Composite Vehicle Bumper Reinforcement Without a Metal Back Beam

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Solution Overview

Problem

Conventional vehicle bumpers require a metal back beam for reinforcement, which increases weight, material costs, and manufacturing complexity, while also potentially degrading the exterior appearance.

Innovation Solution

A bumper design featuring an injection-molded bumper cover with a reinforcing structure made of fiber-reinforced composite material in a linear shape, directly coupled to the rear surface of the bumper cover, eliminating the need for a back beam and incorporating a clip portion with a coupling groove for secure fitting and elastic support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal back beam is used for reinforcement, then collision protection is ensured, but vehicle weight increases

Engineering Contradiction:

Improvecollision protectionVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces traditional metal back beams with composite material components including a foam core layer, fabric reinforcement layers, and thermoplastic resin. This composite structure provides the necessary collision protection while significantly reducing weight compared to solid metal beams.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters from solid metal to a multi-layer composite structure with varying densities and mechanical properties. The foam core provides lightweight cushioning while fabric layers add tensile strength, achieving the required protection with reduced weight.

Inventive Principle:

Principle #35Parameter changes

2Strength

If a metal back beam is used for reinforcement, then structural strength is improved, but material cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial cost

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent uses composite materials (foam, fabric, thermoplastic resin) that are more cost-effective than solid metal beams while providing equivalent or superior structural strength. The multi-layer construction allows optimization of material usage and cost.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The foam core material can be easily recovered or recycled after the bumper's service life, reducing waste disposal costs and potentially enabling material recovery, which contributes to cost reduction.

Inventive Principle:

Principle #34Discarding and recovering

3Strength

If a metal back beam with coupling members is used, then reinforcement is achieved, but manufacturing complexity increases

Engineering Contradiction:

ImprovereinforcementVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple components (back beam, coupling members, mounting structure) into an integrated composite bumper assembly. The fabric layers are directly coupled to the foam core and thermoplastic housing, eliminating the need for separate metal beams and coupling hardware.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The composite construction allows the reinforcement structure to be built as an integrated unit during molding, rather than assembling separate metal components. This reduces manufacturing steps and complexity while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

4Strength

If a metal back beam is used, then structural support is provided, but exterior appearance is degraded

Engineering Contradiction:

Improvestructural supportVSAvoidexterior appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The composite material construction allows the bumper to be molded as a smooth, continuous surface without the visible seams, bolts, or metal components that would mar the appearance. The thermoplastic resin encapsulates all structural elements, providing a clean exterior finish.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The structural reinforcement elements (foam core, fabric layers) are nested within the thermoplastic resin housing, which forms the visible exterior surface. This nesting arrangement hides all structural components from view while maintaining their support functions.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design provides collision protection, reduces vehicle weight and material costs, simplifies manufacturing, and maintains exterior beauty by eliminating the need for a back beam and its associated structural components.

Implementation Method 1

a reinforcing structure provided in a linear shape with fiber reinforced composite material and coupled by direct fitting onto a rear surface of the bumper cover

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

a clip portion provided with a coupling groove, to which the reinforcement structure is fitted

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS11780390B2Bumper for vehicle

Publication Date: 2023.10.10 HYUNDAI MOTOR CO LTD

AI summary

A bumper for vehicle may include an injection-molded bumper cover; and a reinforcing structure provided in a linear shape with fiber reinforced composite material and coupled by direct fitting onto a rear surface of the bumper cover to reinforce a rear side of the bumper cover.