Aluminum Bumper Profile with Steel Insert for Corrosion Prevention
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Solution Overview
Problem
Existing bumper designs face challenges in achieving low weight, high dimensional stability, efficient energy absorption, and corrosion prevention between aluminum and steel components, while also compensating for material inaccuracy and large gaps during the joining process.
Innovation Solution
A profile element with a light metal material plug-in section, coated with anti-corrosion agents, is designed to fit into a steel longitudinal member, featuring deformable walls and anti-corrosion coatings to prevent corrosion and simplify installation, with a method involving tension screws to align and secure the profile element effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a profile element made of light metal material is used to reduce weight, then the weight of the bumper is reduced, but corrosion between the light metal and steel longitudinal member occurs
Solution Approach 1:
A plug-in element made of corrosion-resistant material (such as plastic or corrosion-resistant metal) is introduced as an intermediary component between the light metal profile section and the steel longitudinal member. This plug-in element prevents direct contact between the dissimilar metals, thereby preventing galvanic corrosion while allowing the lightweight profile element to maintain its weight-reducing function.
2Ease of manufacture
If the profile element cross section is smaller than the longitudinal member to simplify design, then manufacturing is easier, but large gaps are created during the joining process
Solution Approach 1:
The plug-in element serves as a mediator that fills the gap between the smaller profile element and the larger longitudinal member. It provides a precise fit within the longitudinal member's cavity, eliminating gaps and ensuring accurate positioning while allowing the profile element to maintain its simplified, smaller cross-sectional design.
Solution Approach 2:
The plug-in element is pre-formed with dimensions and features that ensure proper fit and alignment before assembly. By preparing the intermediary component in advance with precise dimensions, the gap issue is resolved during assembly without requiring complex adjustments or modifications to the profile element itself.
3Manufacturing precision
If the profile element walls are made deformable to compensate for inaccuracy during joining, then alignment accuracy is improved, but the structural strength is reduced
Solution Approach 1:
The plug-in element acts as a mediator that absorbs and compensates for dimensional inaccuracies and misalignments during assembly. By designing the intermediary component with appropriate flexibility or tolerance compensation features, alignment accuracy is improved without requiring the main profile element walls to be deformable, thereby preserving their structural strength.
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 solution results in a lightweight bumper with enhanced energy absorption capabilities, reduced material incompatibility issues, and improved corrosion resistance, while simplifying the installation process and ensuring accurate alignment and fixation.
Implementation Method 1
walls of the plug-in section of the profile element formed from a light metal material are arranged with their end edge in a plug-in element with a material that prevents corrosion on adjacent surfaces made of light metal alloys on the one hand and iron-carbon alloys on the other hand
Data Source
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AI summary
Disclosed is a profiled element (66) which is designed as a hollow profiled support section and is used for fastening a bumper to longitudinal beams (30) of a vehicle. Said profiled element (66) is assigned to a longitudinal beam (30) made of steel as an insertable section for the interior (32) of the longitudinal beam (30). The final edge (67) of at least two opposite walls (68) of the insertable section of the profiled element (66), which is made of a light metal material, is attached inside an insertion member (70) which, as a separation layer, prevents adjacent surfaces that are made of light metal and iron-carbon alloys from corroding. The insertable section is inserted into the longitudinal beam (30) along with the insertion members (70).