Bumper Bracket Weakening Structure for Controlled Collision Crumpling

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Solution Overview

Problem

Existing vehicle bumper systems lack effective energy absorption and crumple capabilities during collisions, leading to secondary damage due to limited deformation of sheet metal and non-retractable plastic brackets, and increased parts complexity with added elastic buffers.

Innovation Solution

A bumper bracket with a weakening portion of lower structural strength than the rest of the bracket, positioned in front of a mounting hole, allows for controlled deformation and energy absorption by shifting the fastener from the mounting hole to the weakening portion upon impact, enhancing crumple capability and reducing secondary damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sheet metal bracket and non-retractable plastic bracket are used to mount the bumper, then the bumper can be securely connected to the vehicle body, but the bracket cannot effectively crumple and absorb energy during collision

Engineering Contradiction:

Improveconnection reliabilityVSAvoidenergy absorption capability

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The bumper bracket employs local quality by creating a weakening portion with specifically reduced structural strength at a defined location. This localized weak area allows controlled deformation and energy absorption during collision, while the rest of the bracket maintains sufficient strength for secure mounting. The weakening portion is positioned between the mounting hole and the front end of the bracket, creating a controlled deformation zone that balances connection reliability with energy absorption capability.

Inventive Principle:

Principle #3Local quality

2Loss of energy

If elastic buffer parts or airbags are added to improve bumper deformation capability, then the bumper can crumple during collision, but the number of parts increases and secondary damage occurs due to recovery deformation

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidnumber of parts

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The invention merges the mounting bracket and energy absorption function into a single integrated component. The weakening portion is formed as an integral part of the bumper bracket through processes like injection molding or die-cutting, eliminating the need for separate elastic buffers or airbags. This unified design reduces part count while maintaining effective crumple capability through the controlled weak area that deforms preferentially during collision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The weakening portion is designed as a sacrificial element intended to deform or fail during collision to absorb energy. This disposable-like approach allows the bracket to effectively crumple in the weakening region, absorbing impact energy without requiring expensive elastic buffers or airbags. The controlled weakness enables reliable energy absorption while keeping the overall system simple and cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of energy

If elastic deformation is used to crumple the bumper, then energy absorption is achieved, but secondary damage occurs due to recovery deformation after impact

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidsecondary damage to pedestrian

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The weakening portion is pre-designed and positioned to control where deformation occurs during collision. By strategically locating this weak area between the mounting hole and front end, the design ensures that deformation happens in a controlled manner that prevents rebound. The preliminary placement of the weakening portion guides the deformation path to minimize recovery effects that could cause secondary damage to pedestrians or objects.

Inventive Principle:

Principle #10Preliminary action

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 effectively reduces secondary damage to pedestrians or objects by allowing the bumper to deform rearward, improving the buffering deformation capability of the vehicle bumper system while minimizing the number of components and avoiding recovery deformation issues.

Implementation Method 1

the structural strength of the weakening portion is lower than a structural strength of a portion of the bumper bracket other than the weakening portion... allowing the bumper to deform rearward... improving the buffering deformation capability

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS20240425007A1Bumper bracket, vehicle body front end assembly, and vehicle

Publication Date: 2024.12.26 BYD CO LTD

AI summary

A bumper bracket for connecting with a vehicle body, includes a mounting hole and a weakening portion. The mounting hole is configured to connect the bumper bracket to the vehicle body. In a front-rear direction of a vehicle, the weakening portion is disposed in front of the mounting hole, a projection of the mounting hole in the front-rear direction of the vehicle at least partially overlaps with a projection of the weakening portion in the front-rear direction of the vehicle, and a structural strength of the weakening portion is lower than a structural strength of a portion of the bumper bracket other than the weakening portion.