Ring-End Bumper Crossmember for Multi-Path Crash Load Distribution
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Solution Overview
Problem
Existing bumper arrangements on motor vehicles do not effectively distribute impact forces to prevent peak loads during collisions, leading to potential damage to the vehicle and its occupants.
Innovation Solution
A bumper arrangement featuring a high-strength, top-hat shaped crossmember with a ring-shaped end region oriented obliquely downwards, coupled to crash boxes and longitudinal members, providing additional support through engagement with the wheelhouse and wheel suspension, and optionally supplemented by an auxiliary crossmember for enhanced load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional crossmember design is used, then the bumper arrangement provides basic structural support, but it does not effectively distribute impact forces leading to peak loads during collisions
Solution Approach 1:
The crossmember is segmented into multiple functional regions: a first region with downward orientation for initial impact absorption, a second region with oblique downward orientation for force distribution to the wheel, and a third region for structural connection. This segmentation allows different portions of the crossmember to handle different aspects of impact forces, effectively distributing the load and preventing peak concentrations.
Solution Approach 2:
The crossmember transitions from a conventional horizontal design to a three-dimensional structure with regions oriented at different angles (downward and obliquely downward). This dimensional change enables the crossmember to engage with the wheel at an optimal angle, creating additional load paths in multiple directions rather than solely along the longitudinal axis.
2Shape
If the crossmember is mounted at a high level, then sufficient overlap is achieved in bump-to-bumper tests, but the end region needs additional support to prevent deformation and protect the passenger compartment
Solution Approach 1:
The load path is extended from the conventional two-dimensional plane to three dimensions by routing forces through the obliquely oriented second region down to the wheel and further to the sill. This creates a volumetric load distribution that strengthens the overall structure against deformation while maintaining the high-level mounting for proper overlap geometry.
Solution Approach 2:
The wheel acts as an intermediary support element between the crossmember and the vehicle body. The obliquely oriented second region of the crossmember transfers loads to the wheel, which in turn transfers them to the sill and passenger compartment structure, providing additional intermediate support that prevents deformation at the high-mounted crossmember.
3Ease of operation
If the crossmember strikes the wheel located behind it, then engagement below the wheel prevents jacking up and sliding away, but the orientation must be precisely controlled to achieve this effect
Solution Approach 1:
The crossmember features asymmetric orientation with the second region specifically angled obliquely downward at a defined angle alpha. This asymmetric design ensures that the end region engages with the wheel at the correct position below the wheel center, preventing jacking up and sliding away. The asymmetric geometry inherently guides the impact force into the desired direction, reducing the need for post-manufacturing orientation adjustments.
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 design achieves improved load distribution and resistance to deformation, preventing damage to the tire and enhancing passenger compartment protection by creating multiple load paths and a larger impact surface, thereby reducing peak loads during collisions.
Implementation Method 1
the crossmember itself is designed as a press-formed component of the same material and in one piece. The latter, in cross section, has a top-hat shape, consequently a top-hat-shaped cross section. For this purpose, the component is formed from a high-strength streel having a tensile strength of more than 1200 MPa, or more than 1300 MPa. The crossmember is produced as a hot-formed and press-hardened component.
Data Source
AI summary
A bumper arrangement for a motor vehicle has a crossmember which can be coupled to the motor vehicle via crash boxes and is produced as a press-formed component of the same material and in one piece therewith, with a top-hat-shaped cross section. The crossmember is designed in a respective end region to run with an orientation obliquely downwards with respect to the vertical direction of the motor vehicle, and the end region is of ring-shaped design.