Vehicle Crash Box Flange Structure for Stronger Bumper Welds
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Solution Overview
Problem
Conventional vehicle crash boxes do not provide sufficient resistance to high loads during collisions, leading to potential failure of weld joints and inadequate energy absorption.
Innovation Solution
A vehicle crash box with a tubular member and integrally formed flanges having oblong openings for increased welds, enhancing the rigidity and reinforcement of the bumper structure to prevent penetration and absorb impact energy effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional vehicle crash boxes are used, then the structure is simpler and easier to manufacture, but the resistance to high loads during collision is insufficient
Solution Approach 1:
The crash box structure is segmented into distinct functional zones: the tubular member for energy absorption, the integrally formed flanges for attachment, and the oblong openings for enhanced welding. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity under high loads.
Solution Approach 2:
The flanges are integrally formed with the longitudinal walls of the tubular member, merging the attachment function and the structural function into a single integrated component. This eliminates separate attachment brackets and reduces the number of parts while enhancing load resistance through the continuous material structure.
2Reliability
If conventional crash boxes are used, then the manufacturing process is simpler, but the weld joint strength and reliability are insufficient
Solution Approach 1:
The oblong openings are pre-formed in the flanges during the integral forming process, preparing the structure in advance for enhanced welding. This preliminary action ensures that the welding interface is optimally positioned and shaped before the actual welding occurs, improving weld joint strength without requiring complex post-processing.
Solution Approach 2:
The use of oblong openings instead of conventional circular holes or solid flanges changes the geometric parameters of the welding interface. This parameter change increases the weld surface area and improves weld distribution, thereby enhancing weld joint strength and reliability.
3Use of energy by moving object
If the crash box allows deformation for energy absorption, then the impact energy is absorbed effectively, but the structural rigidity is reduced
Solution Approach 1:
Different parts of the crash box are given different mechanical properties: the tubular member is designed with wall thickness and geometry that allow controlled deformation and energy absorption, while the integrally formed flanges provide rigid attachment points. This local differentiation of mechanical properties allows simultaneous energy absorption and structural rigidity.
Solution Approach 2:
The integral formation of flanges with the tubular member adds a dimensional aspect to the structure, creating a three-dimensional integrated form that enhances both rigidity at the attachment points and deformation capability in the tubular section. The spatial arrangement of the oblong openings also contributes to the structural behavior under load.
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 enhanced weld interface and deformation capabilities improve the vehicle bumper's performance in collisions by increasing resistance to failure and controlled deformation, ensuring better energy absorption and structural integrity.
Implementation Method 1
the one or more flanges and the one or more longitudinal walls are formed from a single piece by way of hot press forming or cold working
Implementation Method 2
the one or more flanges and the one or more longitudinal walls are formed from a single piece by way of hot press forming or cold working
Implementation Method 3
the flange forms one or more oblong openings for one or more welds for the attachment of the flange to the bumper beam
Implementation Method 4
the rigidity and reinforcement of a vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect for attaching a bumper beam to a vehicle is improved in order to prevent penetration upon collisions while maintaining or providing an advantageous deformation of the vehicle bumper structure including one or more embodiments of the vehicle crash box according to the first aspect for absorbing impacts, or absorbing energy from impacts
Data Source
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AI summary
A vehicle crash box (100a, 100b; 400; 600; 800) for attaching a bumper beam (200) to a vehicle (230). The vehicle crash box (100a) is attachable to the vehicle (230). The vehicle crash box (100a) comprises a tubular member (102) having a longitudinal extension (104) extending in a longitudinal direction (106). The tubular member (102) comprises one or more longitudinal walls (108a-d) having a longitudinal extension (110a-d) extending in the longitudinal direction (106). The vehicle crash box (100a) comprises one or more flanges (114) integrally formed with one or more longitudinal walls (108a-d) of the one or more longitudinal walls (108a-d) of the tubular member (102). The flange forms one or more oblong openings (116a-c) for one or more welds for the attachment of the flange (114) to the bumper beam (200). A vehicle bumper structure (300; 500; 700; 900) comprising a bumper beam (200; 250) and one or more such vehicle crash boxes (100a, 100b; 400; 600; 800).