C-Shaped Bumper Support with Aluminum Foam for Vertical Shock Absorption
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Solution Overview
Problem
Motor vehicle manufacturers face challenges in designing bumper devices that effectively absorb various types of impacts while reducing manufacturing costs and weight, as existing solutions are either costly or heavy.
Innovation Solution
A bumper device with 'C' shaped supports that include a core and branches, featuring a housing for spar reception, hollow side faces with reinforcing ribs, and optional energy-absorbing inserts, allowing for enhanced shock absorption without the need for additional heavy structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heavy structures (cradle extensions, etc.) are used to widen vertical absorption range, then shock absorption capability is improved, but vehicle weight and manufacturing cost increase
Solution Approach 1:
The support structure utilizes material parameter changes through a metallic core providing rigidity and aluminum foam inserts providing energy absorption. This combination allows the structure to achieve high shock absorption capability across different impact speeds (10-64 km/h) without increasing overall weight, as the foam material provides energy absorption at lower densities than traditional solid metal structures
Solution Approach 2:
The support employs a composite structure combining a metallic core with aluminum foam inserts. The metallic core provides structural rigidity and load-bearing capacity, while the aluminum foam provides energy absorption during impacts. This composite approach enables the bumper to handle various impact types (pedestrian, parking, repairability, low speed compatibility, high speed) without requiring heavy single-material structures
2Reliability
If traditional heavy structures are used to widen vertical absorption range, then shock absorption capability is improved, but manufacturing cost increases
Solution Approach 1:
The support is divided into distinct functional zones: a metallic core providing structural framework and aluminum foam inserts providing energy absorption. This segmentation allows each component to be manufactured separately using optimized processes (metal forming for the core, foam injection for the inserts) and then assembled, reducing overall manufacturing complexity and cost compared to manufacturing a single heavy monolithic structure
Solution Approach 2:
By changing the material parameters from solid metal to aluminum foam with controlled density and porosity, the structure achieves equivalent or superior energy absorption at lower material cost and weight. The foam material's cellular structure provides efficient energy dissipation during impacts across different speed ranges, reducing the need for expensive heavy-duty metal components
3Adaptability or versatility
If multiple bumper crossmembers are added to meet different impact criteria, then adaptability is improved, but device complexity increases
Solution Approach 1:
The support with metallic core and aluminum foam inserts serves multiple functions: it provides structural support, absorbs energy during impacts, and adapts to different impact types (pedestrian, parking, repairability, low speed compatibility, high speed) through its material properties. This multi-functional design eliminates the need for multiple separate crossmembers for different impact scenarios, simplifying the overall bumper structure while maintaining versatility
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 provides improved vertical shock absorption capabilities, reduces vehicle weight and manufacturing costs, and allows for adaptable bumper crosspiece arrangements to meet different impact criteria, including pedestrian, parking, and high-speed impacts, while enabling easy repair by replacing supports and crossmembers.
Implementation Method 1
at least one energy-absorbing insert placed in a cavity made in the core of each support
Implementation Method 2
each support comprises at least one hollow side face provided with reinforcing ribs converging towards the housing defined between the branches
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The device (2) has upper and lower bumper crosspieces (6, 8) transversely extending between front ends of rails (4) of a motor vehicle, and two fixation supports (10) respectively fixing the crosspieces on the rails. Each support comprises a front face (18) for receiving the crosspieces, and has a C-shape defined by a core (12) and two branches (14) extending from the core. The branches and the core of each support delimit a housing (16) for receiving an end portion (20) of the corresponding rail.