Vehicle Bumper Assembly with Angled Crash Boxes

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Solution Overview

Problem

Existing vehicle bumper assemblies are inadequate in distributing collision energy during side collisions, leading to increased passenger injury due to insufficient energy dispersion and subsequent deformation of the passenger compartment.

Innovation Solution

A vehicle bumper assembly design featuring aligned first and second crash boxes with predetermined angles and a triangular second side member, along with a bumper beam and mounting flanges, to efficiently distribute and absorb collision energy by directing it away from the passenger compartment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional bumper assembly with a single crash box and straight bumper beam is used, then the structure is simple and easy to manufacture, but collision energy is not effectively distributed during side collisions, leading to passenger compartment deformation

Engineering Contradiction:

Improvecollision energy distributionVSAvoidbumper assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bumper assembly is segmented into multiple functional components: a first crash box for front collisions, a second crash box for side collisions, and a bumper beam with bent distal sides. This segmentation allows each component to specialize in absorbing collision energy from specific directions, effectively distributing collision energy while maintaining a manageable structural complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bumper beam's distal sides are bent at a predetermined angle (e.g., 45 degrees) relative to the longitudinal direction, transitioning from a straight one-dimensional structure to a multi-dimensional configuration. This angular arrangement enables the bumper beam to effectively distribute collision energy from both front and side directions simultaneously

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the bumper beam distal sides are bent with a radius of curvature at a predetermined angle, then collision energy is effectively distributed to the crash boxes, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvecollision energy absorptionVSAvoidbumper beam bending angle

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The bumper beam distal sides are bent at a predetermined angle (e.g., 45 degrees) with a specific radius of curvature. By optimizing these geometric parameters, the design achieves effective collision energy distribution while establishing clear manufacturing specifications that balance performance requirements with manufacturability

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the second side member is formed in a triangular shape, then side collision energy is effectively directed away from the passenger compartment, but the structural complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvepassenger compartment protectionVSAvoidside member fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The second side member is formed with an asymmetric triangular cross-section rather than a symmetric shape. This asymmetric geometry is specifically designed to efficiently direct side collision energy away from the passenger compartment while remaining manufacturable using standard forming processes

Inventive Principle:

Principle #4Asymmetry

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design effectively minimizes collision energy delivered to the vehicle body, enhancing passenger safety and reducing deformation of the side member, thereby improving the durability of the vehicle body during front and side collisions.

Implementation Method 1

a first crash box having a rear end connected to the mounting flange, a second crash box having a rear end connected to the mounting flange

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Implementation Method 2

The both distal sides of the bumper beam are bent with a radius of curvature

Methodology Applied

Scientific EffectForce distribution through curved structure: Geometry

Data Source

PatentUS8764096B2Bumper assembly for vehicle

Publication Date: 2014.07.01 HYUNDAI MOTOR CO LTD

AI summary

A bumper assembly for vehicle may include a first side member disposed in each of both sides of a vehicle body in a longitudinal direction thereof, a second side member coupled to an external surface of the first side member, a fender member having one side coupled to an external side of the second side member, a member flange connected to front ends of the first and second side members respectively, a mounting flange coupled with the member flange, a first crash box having a rear end connected to the mounting flange, a second crash box having a rear end connected to the mounting flange, and a bumper beam having both distal sides, each of which may be coupled to front ends of the first and second crash boxes.