Fiber-Reinforced Plastic Bumper Deformation Element
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Solution Overview
Problem
Existing deformation elements for vehicle bumpers are heavy and inefficient in reducing crash energy, as they either deform or break apart, failing to effectively dissipate impact energy.
Innovation Solution
A deformation element made of fiber-reinforced plastic with a fiber fabric embedded in a bedding material, designed to break apart during a crash, with the fiber fabric exposed between segments to absorb and dissipate energy, featuring a three-layer structure with high-tensile strength fibers aligned to manage force transmission effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If deformation elements are made of traditional sheet steel and designed to break apart, then energy reduction is achieved, but the weight is excessive and energy dissipation efficiency is insufficient
Solution Approach 1:
The deformation element uses a composite structure consisting of a fiber fabric (high-tensile-strength material) embedded in a bedding material (brittle material). This composite design allows the element to be lighter than traditional sheet steel while maintaining effective energy dissipation through the combination of fiber tearing and matrix cracking mechanisms.
2Weight of moving object
If deformation elements break apart without fiber reinforcement, then weight is reduced, but energy dissipation capability is insufficient
Solution Approach 1:
By embedding high-tensile-strength fibers in a brittle bedding material, the composite structure achieves both weight reduction and enhanced energy dissipation. The fibers prevent complete structural failure while the brittle matrix allows controlled cracking and fragmentation to absorb impact energy.
Solution Approach 2:
The fiber fabric is specifically oriented with fibers aligned in the tension direction to provide localized high tensile strength where needed during impact, while the bedding material provides bulk volume and brittle fracture characteristics for energy absorption.
3Loss of energy
If fiber fabric is made limp and formless for flexibility, then energy absorption improves, but structural integrity during normal operation deteriorates
Solution Approach 1:
The fiber fabric is designed to be limp and formless only in the exposed sections between breaking segments where energy absorption is needed, while maintaining high tensile strength through proper fiber orientation. The bedding material provides the necessary structural form stability during normal operation.
Solution Approach 2:
The fiber fabric is pre-oriented with fibers aligned in the tension direction before impact to ensure maximum tensile strength is available when needed, while the overall structure remains limp and flexible for energy absorption.
4Strength
If outer material layers are made strong for protection, then structural strength improves, but energy dissipation through fiber tearing reduces
Solution Approach 1:
The outer material layers are designed with different properties than the middle layer. The fiber fabric in outer layers can be oriented perpendicular or inclined to the longitudinal direction, providing structural strength and protection while the middle layer's longitudinally aligned fibers are optimized for energy dissipation through tearing.
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 deformation element effectively reduces crash energy by allowing the breaking segments to move past each other, with the exposed fiber fabric absorbing and distributing the impact, resulting in a lighter and more efficient energy dissipation mechanism.
Implementation Method 1
the fiber fabric is torn from the bedding material (matrix) when impact forces occur, and impact energy is specifically reduced as a result
Implementation Method 2
The exposed fiber fabric section is designed with a high tensile strength so that it does not tear apart
Data Source
AI summary
The invention relates to a deformation element, in particular for bumper cross member (2) on a motor vehicle, having at least one predetermined breaking point (S) at which, in the event of a crash, the deformation element (1) breaks apart into a breaking segment (1a) facing the crash which is displaced over the course of the crash and into a stationary breaking segment (1b) facing away from the crash. According to the invention the deformation element (1) is produced with at least one material layer (4) made of a fibre-reinforced plastic having a fibre fabric (14) embedded in a bedding material (10), said fibre fabric being exposed, after the deformation element (1) breaks apart, between the breaking segments (1a, 1b) and connecting said breaking segments to each other.