Vehicle Bumper Assembly with Composite Cross Member
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Solution Overview
Problem
Existing bumper assemblies designed for European market standards often fail to meet North American crash test requirements without increasing vehicle length, affecting aerodynamics and aesthetics.
Innovation Solution
A bumper assembly with a plastic first cross member and connecting plates, reinforced with glass fibers, and a shock-absorbing element between cross members, allowing for adjustable design to meet various regulatory standards without lengthening the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the cushioning material layer is increased to meet North American crash test standards, then the impact protection capability is improved, but the vehicle length increases and aerodynamics deteriorate
Solution Approach 1:
The bumper assembly is divided into multiple functional segments: a first cross member for structural support, a second cross member for additional reinforcement, and a shock-absorbing element positioned between them. This segmentation allows the cushioning function to be distributed across multiple components rather than requiring a single thick layer, thereby maintaining impact protection while reducing overall protrusion and vehicle length.
Solution Approach 2:
The bumper assembly uses composite construction combining plastic materials for the cross members with glass fiber reinforcement. The first cross member is made of plastic material reinforced with glass fibers, creating a composite structure that achieves high strength-to-weight ratio and excellent impact resistance without requiring excessive thickness, thus protecting against vehicle length increase while maintaining aerodynamics.
2Strength
If the cross member is greatly reinforced to support thicker cushioning material, then the impact resistance is improved, but the vehicle dimensions increase and aerodynamics worsen
Solution Approach 1:
The structural reinforcement function is segmented between the first cross member (plastic with glass fiber reinforcement) and the second cross member. This distribution of structural duties allows each component to be optimized for its specific function without requiring excessive reinforcement of a single element, thereby maintaining impact resistance while controlling overall vehicle dimensions and preserving aerodynamic shape.
Solution Approach 2:
The first cross member employs plastic material reinforced with glass fibers, creating a composite structure that provides exceptional strength and stiffness without increasing cross-sectional dimensions. This composite construction enables the cross member to support the cushioning system effectively while maintaining sleek vehicle contours and optimal aerodynamic properties.
3Reliability
If a thick layer of cushioning material is used to pass North American crash tests, then the crash test compliance is improved, but the aesthetic appearance deteriorates
Solution Approach 1:
The cushioning function is segmented between the shock-absorbing element positioned between the cross members and the outer bumper cover. This segmentation allows the functional cushioning components to be concealed within the bumper assembly structure, ensuring crash test compliance while maintaining a sleek, aesthetically pleasing exterior appearance without excessive protrusion or bulky appearance.
4Length of moving object
If the bumper assembly is designed for European standards, then the vehicle length is minimized, but the crash test compliance for North American market deteriorates
Solution Approach 1:
The bumper assembly is designed with multi-functionality to satisfy both European and North American crash test standards. The combination of the reinforced first cross member with glass fiber reinforcement, the additional second cross member, and the shock-absorbing element creates a universal design that achieves the higher impact protection requirements of North American standards while maintaining compact dimensions suitable for European market vehicles.
Solution Approach 2:
The use of plastic material reinforced with glass fibers in the first cross member provides enhanced strength and stiffness that enables the bumper assembly to meet the more stringent North American crash test requirements without increasing vehicle length. This composite material solution allows a single design to comply with both European and North American regulations.
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 enables compliance with different crash test regulations while maintaining vehicle aerodynamics, aesthetics, and functionality, with improved impact strength and reduced deformation during crashes.
Implementation Method 1
at least a first cross member (30) made of a plastic material reinforced with glass fibers
Implementation Method 2
at least a shock-absorbing element (70) arranged between the first cross member (30) and the second cross member (60)
Data Source
Figure 1~2
Figure 3~3b
Figure 3c~3e
AI summary
A bumper assembly for a vehicle and the associated vehicle comprising this bumper assembly are described. The vehicle comprises a chassis. The bumper assembly comprises: a bumper core. The bumper core, in turn, comprises: a first cross member made of a first thermoplastic material and a first and a second substantially undeformable connection device for rigidly fixing the first cross member to the chassis of the vehicle. The first and the second substantially undeformable connection devices co-operate with the first cross member. The bumper core also comprises a second cross member and at least one shock absorbing element arranged between the first cross member and the second cross member. The second cross member is connected to said first and second substantially undeformable connection devices or it is formed as one piece with said substantially undeformable connection devices.