Bumper Beams With Interlocking Projections
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Solution Overview
Problem
Existing manufacturing methods for bumper beams and rocker panels often require welding, which can be costly, time-consuming, and affect the quality of the joint, while also limiting tolerance in the mechanical joining process.
Innovation Solution
A method of forming bumper beams and rocker panels with closed cross-sections using metal plates with holes and projections that engage to retain the shape, eliminating the need for welding and allowing for higher tolerance and faster, cheaper manufacturing, with the option to use different materials and thicknesses for optimized structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join metal plates, then joint strength is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical joining system consisting of projections and corresponding recesses that interlock to secure metal plates together. This mechanical substitution eliminates the need for welding operations while maintaining structural integrity, thereby reducing manufacturing time and cost without significantly compromising joint strength.
2Reliability
If welding is used to join metal plates, then joint reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the joining function into separate geometric features: projections on one metal plate and corresponding recesses on another. This segmentation transforms the complex welding process into simpler, discrete mechanical elements that can be independently manufactured and assembled, reducing overall manufacturing process complexity while maintaining joint reliability through the interlocking mechanism.
3Strength
If welding is used to join metal plates, then structural strength is improved, but tolerance requirements increase
Solution Approach 1:
The patent changes the joining parameter from thermal/chemical bonding (welding) to mechanical interlocking (projections and recesses). This parameter change allows for greater manufacturing tolerance because the mechanical features can accommodate variations in dimensions and alignment more readily than welding, which requires precise positioning and control of thermal processes, while still achieving sufficient structural strength through the interlocking geometry.
Data Source
AI summary
The present disclosure relates to bumper beams having a closed cross-section, the closed cross-section being formed by one or more metal plates. The metal plates include a plurality of holes and a plurality of projections, wherein the projections engage with corresponding holes to retain the closed cross-section. The present disclosure further relates to rocker panels having a closed cross-section, the closed cross-section being formed by one or more metal plates, and the metal plates including a plurality of holes and a plurality of projections, wherein the projections engage with corresponding holes to retain the closed cross-section. The present disclosure further relates to methods of manufacturing such bumper reinforcing members and rocker panels.