Injection Molded Vehicle Bumper Beam Energy Absorption

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Solution Overview

Problem

Bumper beams designed for regions with strong regulatory requirements, such as North America, face challenges in meeting performance standards due to limitations in injection molding techniques, which struggle to satisfy continuous performance tests.

Innovation Solution

A bumper beam structure incorporating a pair of mounting portions, a supporting portion with a closed front and open rear, a web, an energy absorbing portion, and an energy transmitting portion, all integrally formed by injection molding, with additional ribs for enhanced energy distribution and absorption, allowing for efficient energy absorption and reduced damage during collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If bumper beams are made by injection molding for regions with weak regulations, then production cost and weight are reduced, but the ability to satisfy continuous performance tests required by strong regulations deteriorates

Engineering Contradiction:

Improveproduction costVSAvoidability to satisfy continuous performance tests

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bumper beam is divided into distinct functional segments: a mounting portion for structural attachment, a supporting portion with closed front and open rear, a web section, an energy absorbing portion, and an energy transmitting portion. This segmentation allows each part to be optimized for its specific function while maintaining manufacturability through integral injection molding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the bumper beam are designed with locally optimized properties: the energy absorbing portion has a plate shape disposed horizontally to maximize energy absorption, the supporting portion has a specific cross-sectional geometry for structural integrity, and the mounting portions are positioned for optimal attachment. This local quality optimization enables the molded bumper beam to meet stringent regulatory requirements.

Inventive Principle:

Principle #3Local quality

2Weight of moving object

If bumper beams are made by injection molding, then weight is reduced, but the ability to meet performance conditions required by countries with strong regulations deteriorates

Engineering Contradiction:

ImproveweightVSAvoidability to meet performance conditions

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The design optimizes geometric parameters of the bumper beam structure, including the cross-sectional shape of the supporting portion, the dimensions and orientation of the web, and the configuration of the energy absorbing portion. These parameter changes enable the lighter molded structure to achieve the required performance levels.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bumper beam utilizes composite material properties through its multi-part structure, combining different geometric configurations and material distributions within the molded component to achieve both weight reduction and high performance.

Inventive Principle:

Principle #40Composite materials

3Reliability

If bumper beams are designed with complex structures to meet North American regulations, then performance in continuous collision tests is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveperformance in continuous collision testsVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functional components that would traditionally be separate parts (mounting brackets, support structures, energy absorption elements) are merged into a single integrally molded bumper beam component. This reduces assembly complexity while maintaining the complex geometry needed for high performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bumper beam is designed as a multi-functional component where a single molded part performs multiple functions: structural support, energy absorption, energy transmission, and mounting attachment. This universality reduces the number of parts and manufacturing steps while achieving the required performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 proposed bumper beam design effectively absorbs collision energy, suppresses damage to the mounting portions, and meets stringent regulatory requirements while reducing production costs and weight through efficient injection molding.

Implementation Method 1

an energy absorbing portion supporting a rear surface of the web and supported by the front surface of the supporting portion to absorb energy generated when a colliding object collides with the web

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS11318900B2Bumper beam of vehicle

Publication Date: 2022.05.03 LOTTE CHEM CORP

AI summary

A bumper beam of a vehicle according to the present invention includes a pair of mounting portions for being fixed to a vehicle member, a supporting portion having a cross-section in which a front surface is closed and a rear surface opens and having both ends supporting the pair of mounting portions, a web disposed in front of the supporting portion, an energy absorbing portion supporting a rear surface of the web and supported by the front surface of the supporting portion to absorb energy generated when a colliding object collides to with the web, and an energy transmitting portion connecting the energy absorbing portion and the pair of mounting portions.