Vehicle Bumper Beam Tow Eyelet Fastening Socket
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Solution Overview
Problem
Existing fastening solutions for tow eyelets in bumper beams often compromise stability and safety while potentially weakening the bumper beam, and they are not cost-effective.
Innovation Solution
A bumper beam design featuring an internally threaded fastening socket welded to a bulkhead within the beam, which is reinforced by longitudinal welds, allowing for secure attachment and removal of a tow eyelet without compromising the structural integrity of the beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal insert with collar is used to mount the threaded tow eyelet in a cylindrical hole, then the fastening can be provided, but the structural integrity of the bumper beam is weakened
Solution Approach 1:
The invention divides the fastening system into separate functional components: the bumper beam structure, the bulkhead reinforcement plate, and the threaded socket assembly. This segmentation allows the beam to maintain its structural integrity while the bulkhead provides the necessary reinforcement for the fastening function, preventing weakening of the main beam structure.
Solution Approach 2:
The bulkhead acts as an intermediary element between the bumper beam and the threaded socket. It transfers and distributes the loads from the tow eyelet fastening, preventing direct stress concentration in the beam itself. The bulkhead serves as a mediator that protects the beam structure while enabling the fastening function.
2Reliability
If a mounting flange with U-shaped cross-section is used, then the fastening can be attached to the bumper beam, but the manufacturing cost increases
Solution Approach 1:
The invention extracts the reinforcement function from the main bumper beam structure and places it in a separate bulkhead component. This allows the beam to remain simple in structure while the bulkhead provides the necessary reinforcement. The separation simplifies manufacturing of the beam itself and allows the bulkhead to be added only where needed.
Solution Approach 2:
Instead of reinforcing the entire bumper beam structure, the bulkhead provides localized reinforcement only at the specific position where the tow eyelet fastening is required. This local quality approach minimizes material usage and manufacturing complexity while achieving the necessary structural reinforcement for the fastening application.
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 solution provides a stable and safe fastening mechanism for tow eyelets that does not weaken the bumper beam, ensuring reliable attachment and detachment while maintaining the structural integrity of the vehicle's bumper system at a low cost.
Implementation Method 1
The fastening socket is welded firmly in a bulkhead 23 by longitudinal welds 26, 27 along the socket. The bulkhead 23 is welded firmly in the hat beam by being welded to the two webs 12, 13 by welds 24, 25.
Data Source
Figure 1~2
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Figure 4
AI summary
A bumper beam in the form of an open hat beam with a central flange (11) pointing outwards has a transverse bulkhead (23) at one of its fastening portions (17). An internally threaded socket (22) is welded to the transverse bulkhead parallel with the bulkhead and protrudes through a hole (21) in the central flange (11) so that a tow eyelet can be screwed firmly into the socket when needed and thereafter be unscrewed.