Vehicle Bumper Beam Offset Crash Strength via Tube-Expanding Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bumper structures are not adequately designed to withstand high-speed offset crashes, as they primarily focus on front crash loads, leading to limitations in extending length or increasing thickness, which can result in increased weight and processing difficulties for aluminum and steel materials.
Innovation Solution
A vehicle structure with a bumper beam and reinforcement members arranged to overlap in the vehicle width direction, where the reinforcement members are joined to the bumper beam by press-fitting and tube-expanding, enhancing the structural strength against offset loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bumper structure length in vehicle width direction is increased to improve offset load strength, then the strength against offset load is improved, but the bending length increases and bending curvature decreases making processing difficult
Solution Approach 1:
The bumper structure is divided into a main body portion and a reinforcement portion that can be manufactured separately and then joined together. This segmentation allows each part to be optimized independently - the main body can be processed with standard bending curvature while the reinforcement portion adds the necessary strength without requiring excessive length extension
Solution Approach 2:
The bumper structure combines different materials or structural configurations in the main body and reinforcement portions. This composite approach enables the structure to achieve high offset load strength through material properties and structural design rather than simply increasing length, thereby avoiding processing difficulties
2Strength
If the bumper beam thickness or size is increased to improve strength against offset load, then the strength is improved, but the overall weight of the bumper structure increases
Solution Approach 1:
The reinforcement portion is strategically positioned at specific locations where offset loads are most critical, rather than uniformly increasing the bumper beam thickness throughout. This localized reinforcement approach achieves the necessary strength improvement only where needed, minimizing the addition of material and thus controlling the overall weight increase
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
This configuration improves the strength of the vehicle structure against offset loads while maintaining a simple design, reducing weight and processing challenges, and enhancing joint strength through precise fitting and adhesive use.
Implementation Method 1
joining by press-fitting the second member into the first member and the third member by tube-expanding the insertion part of the second member into the first member and the third member
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A vehicle structure (90) includes a first member (1) that extends in a vehicle width direction, second members (2, 3) that extend in a front-back direction that are inserted in the front-back direction with respect to the first member (1), and third members (4, 5) that are arranged at end portions (la, 1b) of the first member (1) in the vehicle width direction and joined to the end portions (1a, 1b).