Bumper Beam Attachment Flange for Sensor Mounting
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Solution Overview
Problem
Existing methods for attaching additional parts to the front of a bumper cross-beam, such as energy-absorbing elements or sensors, weaken the cross-beam and compromise its force intrusion properties, requiring costly and time-consuming drilling and riveting processes.
Innovation Solution
A hollow section profile attachment means with a flange extending beyond the vertical front wall of the bumper cross-beam, allowing for the secure attachment of components without compromising the cross-beam's integrity, using a multi-chamber extruded profile made from aluminum alloy, where the flange can be adapted in length and width to accommodate various components, and optionally reinforced for bolting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional parts are attached to the front of the cross-beam using traditional methods (cut-outs or holes with blind rivets), then components can be mounted, but the cross-beam's force intrusion properties are weakened and manufacturing complexity increases
Solution Approach 1:
The attachment means is separated from the cross-beam itself, consisting of a separate hollow section profile that attaches to the cross-beam's rear wall. This segmentation allows additional parts to be mounted on the attachment means rather than directly on the cross-beam, preserving the cross-beam's structural integrity while providing mounting capability.
Solution Approach 2:
The attachment means acts as an intermediary element between the cross-beam and additional components. It provides the mounting function for sensors, energy-absorbing elements, and other parts while the cross-beam maintains its original force intrusion properties without direct modifications.
2Adaptability or versatility
If traditional attachment methods (drilling holes and riveting) are used to mount additional parts, then components can be secured, but manufacturing time and cost increase
Solution Approach 1:
The attachment means is integrated into the cross-beam assembly during the extrusion process. The hollow section profile is extruded as a single piece with the cross-beam, eliminating the need for separate drilling and riveting operations. This merging of processes reduces manufacturing steps, time, and cost while maintaining the ability to attach additional parts.
3Adaptability or versatility
If the attachment means extends beyond the vertical front wall of the cross-beam, then additional components can be mounted in front of the cross-beam, but the attachment means becomes more complex
Solution Approach 1:
The attachment means is designed as a multi-functional element that serves both as a structural connector between the cross-beam and vehicle body, and as a mounting platform for additional components. The flange extending beyond the front wall provides universal mounting capability for various components (sensors, energy-absorbing elements, horns) without requiring separate mounting structures, thus managing complexity through functional integration.
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
Enables the attachment of additional parts like energy-absorbing elements and sensors without weakening the cross-beam, potentially improving energy absorption and reducing assembly costs and complexity, while maintaining the cross-beam's force intrusion properties.
Implementation Method 1
They are designed to be plastically deformed as soon as the kinetic energy of the vehicle at the time of the collision is higher than a critical value. Their plastic deformation is advantageously a progressive folding, which absorbs at least partially the energy of impact.
Implementation Method 2
Bumper cross-beams are designed such that the force at which they begin to plastically deform is lower than the force necessary to irreversibly deform the vehicle structure.
Data Source
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AI summary
The invention concerns an attachment means (20) for mounting a bumper cross-beam (10) having a vertical front wall (11) and a vertical rear wall (12) spaced apart by at least one transverse wall (13) onto a vehicle structure, the said attachment means having a first end (22) to be fixed to the said vehicle structure and a second end (23) designed to be attached to the said bumper cross-beam, the said attachment means being made from a hollow section profile (21), the periphery of which comprises opposite side walls (24 and 25) and substantially parallel opposite outer walls (26 and 27), characterised in that the said second end (23) comprises at least one flange (41), which can extend substantially beyond said vertical front wall (11) after mounting said bumper cross beam (10). The invention is useful in particular for assembling additional parts in the front part of the cross-beam, without affecting the properties of the cross-beam and deteriorating the force intrusion properties