Monolithic Bumper Connecting Element for Crash Deformation
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Solution Overview
Problem
Existing connecting elements for fastening bumpers to vehicle body structures require separate fastening lugs and complex assembly processes, which can compromise crash performance and manufacturing efficiency.
Innovation Solution
A connecting element with a screw section extending to the bumper end face, allowing monolithic manufacturing and eliminating the need for separate fastening elements, featuring a design that minimizes impact on crash properties and enhances deformation capabilities through strategic placement and geometry of the screw section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fastening lugs are used to fasten the bumper to the connecting element, then the fastening reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the fastening lugs directly into the connecting element as monolithic integral structures, eliminating the need for separate fastening components. The connecting element is designed with built-in fastening lugs that are formed as one piece during the extrusion process, thereby reducing device complexity while maintaining fastening reliability through the robust integrated design
2Strength
If separate fastening lugs are used, then the fastening strength is improved, but the manufacturing time and assembly complexity increase
Solution Approach 1:
The connecting element and fastening lugs are manufactured as a single monolithic component through extrusion processes, eliminating separate assembly steps. This integration maintains the required fastening strength while significantly improving manufacturing efficiency by producing the entire assembly in one operation without additional welding or fastening steps
Solution Approach 2:
The fastening lugs are pre-formed as integral parts of the connecting element during the extrusion process, rather than being added as separate components during assembly. This preliminary integration of the fastening function into the main structure eliminates subsequent assembly operations and maintains structural integrity
3Ease of manufacture
If the screw section is extended to the end face, then the monolithic manufacturing is enabled, but the crash deformation properties may be affected
Solution Approach 1:
The connecting element features localized screw sections with internal threads positioned at specific locations along its length, rather than being uniformly threaded throughout. This local threading approach enables monolithic manufacturing while preserving the crash deformation properties in the non-threaded sections, allowing the structure to deform as intended during impact events
Data Source
AI summary
The invention relates to a connecting element (10) for fastening a bumper (1) to a body structure of a vehicle, the connecting element (10) having a first end face (16) facing the bumper (1) and a second end face (18) facing the body structure, and the connecting element (10) being realized as an extrusion component and having at least one screw section (14) monolithically connected to the extrusion component and having an internal thread (12), the screw section (14) extending over a part of the length of the connecting element (10) in the direction of a longitudinal axis (22) of the connecting element (10).