Vehicle Bumper Deformation Element Welding
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Solution Overview
Problem
Existing bumpers with deformation elements or holders tend to experience connection slippage or tearing at weld seams when subjected to high loads, particularly during vehicle collisions, due to inadequate stability and the presence of heat-affected zones.
Innovation Solution
The deformation element is welded to the inner surface of the outer compression chord, passing through the inner tension chord, and inserted into the bumper, with weld seams placed in the longitudinal direction to prevent tearing and keep the deformation element free of heat-affected zones, while the bumper is reinforced with additional chambers and thickened wall sections to enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the deformation element is welded to the cross member, then the connection stability is improved, but the heat-affected zone causes tearing when the cross member is severely deformed or bent
Solution Approach 1:
A connection element is introduced as an intermediary component between the deformation element and the cross member. This connection element is welded to both components, distributing the welding heat and reducing the size of the heat-affected zone. The connection element acts as a buffer that prevents direct heat transfer to the cross member, thereby preventing tearing while maintaining connection stability.
Solution Approach 2:
The welding connection is segmented into multiple smaller weld joints between the deformation element, connection element, and cross member. This segmentation distributes the welding heat across multiple locations, reducing the concentration of heat-affected zones and preventing localized tearing. The segmented approach allows each weld to be smaller and less stressful on the surrounding material.
2Ease of manufacture
If the deformation element is screwed to the bumper, then the connection is easier to manufacture, but the connection slips between the deformation element and the cross member under high loads
Solution Approach 1:
The connection solution merges both screwing and welding methods. The deformation element is screwed to the connection element for easy assembly, and the connection element is welded to the cross member for stable, load-bearing connection. This combination leverages the advantages of both connection types: the ease of screwing and the reliability of welding, while avoiding their respective disadvantages.
3Reliability
If the holder passes through the inner tension chord, then the connection stability is improved, but the inner tension chord is punched out requiring additional reinforcement
Solution Approach 1:
The inner tension chord is pre-reinforced with a reinforcement element at the location where the holder will pass through. This preliminary reinforcement prevents the chord from being punched out when the holder is installed. The reinforcement element is positioned in advance to anticipate and prevent the damaging effect of the holder installation process.
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 configuration creates a stable connection between the bumper and its brackets, preventing premature collapse and maintaining structural integrity under high loads, with improved energy absorption and reduced risk of heat-affected zones, ensuring the bumper can effectively absorb impact forces without tearing.
Implementation Method 1
The deformation element or the holder is associated with an end face of the inner surface of the outer or compression chord—thus passing through the inner or tension chord—and is welded to the bumper
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The bumper (40) has a deformation element formed as a retainer (60) and attached to the bumper. Profile walls are arranged in a distance to each other as an outer- or pressure belt (44) and/or as an inner- or traction belt (44i). The deformation element is formed as a hollow profile with side walls (62), which connect cross walls (66). The deformation element and/or the retainer are attached with a front side (68) of an inner surface (42) of the outer- or pressure belt, and are fused with the bumper.