Bumper Crossmember Profile-in-Profile Joint for Load Stability
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Solution Overview
Problem
Existing bumper crossmembers suffer from instability under high loads, leading to potential tearing off and increased vehicle damage and occupant injury, with limited design freedom for widening elements.
Innovation Solution
A profile-in-profile connection between the carrier profile and widening element, allowing for a stable and customizable design with a two-point fastening system, reducing contact surface area to minimize corrosion and enabling individual extension section design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tabs are used to connect widening elements to the carrier profile, then assembly is quick and easy, but the connection is not stable under high loads and widening elements can tear off
Solution Approach 1:
The connection section is inserted into the U-shaped section of the carrier profile, creating a nested structure where the connection section fits inside the carrier profile's U-shaped channel. This nesting provides mechanical interlocking and distribution of loads across multiple contact points, significantly improving connection stability under high loads while maintaining ease of assembly.
Solution Approach 2:
The connection is enhanced by utilizing the third dimension (depth) through the U-shaped profile structure. The connection section extends into the U-shaped section, creating engagement in the longitudinal direction rather than just surface-level tab attachment. This dimensional engagement distributes forces across a larger volume and prevents tearing under high loads.
2Strength
If the connection section is made larger to improve stability, then connection strength increases, but design freedom and adaptability decrease
Solution Approach 1:
The widening element is divided into distinct functional sections: the connection section for joining to the carrier profile, and the extension section for providing the desired geometric extension. This segmentation allows the connection section to be optimized for strength through its U-shaped engagement, while the extension section maintains complete design freedom for various applications, geometries, and materials.
Solution Approach 2:
Different sections of the widening element have different properties optimized for their specific functions. The connection section has a U-shaped profile optimized for mechanical engagement and load distribution, while the extension section can have any geometry, material, or design characteristics needed for the specific application, thus maintaining design freedom while ensuring connection strength.
Data Source
AI summary
A bumper crossmember having a profiled carrier profile, which extends with its longitudinal direction in the vehicle transverse direction (y direction) and has portions with a U-shaped profile in the z direction at least on the end sides formed by two limbs and a profile base connecting the two limbs, and a widening element profiled in the z direction, connected to each end side of the carrier profile, via which the carrier profile is extended in the longitudinal direction. Each widening element has a connecting portion, which has a U-shaped profile with a contact portion and a mating portion adjoining the contact portion, and an extension portion adjoining the mating portion. The connecting portion has a profile base connecting two limbs of the U-shaped profiling, engages with one of the two U-shaped portions of the carrier profile, and is arranged overlapping the latter in the y direction. At least in the region of its contact portion, the connecting portion is connected to the profile base of the carrier profile, and in the region of its mating portion, the connecting portion makes contact at least in regions by way of its limbs with the limbs of the carrier profile.