Steel-Reinforced Bumper Beam with Non-Matching Cross Sections
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Solution Overview
Problem
The existing design of bumper beam cross members faces challenges in manufacturing and assembly due to the need for high geometrical tolerance between outer beams and reinforcement elements with matching cross sections, which increases production costs and complexity, while also limiting the optimization of energy absorption capacity.
Innovation Solution
The cross member design features an outer beam and reinforcement element with non-matching cross sections, allowing for separate optimization of each part's shape and manufacturing process, with the reinforcement element having a M-shaped cross-section optimized for energy absorption and the outer beam comprising a central portion with higher crash ductility and side portions with high mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the reinforcement element has a cross section shape matching the outer beam, then the assembly contact surface area is increased, but the manufacturing precision and geometrical tolerance requirements become excessively high
Solution Approach 1:
The patent applies asymmetry by deliberately designing the reinforcement element with a cross-section shape that does not match the outer beam shape. This asymmetric design breaks the symmetry requirement of traditional matching cross-sections, allowing each component to be manufactured independently with standard tolerances while still achieving proper fit and function through the asymmetric interface geometry.
Solution Approach 2:
The patent segments the bumper beam into two independently manufactured components: the outer beam and the reinforcement element. By separating the manufacturing process and allowing different cross-section shapes, each component can be produced with standard geometrical tolerances, avoiding the need for high-precision matching while maintaining structural integrity through their interface.
2Ease of manufacture
If the reinforcement element cross section matches the outer beam, then the assembly process is simplified conceptually, but the manufacturing cost and complexity increase due to high tolerance requirements
Solution Approach 1:
The asymmetric cross-section design simplifies manufacturing by allowing each component to be produced independently with standard tolerances. The asymmetric interface geometry provides inherent alignment features that guide assembly, reducing the need for complex alignment procedures while maintaining ease of assembly.
Solution Approach 2:
Segmenting the design into non-matching cross-sections allows each component to be manufactured using standard processes without requiring high-precision tolerance control. This reduces manufacturing complexity and cost while the interface design ensures proper assembly through geometric compatibility.
3Strength
If the reinforcement element has a matching cross section shape, then the structural integrity is maintained, but the energy absorption capacity is not optimized
Solution Approach 1:
The patent applies local quality by optimizing the reinforcement element's cross-section shape specifically for energy absorption in the impact zone, rather than requiring a matching shape throughout. The asymmetric design allows the reinforcement to have enhanced energy-absorbing geometry at the impact end while maintaining adequate structural integrity through the interface with the outer beam.
Solution Approach 2:
The asymmetric cross-section design enables the reinforcement element to have an optimized shape for energy absorption that differs from the outer beam shape. This allows the reinforcement to feature geometry specifically tailored for crash energy management while maintaining structural integrity through the asymmetric interface connection.
Data Source
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AI summary
The cross member (1) for a bumper beam comprises: -an outer beam (2) with a main beam portion (3) comprising an upper beam wall (12), a lower beam wall (14) and a front beam wall (16), defining together a beam inner volume (17) open in a back direction, -a reinforcement element (4) defining a reinforced area (24) of the outer beam (2), located inside a part of said beam inner volume (17) and having a cross section, defining a reinforcement inner volume (25) open in the rear direction, -a closing plate (6) closing at least a part of the beam inner volume (17), wherein the cross section of the reinforcement element (4) has a shape which is not matching the shape of the outer beam (2) in the reinforced area (24).