Hollow Bumper Beam Connector for Car-to-Car Crash Compatibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crash management systems face challenges in enhancing crash compatibility to minimize damage to other vehicles in car-to-car collisions, while also preventing penetration of external components into the vehicle interior.
Innovation Solution
The integration of an extruded hollow profile connecting element between the upper and lower bumper beams, which stabilizes and deforms into a flat surface upon impact, thereby enhancing the crash management system's deformation behavior and preventing external penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the crash management system uses a fixed offset deformable barrier impact test design, then the system meets current safety standards, but the system fails to address crash compatibility requirements for car-to-car collisions
Solution Approach 1:
The bumper beam is divided into multiple segments including a rigid central portion and deformable end portions. The connecting element further segments the structure by linking the lower bumper beam to the upper bumper beam, creating distinct functional zones that can deform independently to manage crash forces appropriately.
Solution Approach 2:
The system transitions from a static rigid structure to a dynamic system where the connecting element can deform under impact loads. The hollow profile geometry allows the structure to change shape during collision, absorbing energy while maintaining structural integrity and preventing penetration.
2Strength
If the connecting element uses a solid rigid structure, then the structural strength is high, but the energy absorption capability during impact is reduced
Solution Approach 1:
The connecting element employs a hollow profile structure with internal cavities. This porous-like geometry provides structural strength while allowing controlled deformation and energy absorption during impact, as the hollow sections can collapse and deform to dissipate crash energy.
Solution Approach 2:
The connecting element is constructed as a composite structure combining the hollow profile geometry with appropriate material selection to achieve optimal balance between strength and energy absorption. The composite design allows the structure to exhibit both rigidity for strength and deformability for energy management.
3Adaptability or versatility
If the bumper beam structure is extended in length and width, then the crash compatibility is improved, but the device complexity increases
Solution Approach 1:
The connecting element serves multiple functions simultaneously: it structurally links the lower and upper bumper beams, absorbs crash energy through deformation, extends the effective barrier length, and prevents penetration into the vehicle interior. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The invention merges the functions of structural connection, energy absorption, and penetration prevention into a single integrated connecting element. By combining these functions, the overall device complexity is reduced compared to using separate components for each function.
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
This solution improves the crash management system's performance by extending its length and width, enhancing energy absorption, and maintaining a constant barrier deformation without deep impact, thus addressing the requirements of the Mobile Progressive Deformable Barrier test.
Implementation Method 1
The connecting element is an extruded hollow profile which extrusion direction is substantially parallel to said vertical direction Z... in case of impact the connecting element may be stabilized in contact with another component of the vehicle like for example a wheel, or a longitudinal beam and may be deformed into a flat surface
Data Source
AI summary
A crash management system (1, 1′, 1″) for a front part of a vehicle, oriented in a local referential, having a longitudinal direction X a transverse direction Y perpendicular to the longitudinal direction X and a vertical direction Z perpendicular to the plane defined by said directions X and Y, comprising an assembly (2, 2′, 2″) of bumper beams with at least a first bumper beam (3, 3′, 3″) and a second bumper beam (4, 4′, 4″), oriented in said transverse direction Y, said first bumper beam (3, 3′, 3″) and second bumper beam (4, 4′, 4″) being vertically spaced wherein said first bumper beam (3, 3′, 3″) is located above said second bumper beam (4, 4′, 4″), optionally comprising at least one crash box (5, 6) connected to at least a bumper beam (3, 3′, 3″, 4, 4′, 4″), and comprising at least a connecting element (100, 200,300, 400, 500) characterized in that said connecting element (100, 200,300, 400, 500) connects said first bumper beam (3, 3′, 3″) and said second bumper beam (4, 4′, 4″), and wherein said connecting element (100, 200, 300, 400, 500) is an extruded hollow profile which extrusion direction (E) is substantially parallel to said vertical direction Z.