L-Shaped Mounting Brackets for Vehicle Bumper Beam Vibration
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Solution Overview
Problem
Existing vehicle body front structures face limitations in suppressing vibration and enhancing durability of the front bumper beam, particularly in large passenger cars like SUVs and minivans, due to concentrated stress at joint portions and inadequate support rigidity, which affects noise and vibration performance.
Innovation Solution
The implementation of L-shaped mounting brackets with horizontal and vertical plate-like joint portions and gussets that provide increased support rigidity and joining strength, along with the integration of side connecting members and extension portions to absorb collision energy and prevent sideways deformation, thereby enhancing the overall noise and vibration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fillet welding is used to join bumper beam extensions to mounting brackets, then the structure is simple and easy to manufacture, but the vibration suppression capability is limited and stress concentrates at joint portions
Solution Approach 1:
The patent transitions from a single-point fillet weld connection to a multi-point distributed connection system. The mounting bracket is positioned to connect at multiple locations along the bumper beam extension, distributing the connection points in space. This dimensional change from point-to-line or point-to-surface connection enhances vibration suppression while maintaining manufacturing simplicity through standard welding procedures at multiple locations.
Solution Approach 2:
The mounting bracket is strategically positioned at specific locations where vibration occurs most intensely. The bracket's geometry and placement are optimized to provide localized reinforcement exactly where needed, rather than uniformly strengthening the entire bumper beam extension. This allows targeted vibration suppression at critical joint portions while maintaining ease of manufacture by focusing welding efforts only at necessary locations.
2Strength
If the front bumper beam is made large to provide sufficient strength, then the strength is improved, but the weight increases and vibration is amplified
Solution Approach 1:
The patent divides the front bumper beam structure into modular components: the main bumper beam, bumper beam extensions, and mounting brackets. This segmentation allows each component to be optimized independently for its specific function. The mounting brackets serve as intermediate structural elements that provide reinforcement and vibration suppression without requiring the entire bumper beam to be oversized, thereby reducing overall weight while maintaining necessary strength.
Solution Approach 2:
The patent employs a composite structural system combining the bumper beam extension and mounting bracket as an integrated assembly. This composite structure leverages the complementary strengths of different components - the extension provides longitudinal connectivity while the bracket provides transverse support and mounting functionality. This composite approach achieves enhanced strength and vibration suppression without the weight penalty of a monolithic oversized beam.
3Strength
If mounting brackets are positioned at rear ends of bumper beam extensions, then the joining strength is improved, but stress concentrates at these joint portions reducing durability
Solution Approach 1:
The mounting bracket is positioned to create a distributed connection pattern rather than a single concentrated joint. By extending the bracket's connection points along the bumper beam extension in the longitudinal direction, the stress that would normally concentrate at one location is distributed across multiple points. This dimensional distribution of connection points maintains high joining strength while reducing peak stress concentrations, thereby improving durability.
Solution Approach 2:
The patent modifies the geometric parameters of the mounting bracket, including its length, width, and connection point distribution. By optimizing these parameters, the bracket achieves adequate joining strength while spreading stress over a larger area and multiple locations. The bracket's dimensions are specifically designed to balance joining strength requirements with stress distribution needs, preventing localized stress concentration that would compromise durability.
Data Source
AI summary
There is provided a vehicle body front structure including left and right mounting brackets provided at the rear ends of left and right bumper beam extensions of a front bumper beam, and left and right frame side mounting members connecting the rear ends of the left and right mounting brackets. The left and right frame side mounting members are provided at the front ends of left and right front side frames. The left and right mounting brackets are formed into an almost L shape by horizontal plate-like left and right joint plate portions and vertical plate-like left and right flanges, and each of the left and right mounting brackets is located on at least one of the upper surface and the lower surface of each of the left and right bumper beam extensions.