Hybrid Bumper Reinforcement for Small Overlap Crash Loads

The patent applies composite materials by combining aluminum alloy (lightweight metal) with thermoplastic resin and fiber reinforcement to create a bumper reinforcement that achieves high strength without the weight penalty of steel. The aluminum alloy base provides structural framework while the resin-fiber composite infills provide localized reinforcement at critical areas like the laterally outer ends, achieving strength equivalence to steel reinforcing pipes at reduced weight.

The patent implements local quality by concentrating reinforcement materials only where needed rather than uniformly throughout the structure. The thermoplastic resin with fiber reinforcement is specifically placed at the laterally outer ends and other critical stress areas of the aluminum alloy bumper reinforcement, providing targeted strength enhancement only where required to prevent buckling during small overlap crashes, rather than reinforcing the entire structure.

The patent merges multiple functions into a single integrated bumper reinforcement component. The aluminum alloy structure, thermoplastic resin infills, and fiber reinforcement are combined into one unified part that performs both structural support and crash energy management functions. This eliminates the need for separate steel reinforcing pipes and their associated mounting hardware, simplifying the assembly process while maintaining strength.

The composite construction allows the bumper reinforcement to be manufactured as an integrated component through processes like injection molding or resin transfer molding, where the thermoplastic resin and fibers are embedded directly into the aluminum alloy structure during manufacturing. This integration eliminates subsequent assembly steps required for separate reinforcing components, reducing assembly complexity.