Bumper Deformation Elements for Flush Lighting Impact Protection
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Solution Overview
Problem
Existing bumper designs for motor vehicles face a conflict between achieving a flush transition between the bumper cladding and the lighting unit, and meeting the requirements for corner pendulum impact and pedestrian protection, which results in damage to the lighting unit during testing and prevents vehicle approval.
Innovation Solution
A deformation device is attached to the crossmember of the bumper, featuring multiple deformation elements with unstructured, smooth surfaces that buckle and bend in response to different impact directions, allowing for efficient energy absorption and distribution while maintaining a flush surface with the lighting unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flush transition is implemented between the bumper cladding and the lighting unit, then the aesthetic appearance is improved, but the lighting unit becomes damaged during the corner pendulum impact test
Solution Approach 1:
The deformation device is divided into multiple individual deformation elements (at least two) arranged in a row between the crossmember and the lighting unit. Each element can deform independently to absorb impact energy, preventing force concentration that would damage the lighting unit while maintaining the flush surface geometry.
Solution Approach 2:
The deformation elements are positioned in advance between the crossmember and the lighting unit to provide cushioning protection. When impact occurs, these pre-positioned elements deform to absorb energy before the force reaches the lighting unit, preventing damage while allowing the flush surface design.
2Loss of energy
If complex fin elements with sawtooth structure are used to provide deformation capability, then impact energy absorption is improved, but the production complexity and manufacturing costs increase
Solution Approach 1:
Instead of changing the surface structure (sawtooth pattern), the invention changes the material parameters and geometric dimensions of simple deformation elements. By adjusting thickness, length, and material properties, the elements achieve required energy absorption through buckling and bending without complex surface structures, simplifying production.
Solution Approach 2:
The deformation elements are designed as simple, inexpensive components that can be easily manufactured and potentially replaced if needed. Their simplicity allows for cost-effective production methods while still providing the necessary impact energy absorption function.
3Loss of energy
If the deformation elements are designed to buckle in the direction parallel to their arrangement, then the absorption of corner pendulum impact energy is improved, but the resistance to pedestrian leg impact may be reduced
Solution Approach 1:
The deformation elements are designed with dynamic deformation characteristics that allow them to buckle easily in the corner impact direction (parallel to arrangement) while maintaining sufficient stiffness for pedestrian protection. The elements can adapt their response based on the direction and magnitude of the applied load.
Solution Approach 2:
Different regions of the deformation elements have different structural properties optimized for different functions. The elements are configured to provide high deformability for corner impact energy absorption while maintaining local stiffness characteristics that resist pedestrian leg intrusion, achieving direction-dependent mechanical properties.
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 deformation device effectively converts impact energy, ensuring the lighting unit remains undamaged during testing while meeting the necessary safety standards for vehicle approval, and is produced cost-effectively with a material-saving and easy manufacturing process.
Implementation Method 1
the deformation elements buckle owing to an action of force in a first direction
Implementation Method 2
and bend owing to an action of force in a second direction
Implementation Method 3
converting impact energy on a lighting unit into deformation of the deformation elements
Data Source
AI summary
A deformation device for attaching to a crossmember of a bumper and for converting impact energy onto a lighting device has at least two deformation elements arranged in series and orientated in the same direction. The deformation device also has a support element which can be secured to a crossmember of a bumper, wherein the at least two deformation elements are secured to the support element. Each deformation element has an unstructured, flat surface and is designed such that the deformation elements buckle due to a force acting in a first direction and bend due to a force acting in a second direction.