Hybrid Bumper Beam with Coaxial Composite Section
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Solution Overview
Problem
Existing bumper beams face challenges in increasing safety without increasing weight, as they either become too heavy with added materials or have reinforcing members that fail to attach effectively to metal sections, leading to increased costs and manufacturing complexity.
Innovation Solution
A hybrid bumper beam design combining a metal section with a coaxial composite section, where the composite section is bonded to the inner surface of the metal section using a resin-impregnated fiber preform, allowing for reduced metal thickness while maintaining strength and safety through efficient load transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high density structural foam is used to fill the cavity of the bumper beam, then the weight of the bumper beam is significantly increased, but the strength does not increase significantly
Solution Approach 1:
The patent applies composite materials by combining metal sections with fiber-reinforced plastic (FRP) components to create a hybrid bumper beam structure. The metal sections provide structural framework and crash resistance, while the FRP sections reduce weight compared to solid metal construction. This composite approach achieves the desired strength-to-weight ratio without requiring heavy foam filling.
2Strength
If reinforcing members are added to the bumper beam, then the cost increases, but the reinforcing members provide no/slight benefit because they cannot directly attach to metal members
Solution Approach 1:
The patent merges the reinforcing member function directly into the FRP section by integrating continuous fibers and stacking sequences that provide reinforcement throughout the composite structure. This eliminates the need for separate attachable reinforcing members, as the FRP itself is engineered to provide the necessary structural reinforcement while being inherently compatible with the metal sections through direct bonding.
3Reliability
If the outer metal section is made as a two part section with joining mechanisms, then the manufacturing process becomes more complex, but the joining mechanisms are susceptible to failure in a crash
Solution Approach 1:
The patent uses composite materials to create a monolithic hybrid structure where metal and FRP sections are bonded together to form an integrated assembly. This composite construction eliminates the need for separate joining mechanisms between metal sections, as the FRP acts as a bonding medium that structurally connects components. The resulting structure has fewer potential failure points while maintaining structural integrity during crashes.
4Strength
If the inner molded composite part is separately joined with metal parts, then the load transfer becomes effective in a crash, but more process steps and complexity are introduced in the manufacturing process
Solution Approach 1:
The patent merges the composite part formation and joining operations into a single integrated process step. The FRP section is molded and bonded to metal sections simultaneously during the composite manufacturing process, eliminating subsequent separate joining steps. This integrated approach ensures effective load transfer through the hybrid structure while simplifying the overall manufacturing process by reducing the number of discrete operations required.
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 hybrid design achieves improved mechanical properties and crash performance at reduced weight, lowering manufacturing costs and simplifying the process, with the composite section providing excellent load transfer and minimizing material waste.
Implementation Method 1
the composite section is bonded to the inner surface of the metal section using a resin-impregnated fiber preform
Implementation Method 2
heating the wrapped inflatable and the metal profile so the resin bonds to the metal profile
Implementation Method 3
inflating the inflatable mandrel so that the hollow preform is pressed against the inner side of the metal profile
Data Source
AI summary
A bumper beam for a vehicle including a bumper beam body having a tubular portion extending in a vehicle width direction, the bumper beam having a metal section and a composite section, wherein the metal section and the composite section are coaxial, the composite portion being along an inner surface of the metal section.