Curved Dual-Crossmember Bumper for Lateral Overlap Crashes
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Solution Overview
Problem
Existing bumper arrangements in motor vehicles do not effectively distribute and dissipate crash energy during a head-on collision, particularly in scenarios with lateral overlap, leading to inadequate crash performance and energy absorption.
Innovation Solution
A bumper arrangement featuring a main crossmember and an auxiliary crossmember with curved profiles and offset configurations, coupled by vertical struts, which are produced in one piece and can be made from steel or light metal alloys, allowing for improved energy dissipation and force distribution through integral design and additional support elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single crossmember is used in the bumper arrangement, then the structure is simple, but the crash energy distribution and dissipation capability are insufficient
Solution Approach 1:
The bumper arrangement is divided into a main crossmember and an auxiliary crossmember that are structurally separated but functionally integrated. The auxiliary crossmember is positioned offset from the main crossmember in the longitudinal direction and connected via vertical struts, creating a segmented structure that improves crash energy dissipation while maintaining manageable complexity
Solution Approach 2:
The auxiliary crossmember is offset in the longitudinal direction relative to the main crossmember, adding a longitudinal dimension to the energy dissipation path. This dimensional offset creates additional deformation modes and extends the crash energy absorption distance, thereby improving energy dissipation capability
2Force
If the crossmember is straight and aligned with the vehicle centerline, then the manufacturing is simple, but the force distribution during lateral overlap crashes is inadequate
Solution Approach 1:
The auxiliary crossmember is positioned asymmetrically offset from the main crossmember in the longitudinal direction. This asymmetric arrangement creates non-uniform force distribution patterns during lateral overlap crashes, allowing forces to be distributed more effectively across the vehicle structure rather than concentrating at a single point
Solution Approach 2:
The auxiliary crossmember is designed with a curved profile instead of a straight configuration. This curvature allows the crossmember to better absorb and distribute lateral impact forces during overlapping crashes, converting linear impact forces into multi-directional stress distribution through the curved geometry
3Reliability
If crash boxes are used to convert crash energy into deformation work, then energy absorption is improved, but the overall crash performance in lateral overlap scenarios remains insufficient
Solution Approach 1:
The auxiliary crossmember integrates multiple functions: it serves as an additional energy absorption element, a structural support component via vertical struts, and a force distribution member. By merging these functions into a single offset component, the system achieves improved crash performance without proportionally increasing overall complexity
Solution Approach 2:
The auxiliary crossmember performs multiple functions simultaneously: it absorbs crash energy through its own deformation, distributes forces to the main crossmember and vehicle structure via vertical struts, and provides additional structural support. This multi-functionality improves crash performance while avoiding the need for separate dedicated components for each function
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 arrangement enhances crash performance by distributing intrusion forces more evenly, meeting manufacturer and statutory requirements, and increasing energy dissipation capabilities, thus improving safety in various crash scenarios.
Implementation Method 1
the crash boxes fold, for example, in the manner of a concertina and thus convert crash energy into deformation work
Data Source
AI summary
A bumper arrangement for a motor vehicle, having an upper main crossmember, which is able to be coupled to the motor vehicle by way of crash boxes, and a lower auxiliary crossmember, wherein main crossmember and auxiliary crossmember are coupled to one another by way of vertical struts. The main crossmember and the auxiliary crossmember run so as to be curved about the vertical axis at least in certain portions, wherein main crossmember and auxiliary crossmember have different radii of curvature from one another, and/or in that the auxiliary crossmember is set back with respect to the main crossmember in a motor vehicle longitudinal direction in the direction directed toward the motor vehicle, and/or in that the auxiliary crossmember has a central portion which is offset in relation to the vertical direction.