely of composite material to optimize impact absorption, then the energy absorption is optimized, but the connection solidity with the towing ring deteriorates
Solution Approach 1:
The invention creates a composite structure at the device level by integrating thermoplastic and composite materials. The thermoplastic material specifically addresses the force transmission requirements for towing ring connection, while the composite material handles impact energy absorption.
Solution Approach 2:
The invention changes the material parameter (from purely composite to hybrid thermoplastic-composite) in the fastening regions to improve force transmission characteristics. This parameter change allows the connection solidity to be optimized without compromising the energy absorption capability of the composite portions.
Data Source
AI summary
The invention relates to an energy-absorbing device configured to be mounted between a bumper and a longitudinal member of a motor vehicle, the energy-absorbing device comprising at least a first part, composed of a first reinforced material and forming a reinforcement of the energy-absorbing device, and a second part, composed of a second non-reinforced material and arranged around the reinforcement, the energy-absorbing device extending in a longitudinal main direction between the bumper and the longitudinal member and comprising at least one plate which is made of a material having a hardness greater than the hardness of the second non-reinforced material and which extends across the longitudinal direction of the energy-absorbing device.