Extruded Bumper Cross Beam With Integrated Reinforcement
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Solution Overview
Problem
Existing bumpers for motor vehicles with cross beam elements and reinforcing elements require multiple manufacturing steps, leading to high production costs and complexity, while maintaining optimal crash behavior and low weight.
Innovation Solution
The cross beam element and reinforcing element are manufactured as a single piece through extrusion, with the reinforcing element being partially removed where not needed, allowing for a monolithic configuration that optimizes strength and weight without additional fastening steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate reinforcing elements are joined with the cross beam element through welding or fastening, then the bumper exhibits optimized deformation behavior and crash performance, but the manufacturing complexity and production costs increase
Solution Approach 1:
The patent merges the cross beam element and reinforcing element into a single integrated component manufactured through extrusion. The reinforcing element is formed as an integral part of the cross beam element, eliminating the need for separate fastening or welding operations while maintaining the optimized deformation behavior and crash performance required by legal standards.
Solution Approach 2:
The extruded cross beam element serves multiple functions simultaneously: it provides the structural support function of the cross beam, incorporates the crash absorption function through its hollow chamber design, and integrates the reinforcement function through the built-in reinforcing element. This multi-functionality reduces the number of separate components and assembly steps required.
2Adaptability or versatility
If multiple separate components are used to form the cross beam element and reinforcing element, then the bumper can be adjusted to legal requirements and crash tests with optimized deformation behavior, but the production outlay increases
Solution Approach 1:
The patent enables adjustment to different crash test requirements and legal standards by modifying the geometric parameters of the extruded cross beam element, such as the dimensions and positioning of the reinforcing element, the size and shape of hollow chambers, and the overall profile. These parameter changes can be implemented through tooling modifications in the extrusion process rather than redesigning entire components or assembly procedures.
3Ease of manufacture
If the cross beam element has a constant cross section from extrusion, then the manufacturing process is simplified, but the weight optimization and crash behavior are limited
Solution Approach 1:
The patent applies local quality by creating variations in the cross-sectional geometry of the extruded cross beam element at specific locations. The reinforcing element has different dimensions and configurations at different positions along the length of the cross beam, allowing for optimized weight and crash performance in critical areas while maintaining a relatively simple overall extruded structure.
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 approach reduces manufacturing complexity and costs, enables recycling of removed material, and allows for optimized crash behavior with a homogeneous joint, enabling geometry flexibility and weight reduction.
Implementation Method 1
manufacture a cross beam element of a bumper in particular out of a lightweight material such as aluminum in an extrusion process
Data Source
Figure 1
Figure 2~5
AI summary
The invention relates to a bumper (10) for a motor vehicle, with a cross beam element (30) exhibiting a back side (22) designed to be fastened to the motor vehicle with at least one fastening device (25), preferably in the form of a crash box, and a front side (21) lying opposite the back side (22), wherein the cross beam element (30) has at least one hollow chamber (36, 37) with a closed cross section, and with a reinforcing element (40; 40a), which extends over part of the length of the cross beam element (30) and is joined with the cross beam element (30). The invention provides that the cross beam element (30) be designed together with the reinforcing element (40; 40a) as a single-piece extruded part.