Hybrid Bumper Reinforcement for Small Overlap Crash Resistance
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Solution Overview
Problem
Existing bumper reinforcements for vehicles, particularly those designed to handle small overlap crashes, increase vehicle weight, leading to reduced fuel efficiency and compromised vehicle dynamics, and require additional assembly processes.
Innovation Solution
A bumper reinforcement system comprising a reinforcement main body made of aluminum with integrated CFRP reinforcing channel members and resin blocks, which are designed to effectively distribute and absorb impact forces during a small overlap crash while minimizing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel reinforcing pipe is used to connect the laterally outer end to the side member, then the bumper reinforcement can effectively handle small overlap crashes, but the vehicle weight increases
Solution Approach 1:
The patent employs a composite structure combining aluminum alloy (main body) with resin blocks (energy absorbing material) to create a bumper reinforcement that achieves high strength and rigidity while minimizing weight. The resin blocks are strategically positioned within hollow portions of the aluminum structure to provide both structural integrity and impact energy absorption capabilities
Solution Approach 2:
The bumper reinforcement features non-uniform thickness distribution and strategically placed resin blocks in specific regions to optimize strength where needed while reducing weight in less critical areas. The hollow portions are selectively positioned to balance structural requirements with weight reduction goals
2Strength
If the bumper reinforcement structure is extended laterally outward to handle small overlap crashes, then crash resistance improves, but the vehicle weight increases
Solution Approach 1:
The patent uses a composite aluminum-resin structure where the aluminum alloy provides the extended lateral framework for crash resistance while the resin blocks provide localized reinforcement and energy absorption, achieving the required strength without the weight penalty of fully metal construction
Solution Approach 2:
The patent optimizes the thickness parameters of the aluminum alloy sections and the size/position parameters of the resin blocks to achieve the minimum necessary strength for small overlap crash resistance while minimizing the overall weight of the extended structure
3Strength
If a supplementary reinforcement member is added to connect the laterally outer end to the side member, then the bumper reinforcement can handle small overlap crashes, but the assembly process becomes more complex
Solution Approach 1:
The patent integrates the energy absorbing function and structural reinforcement function into a single unified bumper reinforcement component rather than using separate supplementary members. The resin blocks are embedded within the aluminum structure during manufacturing, creating an integrated component that reduces assembly complexity while maintaining crash resistance capabilities
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A bumper reinforcement (1) includes a main body (10) made of metal, a reinforcing channel member (11), and a resin block (12). A mounting portion of a crash box (2) is formed at a vicinity of each end of the main body (10). The reinforcing channel member (11) includes a web (11A), an upper flange (11C) and a lower flange (11D) that are placed on an outer panel, an upper panel (10C) and a lower panel of the main body (10) at the mounting portion of the crash box (2), respectively. The reinforcing channel member (11) is extended outward from the each end of the main body (10). The resin block (12) is provided on an inner face of the reinforcing channel member (11). The resin block (12) is contact with or joined to the outer panel and an inner panel (10B) of the main body (10) at each end of the main body (10) and extended from the each end to an outer edge (11E) of the reinforcing channel member (11).