Continuous Fiber Bumper Beam with Surface Ridgelines
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Solution Overview
Problem
The curved lateral portions of vehicle bumper beams made of continuous fiber reinforced plastic are prone to random cross-sectional deformation under collision loads, reducing the load-bearing capacity of the bumper beam.
Innovation Solution
Incorporating surface ridgelines on the upper and lower surfaces of the lateral portions, formed by surface steps, which create a load transmission path between the collision load receiving section and the vehicle body attachment section, and using a combination of continuous and short fiber reinforced plastics to enhance structural rigidity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lateral portions are formed in a curved shape to reduce weight and cost, then the manufacturing cost and weight are reduced, but random cross-sectional deformation occurs under collision loads reducing load bearing capacity
Solution Approach 1:
The patent applies local quality by adding surface steps (ridgelines) specifically at critical locations on the lateral portions where cross-sectional deformation occurs. These localized structural modifications reinforce the curved lateral portions without changing the overall curved shape design, thereby maintaining weight reduction while preventing deformation at specific vulnerable areas.
Solution Approach 2:
The patent utilizes composite materials by forming the bumper beam from continuous fiber reinforced plastic, which combines the strength and stiffness of continuous fibers with the structural benefits of plastic matrix. This composite structure enhances the load bearing capacity of the curved lateral portions while maintaining the weight reduction advantages of the curved design.
2Weight of moving object
If the lateral portions are formed in a curved shape to reduce weight and cost, then the weight and manufacturing cost are reduced, but the load bearing capacity is reduced due to cross-sectional deformation
Solution Approach 1:
The surface steps create localized reinforcement zones that prevent cross-sectional deformation without requiring additional material throughout the entire lateral portion. This selective reinforcement maintains the overall weight reduction benefit while locally enhancing strength where needed.
Solution Approach 2:
The continuous fiber reinforced plastic composite material provides high strength-to-weight ratio, enabling the curved lateral portions to maintain both low weight and adequate load bearing capacity when combined with the surface step reinforcement.
3Strength
If surface ridgelines are added to control cross-sectional deformation, then the load bearing capacity is improved, but the device complexity increases
Solution Approach 1:
The surface steps are localized features added only at critical deformation zones on the lateral portions, rather than throughout the entire bumper beam. This minimizes the increase in structural complexity while providing effective reinforcement where it is most needed.
Solution Approach 2:
The surface steps are integrated into the existing curved lateral portion geometry during the molding process, combining the deformation control function with the existing structural design rather than adding separate components, thereby minimizing device complexity.
Data Source
AI summary
A vehicle bumper device includes: (i) a bumper beam formed of a continuous fiber reinforced plastic and including (a) a central portion that extends in a vehicle width direction and (b) a left-right pair of lateral portions that respectively extend from opposite ends of the central portion and curve toward a vehicle body; and (h) bumper auxiliary portions formed of a short fiber reinforced plastic different from the continuous fiber reinforced plastic and protruding respectively from the lateral portions outward in a vehicle front-rear direction. The lateral portions each have at least one ridgeline defined by a surface step formed on the upper surface section or the lower surface section. The ridgeline extends between the collision load receiving section and the vehicle body attachment section.