Composite Bumper Beam with Integrated Energy Absorber
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Solution Overview
Problem
Current vehicle bumpers with energy-absorbing components are costly due to their metal composition, necessitating a more affordable composite material solution for effective energy absorption during collisions.
Innovation Solution
An energy-absorbing bumper component comprising a beam structural member and energy absorber made from injection molded long glass fiber nylon, with a beam cover plate connected via resistive implant welding and overmolded vehicle attachment plates, utilizing expanded polypropylene for energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal components are used for energy absorption, then energy absorption capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining expanded polypropylene foam (energy absorber) with nylon beam structural members and cover plates. This composite construction replaces traditional metal energy absorbers while maintaining effective energy absorption through the foam's cellular structure, thereby reducing manufacturing cost while preserving the required safety performance.
Solution Approach 2:
The patent changes the material parameters from metal to composite materials (expanded polypropylene and nylon). The expanded polypropylene provides energy absorption through its cellular structure collapse, while nylon provides structural integrity. This parameter change in material selection achieves cost reduction without sacrificing energy absorption capability.
2Ease of manufacture
If composite materials are used for the bumper component, then manufacturing cost is reduced, but structural strength may be compromised
Solution Approach 1:
The patent uses a multi-layer composite structure consisting of expanded polypropylene foam core, nylon beam structural members, and nylon cover plates. Each material is selected for its specific properties: the foam for energy absorption, the nylon components for structural strength and rigidity. This composite approach maintains structural strength while enabling cost-effective manufacturing.
Solution Approach 2:
The bumper component is segmented into distinct functional parts: the energy absorber (foam), the structural framework (beam structural members), and the exterior components (cover plates and attachment plates). This segmentation allows each part to be optimized for its specific function while being manufactured separately and assembled, maintaining overall structural strength through proper design of each segment.
3Ease of repair
If multiple separate components are used for the bumper, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The bumper is designed as segmented modular components including cover plates, beam structural members, attachment plates, and an energy absorber. These segments can be independently manufactured, inspected, and replaced. The cover plates can be removed and replaced without affecting the structural members or energy absorber, facilitating ease of repair while maintaining manageable device complexity through functional segmentation.
Solution Approach 2:
The attachment plates are pre-formed with attachment features, and the cover plates are designed with predetermined mounting locations on the beam structural members. This preliminary design of attachment mechanisms simplifies the assembly and repair process, as components are designed for straightforward installation and replacement without complex fastening procedures.
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 solution reduces manufacturing costs while maintaining effective energy absorption capabilities, forming a durable and efficient composite bumper system for vehicle collisions.
Implementation Method 1
a beam cover plate connected to the beam structural member through the use of resistive implant welding
Implementation Method 2
the energy absorber absorbs energy when the vehicle undergoes a collision
Implementation Method 3
The beam structural member and the beam cover plate are made from injection molded long glass fiber nylon material
Implementation Method 4
the energy absorber is made from expanded polypropylene using a steam injection molding process
Data Source
AI summary
The present invention is directed to an energy absorbing component externally mounted to a vehicle having a beam structural member and at least one energy absorber operably connected to the beam structural member. The energy absorber absorbs energy when the vehicle undergoes a collision. Also included is a beam cover plate connected to the beam structural member through the use of resistive implant welding, which simplifies the manufacturing process, and improves manufacturing costs. There are two vehicle attachment plates which are overmolded to the beam cover plate, the vehicle attachment plates allow for the beam cover plate to be attached to a vehicle. The beam cover plate, beam structural member, and energy absorber form a component that is operable to function as a bumper that is connected to a vehicle, which absorbs energy during a collision.