Bumper Connecting Element Hollow Chamber Thread Integration
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Solution Overview
Problem
Existing bumper systems face challenges in integrating towing device fastening means without compromising the impact energy absorption capabilities of the connecting elements, and current methods require significant additional effort and processing steps, such as manual welding of internal threads.
Innovation Solution
The fastening means, including an internal thread, are integrated into the hollow chambers of the connecting element during the extrusion process, allowing for improved integration and reduced manual work, with the thread elevations protruding from a recessed profile wall to maintain energy absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening means are attached to the connecting element, then the towing device can be securely fastened, but the impact energy absorption capability of the connecting element is impaired
Solution Approach 1:
The internal thread is pre-formed in the hollow chamber wall during the extrusion process, so the fastening capability is prepared in advance without compromising the connecting element's structural integrity or impact energy absorption capability
2Ease of manufacture
If threaded bushings are welded to the connecting element, then fastening means are provided, but the number of processing steps and manual work increases
Solution Approach 1:
The fastening means (internal thread) is merged with the hollow chamber structure and formed simultaneously in the same extrusion process, eliminating separate welding or attachment steps and significantly improving production efficiency
3Ease of manufacture
If the internal thread is formed by separate welding, then fastening means are attached, but the additional processing effort and cost increase
Solution Approach 1:
The internal thread is pre-formed during the extrusion process along with the hollow chamber, so no subsequent welding or separate attachment operations are needed, reducing both manual work and manufacturing costs
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
This solution enhances the introduction of tractive force during towing, reduces the number of parts and processing steps, and results in cost savings by automating manual work, while ensuring optimal folding behavior and energy absorption in impact events.
Implementation Method 1
the connecting elements are often designed as hollow chamber profiles, which absorb impact energy in the longitudinal direction of the profile in the event of an impact by compression, in particular by orderly folding
Implementation Method 2
the connecting element is produced from an extruded light metal profile
Data Source
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Figure 3
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AI summary
The invention relates to a bumper system (40) comprising a bumper (35) extending transversely in the direction of the vehicle and at least one connecting element (21) attached to the bumper for fastening the bumper (35) to a vehicle, in particular to a longitudinal member of a passenger car, wherein the connecting element (21) is a multi-chamber extruded profile made of metal with a profile longitudinal axis (x) extending longitudinally in the direction of the vehicle, and the connecting element (21) is designed as a safety element which absorbs impact energy by compression in a collision. The invention is characterized in that fastening means (25) for attaching a towing device (31) are arranged in one of the hollow chambers (24) of the connecting element.