Automotive Bumper Beam and Crash Box Layout for Low-Speed Intrusion Control
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Solution Overview
Problem
Existing bumper systems for automotive vehicles are ineffective in minimizing damage during low-speed collisions, particularly for expensive vehicles equipped with solar panels, as they do not adequately absorb collision energy, leading to unnecessary damage and increased repair costs.
Innovation Solution
A bumper system comprising a bumper beam and crash boxes that absorb at least 35-45% of collision energy in an RCAR low-speed structural crash test, designed to limit the maximum intrusion distance and protect solar panels by distributing energy absorption across both components, allowing for a larger solar panel area without increasing the vehicle's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bumper beam is designed to absorb more collision energy (at least 35-45%), then the damage to the vehicle is reduced, but the structural complexity of the bumper system increases
Solution Approach 1:
The bumper system is segmented into distinct functional components: the bumper beam (absorbing 35-45% of collision energy) and the crash box (absorbing 55-65% of collision energy). This segmentation allows each component to be optimized for its specific energy absorption role, reducing overall vehicle damage while maintaining manageable structural complexity through clear functional division.
2Area of stationary object
If the bumper system limits the maximum intrusion distance, then the solar panel area is increased, but the energy absorption requirement for each component becomes more stringent
Solution Approach 1:
The invention changes the energy absorption parameter distribution between components: the bumper beam absorbs 35-45% of collision energy and the crash box absorbs 55-65%. This parameter optimization enables the system to limit intrusion distance effectively, thereby maximizing solar panel area on the vehicle roof without compromising the required energy absorption capability.
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 damage to the vehicle during low-speed collisions, minimizing repair costs and increasing the space available for solar panels, thereby enhancing the vehicle's solar charging capacity and annual solar kilometres.
Implementation Method 1
the bumper beam is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in an RCAR low-speed structural crash test, and wherein the at least one crash box is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in the RCAR low-speed structural crash test for limiting a maximum intrusion distance of the object
Data Source
AI summary
The present invention relates to an automotive vehicle, the automotive vehicle comprising a distal end, at least one crash, and a bumper system provided at the distal end, wherein the bumper system is configured to limit damage to the automotive vehicle in a low speed collision with an object at the distal end by absorbing a collision energy, wherein the bumper system comprises a bumper beam and at least one crash box, wherein the bumper beam is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in an RCAR low-speed structural crash test, and wherein the at least one crash box is configured to absorb at least 35%, preferably at least 40%, more preferably at least 45% of the collision energy in the RCAR low-speed structural crash test for limiting a maximum intrusion distance of the object.