Crash Extension Flange Bending for Small-Overlap Impact Absorption
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Solution Overview
Problem
Current crash management systems face challenges in effectively absorbing impact energy during small overlap frontal collisions without fracturing, which can lead to increased damage and risk of interior penetration in vehicles.
Innovation Solution
A crash management system featuring a bumper cross member with a hollow profile crash extension that extends behind the bumper cross member, featuring a flange that bends during deformation, allowing energy absorption without transferring forces to the body structure, thereby minimizing damage and preventing fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid supporting element is used to prevent deformation of the bumper cross member end portion, then the structural strength is improved, but the energy absorption capability deteriorates
Solution Approach 1:
The supporting element changes its structural parameters during impact: initially rigid to prevent deformation and maintain strength, then becomes flexible through flange bending to absorb energy. This parameter change allows the element to fulfill both contradictory requirements at different stages of the collision process.
Solution Approach 2:
The supporting element transitions from a static rigid structure to a dynamic system where the flange can bend and deform. This dynamics enables the element to adapt its behavior during impact, providing structural support when needed and energy absorption when the flange bends, thus resolving the contradiction between strength and energy absorption.
2Loss of energy
If the bumper cross member end portion is designed to deform to absorb energy, then the energy absorption capability is improved, but the structural integrity deteriorates
Solution Approach 1:
The supporting element has different local qualities: the main body remains rigid to maintain structural integrity, while the flange is designed to bend and deform for energy absorption. This local differentiation allows the element to absorb energy through controlled flange deformation without compromising the overall structural integrity of the bumper cross member end portion.
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 system effectively absorbs impact energy by deforming the crash extension, reducing the transmission of forces to the vehicle's body and wheels, thus minimizing damage and ensuring passenger safety during small overlap collisions.
Implementation Method 1
The crash extension (6) is a hollow profile having at least one chamber (61, 62, 63) and having at least one flange (60) attached to the bumper cross member (2), wherein the flange (60) bends in the event of a deformation of the end portion of the bumper cross member (2) following a collision of the vehicle
Implementation Method 2
The system effectively absorbs impact energy by deforming the crash extension, reducing the transmission of forces to the vehicle's body and wheels
Data Source
AI summary
A crash management system for a vehicle having a longitudinal direction X a transverse direction Y perpendicular to the longitudinal direction X and a vertical direction Z perpendicular to the plane defined by said directions X and Y, comprising a bumper cross member globally oriented in said transverse direction Y, at least a longitudinal member arrangement, at least a crash extension attached to at least one of the ends of said bumper cross member and extending over a predetermined length behind said bumper cross member in the longitudinal direction wherein said crash extension is a hollow profile having at least one chamber and having at least one flange attached on said bumper cross member, wherein said flange bends in the event of a deformation of the end portion of said bumper cross member following a collision of the vehicle, in particular a collision with small overlap.