Closed-Hollow Bumper Beam With Self-Locking Impact Deformation
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Solution Overview
Problem
Conventional bumper beams often lack sufficient strength and resistance while maintaining a low weight, failing to effectively absorb impact energy and protect vehicles from external collisions.
Innovation Solution
A bumper beam formed from sheet metal, structured as a closed hollow design with a first longitudinal side forming a horizontal member inside the structure and a recess in the second side wall where the first longitudinal side is unwelded, allowing for controlled deformation and energy absorption during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bumper beams are made stronger and more resistant to handle crash forces, then the strength and impact protection are improved, but the weight increases
Solution Approach 1:
The bumper beam is divided into a closed hollow structure with internal longitudinal sides that are not fully welded to the side walls. This segmentation creates internal reinforcement elements that improve strength while using less material, thereby reducing weight compared to fully welded solid structures
Solution Approach 2:
The bumper beam combines welded and unwelded regions of sheet metal to create a composite structure. The unwelded longitudinal sides act as internal reinforcement elements within the hollow structure, providing enhanced strength-to-weight ratio by utilizing the material's inherent properties without requiring additional welding material or mass
2Loss of energy
If conventional bumper beams are made with more material to absorb impact energy, then the energy absorption is improved, but the weight increases
Solution Approach 1:
The hollow structure with internal unwelded longitudinal sides creates multiple compartments that can deform independently during impact. This segmentation allows for more efficient energy absorption through controlled deformation of each segment, reducing the total material needed compared to solid structures
Solution Approach 2:
The unwelded longitudinal sides are designed to deform dynamically during impact, allowing the structure to absorb energy through controlled deformation. This dynamic behavior enables efficient energy absorption without requiring excessive material, as the structure adapts its rigidity during the impact event
3Strength
If conventional bumper beams are designed with sufficient rigidity to prevent penetration, then the protection against external objects is improved, but the weight increases
Solution Approach 1:
The closed hollow structure with internal longitudinal sides creates a segmented framework that provides rigidity through geometric stability. This segmentation allows the structure to resist penetration by external objects while using less material than solid structures, thereby reducing weight
Solution Approach 2:
The internal longitudinal sides extend into the hollow structure, adding a third dimension of reinforcement. This dimensional approach creates a spatial framework that enhances rigidity and penetration resistance without requiring increased material thickness, thus avoiding weight increase
4Strength
If conventional bumper beams are fully welded to ensure structural integrity, then the strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the welding operation from certain regions by leaving the longitudinal sides unwelded to the side walls. This selective non-welding reduces manufacturing complexity and cost while maintaining structural integrity through the geometric configuration and deformation locking mechanism
Solution Approach 2:
The unwelded longitudinal sides self-lock into the hollow structure during deformation, providing structural integrity without requiring welding. This self-service mechanism eliminates the need for complex welding operations in certain regions, simplifying manufacturing while maintaining strength
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 innovative design enhances impact protection by allowing controlled deformation, improving energy absorption, and maintaining or increasing the rigidity and reinforcement of the bumper beam, while reducing weight and production costs.
Implementation Method 1
the first longitudinal side and the recess are configured to form a locking of the horizontal member when the bumper beam is deformed due to an impact
Implementation Method 2
when the bumper beam is deformed due to an impact
Implementation Method 3
efficient energy absorption of energy of an impact, for example upon a collision
Data Source
Figure 1~2
Figure 3~6
AI summary
A bumper beam (10) of a sheet metal formed to a closed hollow structure (11) comprising a first side wall (18) and a second side wall (28). The sheet metal comprises a first longitudinal side (20) and a second longitudinal side (24). The sheet metal is formed such that the first longitudinal side (20) is formed to a horizontal member (22) located inside the closed hollow structure (11) and such that the second side wall (28) forms a recess (26) into which the first longitudinal side (20) extends. The first longitudinal side (20) and the recess (26) are configured to form a locking of the horizontal member (22) when the bumper beam (10) is deformed due to an impact. In the recess (26) the first longitudinal side (20) is unwelded to the second side wall (28) while the second longitudinal side (24) is welded to the closed hollow structure (11).