Integrally Cast Bumper Beam with Variable Wall Thickness
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Solution Overview
Problem
Current vehicle bumper systems face challenges in reducing manufacturing costs and improving energy absorption properties while maintaining structural integrity, with existing designs requiring multiple components and complex assembly processes.
Innovation Solution
A metal-cast bumper system featuring a bumper beam with integrally cast reinforcing ribs and a crash box, manufactured as a single piece to reduce assembly steps and costs, with variable sections and alloys to optimize energy absorption and deformation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate components (bumper beam, reinforcing ribs, crash box) are used and assembled through welding or fastening, then structural integrity can be achieved, but manufacturing complexity and assembly costs increase
Solution Approach 1:
The patent combines the bumper beam, reinforcing ribs, and crash box into a single integrally cast component. The casting process allows these previously separate parts to be manufactured as one unified structure, eliminating the need for welding or fastening operations and reducing assembly complexity while maintaining structural integrity.
Solution Approach 2:
The single cast component performs multiple functions simultaneously: the main body serves as the bumper beam, integrated ribs provide reinforcement, and built-in cavities function as crash boxes. This multi-functional design eliminates the need for separate components and simplifies the overall manufacturing process.
2Weight of moving object
If traditional extrusion or roll forming processes are used for bumper beams, then manufacturing experience is available, but weight reduction and energy absorption optimization are limited
Solution Approach 1:
The patent transitions from extrusion or roll forming processes to metal casting. This parameter change in the manufacturing process enables complex three-dimensional geometries, variable cross-sections, and integrated features that cannot be achieved with traditional methods, allowing for optimized weight and energy absorption characteristics.
Solution Approach 2:
The casting process allows for variable wall thicknesses and material distribution throughout the bumper beam structure. Thinner sections can be placed where less strength is needed while maintaining overall structural integrity, enabling weight reduction without compromising performance.
3Ease of manufacture
If uniform cross-section bumper beams are manufactured, then manufacturing is simpler, but energy absorption during impact is suboptimal
Solution Approach 1:
The patent employs a non-uniform cross-sectional design with varying wall thicknesses and integrated reinforcing ribs at specific locations. The casting process makes this variable geometry feasible, allowing thicker sections where impact forces are highest and thinner sections where less structural support is needed, thereby optimizing energy absorption while managing manufacturing complexity.
Data Source
AI summary
A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.