Bumper Cross Member with Partial Closing Plate

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Solution Overview

Problem

Existing bumper assemblies for motor vehicles face challenges in being cost-effective, lightweight, and meeting crash test and pedestrian protection criteria while maintaining sufficient crash performance and design flexibility.

Innovation Solution

A bumper assembly featuring a cross member with an open hat-shaped hollow profile and a partially closing plate, made of a steel alloy, which enhances crash performance and reduces material usage, combined with a pedestrian protection element like a foam block for enhanced safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a complete closing plate is used to close the opening of the cross member, then crash performance is improved, but weight and production costs increase

Engineering Contradiction:

Improvecrash performanceVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The closing plate is segmented to cover only specific portions of the opening rather than the entire opening. This partial coverage provides sufficient crash performance while reducing material usage, weight, and production costs compared to a complete closing plate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The closing plate is positioned to provide localized reinforcement where crash forces are most critical, rather than uniformly closing the entire opening. This allows the structure to maintain necessary strength properties while using less material.

Inventive Principle:

Principle #3Local quality

2Strength

If a complete closing plate is used to close the opening of the cross member, then crash performance is improved, but production costs increase

Engineering Contradiction:

Improvecrash performanceVSAvoidproduction costs

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a simplified closing plate design that accepts reduced material quantity, thereby lowering production costs while still meeting crash performance requirements through strategic placement and structural design.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If the cross member is designed with high flexural rigidity to absorb impacting obstacles, then penetration protection is improved, but design flexibility and exterior design freedom are reduced

Engineering Contradiction:

Improveflexural rigidityVSAvoidexterior design freedom

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The cross member uses a composite structure combining the open hat-shaped hollow profile with strategically placed closing plates and foam elements. This composite approach achieves high flexural rigidity for penetration protection while the modular design maintains exterior design freedom.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The closing structure is segmented into discrete elements (partial closing plates and foam blocks) rather than a continuous solid structure. This segmentation provides necessary rigidity while leaving other areas open for design flexibility and aesthetic considerations.

Inventive Principle:

Principle #1Segmentation

4Strength

If the cross member height is increased to provide overlap for bumper-to-bumper crashes, then crash performance is improved, but weight and material usage increase

Engineering Contradiction:

Improvecrash performanceVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The closing plate and foam elements are positioned at specific locations within the cross member structure to provide crash performance where needed, rather than uniformly increasing the entire structure's height. This localized approach maintains necessary overlap for bumper-to-bumper crashes while minimizing weight increase.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10023140B2Bumper assembly with closing plate

Publication Date: 2018.07.17 BENTELER AUTOMOBILTECHNIK GMBH

AI summary

A bumper assembly for a motor vehicle comprising a cross member that extends transverse the motor vehicle, and has an open hat-shaped hollow profile with a rear-sided web and legs, extending from the web, wherein flanges extend from a free end of the legs in the vertical direction; and an opening pointing away from the motor vehicle, in the longitudinal direction. At least one closing plate is arranged allowing the opening to be completely closed in the vertical direction and arranged allowing a partial length of less than 50% of the length of the opening to be closed in the transverse direction; and that the flanges are offset from each other with an offset in the longitudinal direction; and that the cross member has a varying cross section over its length, wherein a central region is offset upwards from the end regions with a height offset to the vertical direction.