Bumper Beam Cellular Structure for Tuned Energy Absorption
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Solution Overview
Problem
Current bumper beam designs are complex, costly to manufacture, and heavy, requiring separate designs for each vehicle model and market segment, with limited flexibility and increased weight, which hinders fuel efficiency and regulatory compliance.
Innovation Solution
A modular bumper beam design with variable geometrical features that can be tuned for different vehicle segments, featuring a unique cross-sectional geometry to distribute impact energy and reduce weight, allowing for lighter weight and improved energy absorption without complex tooling changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex cross-ribs and support structures are incorporated to meet performance requirements, then energy absorption capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bumper beam is divided into multiple cells or compartments separated by transverse walls, creating a segmented structure that improves energy absorption through controlled deformation of each cell while maintaining overall structural integrity
Solution Approach 2:
The patent introduces a longitudinal I-beam element that runs along the length of the bumper beam, adding a third dimension to the cross-sectional structure. This longitudinal element provides additional stiffness and energy absorption capability without requiring complex cross-ribs in the transverse plane
2Reliability
If heavier and larger bumper beams are designed for robust performance, then energy absorption capability is improved, but weight increases reducing fuel efficiency
Solution Approach 1:
The bumper beam utilizes a composite structure combining the longitudinal I-beam element with the cellular cross-section, creating a lightweight yet high-strength design that absorbs energy effectively without requiring increased weight
Solution Approach 2:
The cellular structure divides the bumper beam into multiple compartments, allowing energy to be absorbed through progressive deformation of individual cells rather than requiring a solid, heavy structure
3Reliability
If separately designed bumper beams are created for each vehicle model, then performance characteristics are optimized, but adaptability across vehicle segments decreases and tooling costs increase
Solution Approach 1:
The bumper beam design with its modular cellular structure and longitudinal I-beam element can be adapted to serve multiple vehicle types and market segments, reducing the need for completely separate designs while maintaining performance requirements
Solution Approach 2:
The geometry of the cellular structure, including cell size, wall thickness, and I-beam dimensions, can be modified through parameter changes to optimize performance for different vehicle segments without changing the fundamental design architecture
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 enables rapid and cost-effective modification across various vehicle segments, reducing manufacturing costs and weight while maintaining or improving energy absorption characteristics, thus enhancing fuel efficiency and regulatory compliance.
Implementation Method 1
each of which extends continuously along the bumper beam between the first and second ends for absorbing energy during a front or rear impact of the vehicle to which the bumper beam is secured
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A bumper beam includes an outer portion and an inner portion each extending between a top end and a bottom end. At least one of the outer portion or the inner portion includes a pair of geometrical features each of which are disposed in spaced relationship to one another and adjacent a respective one of the top or bottom ends. A top wall and a bottom wall each extend from one of the geometrical features to the other of the outer portion or the inner portion to interconnect the outer and inner portions of the bumper beam. The geometrical features can be varied in size and shape to change and tune the energy absorption properties of the bumper beam and ultimately provide for a bumper beam that is adaptable and flexible over a range of vehicle applications.