Double Cross-Beam Bumper Assembly With Integrated Tow Lug
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Solution Overview
Problem
Existing bumper arrangements for motor vehicles struggle to balance improved crash behavior with the integration of towing capabilities while maintaining cost-effectiveness and production efficiency.
Innovation Solution
The bumper arrangement incorporates a main cross-carrier and an auxiliary carrier coupled through vertically running struts, where the towing socket is integrated into the struts as a separate hollow profile, allowing for thermal joining and maintaining structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a towing eye bushing is integrated into the cross member, then towing functionality is achieved, but the rigidity of the cross member and crash box deformation capability are compromised
Solution Approach 1:
The towing eye bushing is separated from the cross member and integrated into the vertical strut instead. This segmentation allows the cross member to maintain its full rigidity for crash protection while the vertical strut provides the towing function. The bushing is inserted into the hollow profile of the vertical strut and coupled via thermal joining process, creating an independent towing system that does not compromise the cross member's structural integrity.
2Adaptability or versatility
If the towing eye is connected to the crash box, then towing is enabled, but the crash box deformation capability is reduced
Solution Approach 1:
The towing eye bushing is positioned in the vertical strut away from the crash box connection points. This spatial segmentation ensures that the towing function is decoupled from the crash energy absorption path. The vertical strut acts as an independent load-bearing element that does not interfere with the crash box's ability to deform and absorb impact energy during collisions.
3Adaptability or versatility
If a separate towing device is added to the bumper assembly, then towing functionality is achieved, but device complexity and production costs increase
Solution Approach 1:
The towing eye bushing is integrated into the vertical strut, which is already a necessary component connecting the main and auxiliary cross members. This merging approach allows the towing function to be added without requiring a completely separate towing device. The vertical strut serves dual purposes: structural connection and towing support, thereby reducing overall device complexity and production costs compared to adding an independent towing mechanism.
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
This design enhances crash behavior by allowing the struts to deform and absorb crash energy, while the integrated towing socket provides secure towing without compromising the structural integrity or increasing production costs.
Implementation Method 1
The coupling is achieved, in particular, by a thermal joining process
Implementation Method 2
the vehicle impacts the cross member, causing the crash boxes to deform and convert crash energy into deformation energy
Data Source
Figure 1a~1d
Figure 2a~2f
Figure 3a~3e
AI summary
The present invention relates to a bumper assembly (1) for a motor vehicle, comprising a main crossmember (2) and a preferably sub-crossmember (3) arranged below it, which are coupled to each other via vertical struts (4), wherein the bumper assembly 1 is coupled to the motor vehicle via crash boxes (5), characterized in that the vertical strut (4) is designed as a separate hollow profile (10) and a towing eye bushing (6) extending through the wall surface is coupled into at least one vertically extending wall surface of the hollow profile (10).