Crash Bracket Notch Design for Controlled Bumper Beam Deformation
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Solution Overview
Problem
Conventional crash brackets used to attach bumper beams to side beams have limited ability to absorb collision forces, leading to unwanted deformation and bending during collisions, without increasing weight or complexity.
Innovation Solution
A crash bracket design featuring first and second attachment flanges, a support portion aligned with the bumper beam's web, and leg portions with notches to guide deformation, allowing controlled bending without collapsing, attached to the side beam via welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crash brackets are used to attach bumper beam to side beam, then weight and complexity are kept low, but the ability to absorb collision forces is limited causing unwanted deformation
Solution Approach 1:
The crash bracket is divided into distinct functional segments: attachment flanges for securing to side beams, a support portion for aligning with the bumper beam web, and leg portions with notches for controlled deformation. This segmentation allows each part to perform its specific function optimally while maintaining overall structural efficiency.
Solution Approach 2:
Different regions of the crash bracket are designed with different properties: the attachment flanges are designed for rigid connection, the support portion for alignment, and the leg portions with notches for controlled deformation. This local differentiation of structural properties enables the bracket to manage collision forces effectively without requiring uniform reinforcement throughout.
2Stability of the object's composition
If crash bracket design is simplified to reduce weight, then manufacturing is easier, but deformation control during collision becomes insufficient
Solution Approach 1:
Notches are pre-formed in the leg portions of the crash bracket during manufacturing. These notches serve as predetermined deformation zones that will guide how the bracket deforms during a collision. By preparing these deformation guides in advance, the bracket achieves reliable deformation control without requiring complex real-time adjustment mechanisms.
3Strength
If crash bracket uses more material to increase strength, then collision force absorption improves, but weight increases
Solution Approach 1:
The crash bracket utilizes strategic changes in geometric parameters: the leg portions are designed with varying thicknesses, and notches are positioned to create optimized stress distribution. This allows the bracket to achieve high collision force absorption capability through intelligent geometric design rather than simply increasing material quantity, thereby controlling weight.
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 design enables controlled deformation of the bumper beam during collisions, enhancing its structural strength without increasing weight or complexity, ensuring effective force transmission and preventing collapse.
Implementation Method 1
a notch is provided in the proximal portion of at least on leg portion to provide a deformation guide for the leg portions
Data Source
Figure 1~3
Figure 4~5B
Figure 6A~6B
AI summary
The invention relates to crash bracket (10) for attaching a bumper beam (2) to a side beam (20) The bracket comprises a first attachment flange (11) and a second attachment flange (12) for attachment to upper and lower sides (21,22) of the side beam (20), respectively, a support portion (13) configured to align with and attach to a web (3) of the bumper beam (2), the support portion (13) having a proximal side (13A) configured to be arranged facing a centre portion (2A) of the bumper beam (2) and a distal side (13B) configured to be arranged facing an end portion (2B) of the bumper beam (2), opposite to the proximal side (13A), and first and second leg portions (14,15) that connect the support portion (13) to the respective first and second flanges (11,12), wherein the first and second leg portions (14,15) at least partly extend orthogonally with respect to the first and second flanges (11,12) and the support portion (13). A notch (17,17') is provided at the proximal portion (14A,15A) of the leg portions (14,15) to provide deformation guides for the leg portions (14,15).