Composite Jounce Bumper Structure for Compact BEV Energy Absorption

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Solution Overview

Problem

Battery Electric Vehicles (BEVs) require suspension systems that can absorb more energy due to their greater mass compared to similar Internal Combustion Engine (ICE) vehicles, while maintaining a compact size.

Innovation Solution

A jounce bumper with a main body made of microcellular urethane and an integral insert of thermoplastic urethane, featuring multiple plates and connecting lattices, which enhances energy absorption and noise damping capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a single-material jounce bumper is used, then the device complexity is low, but the energy absorption capability is insufficient for BEVs

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoiddevice complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining a rigid thermoplastic urethane insert with a softer microcellular urethane material. The rigid insert provides structural support and initial energy absorption, while the softer surrounding material provides additional cushioning and energy absorption. This composite structure enables the jounce bumper to absorb the higher energy demands of BEV suspension systems without requiring a completely redesign of the entire device.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by creating regions with different material properties within the same component. The central insert region has higher rigidity and density for structural support, while the outer regions have lower rigidity for cushioning. This spatial variation in material properties allows different parts of the jounce bumper to perform specialized functions, optimizing overall energy absorption while maintaining a relatively simple single-piece construction.

Inventive Principle:

Principle #3Local quality

2Use of energy by moving object

If the jounce bumper volume is increased to absorb more energy, then the energy absorption capability improves, but the space available for suspension components is reduced

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidjounce bumper volume

Core Design Contradiction:

Use of energy by moving objectVSVolume of moving object

Solution Approach 1:

By using composite materials with different densities and energy absorption characteristics, the patent achieves higher energy absorption per unit volume. The rigid thermoplastic urethane insert provides high structural efficiency, allowing the jounce bumper to maintain compact dimensions while absorbing the increased energy loads generated by BEV suspension systems.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes material parameters (rigidity, density, damping characteristics) rather than simply increasing the physical size of the jounce bumper. By selecting materials with optimized parameters for high energy absorption density, the component achieves the required performance within the constrained volume available in BEV suspension systems.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If a rigid insert is added to enhance energy absorption, then the energy absorption capability improves, but the manufacturing complexity increases

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidease of manufacture

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent merges the rigid insert and the softer cushioning material into a single integrated jounce bumper component. This combining approach eliminates the need for separate manufacturing and assembly steps for multiple parts, reducing manufacturing complexity despite using composite materials. The insert is formed as an integral part of the overall structure, allowing for streamlined production processes.

Inventive Principle:

Principle #5Merging (Combining)

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 jounce bumper effectively absorbs more energy and reduces noise, vibration, and harshness, providing improved suspension performance for BEVs.

Implementation Method 1

Jounce bumpers absorb energy and limit suspension travel during interaction with potholes, curbs, etc.

Methodology Applied

Scientific EffectEnergy absorption: Deformation

Implementation Method 2

The jounce bumper effectively absorbs more energy and reduces noise, vibration, and harshness

Methodology Applied

Scientific EffectNoise damping: Damping

Implementation Method 3

The insert further includes a first plate, a second plate, and a connecting lattice that connects the first plate and the second plate together

Methodology Applied

Scientific EffectStructural support: Geometry

Data Source

PatentUS12533919B2Jounce bumper

Publication Date: 2026.01.27 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present disclosure includes a jounce bumper with a main body and an insert. The main body includes a first polymeric material. The insert is integral with the main body and includes a second polymeric material that is different from the first polymeric material. The insert further includes a first plate, a second plate, and a connecting lattice that connects the first plate and the second plate together. The first polymeric material of the main body is between the first plate and the second plate, and is within the connecting lattice.