Vehicle Impact Beam Strap Attachment for Crossmember Shock Absorber
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Solution Overview
Problem
The existing impact beams for motor vehicles face challenges in maintaining mechanical integrity during various impact types, such as 'Danner' and 'Bumper test' impacts, where the crosspiece is stressed in compression and bending, leading to potential separation from shock absorbers, reducing efficiency and increasing damage.
Innovation Solution
Incorporating a hooking device, such as a strap-like attachment member, to provide additional resistance and a solid anchoring system between the crosspiece and shock absorbers, enhancing mechanical behavior and preventing separation during impacts by increasing contact surfaces and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crossmember is rigidly connected to shock absorbers using conventional methods (riveting, bonding, welding), then the connection provides structural support, but the connection fails under tensile stress during bumper tests or pole impacts, causing separation
Solution Approach 1:
The connection system is divided into multiple independent attachment points along the crossmember. Instead of relying on a single rigid connection, the shock absorbers are secured at multiple locations, distributing the stress and preventing catastrophic failure at any single point. This segmentation allows the connection to maintain integrity under both compression and tension loads.
Solution Approach 2:
The attachment mechanism incorporates localized reinforcement elements at critical stress points on the crossmember. These reinforcement ribs or extended attachment surfaces are strategically positioned where tensile stresses occur during bumper tests, providing enhanced local strength without compromising the overall structural design or adding excessive weight.
2Loss of energy
If the crossmember is designed to absorb impact energy through deformation, then energy absorption is improved, but the connection between crossmember and shock absorbers is subjected to significant stress, potentially causing separation
Solution Approach 1:
The attachment mechanism is pre-designed and pre-positioned to anticipate and withstand the tensile stresses that occur during impact events. The reinforcement ribs and extended attachment surfaces are built into the crossmember structure before impact, ensuring that the connection is already strengthened and ready to handle the sudden tensile loads generated when the crossmember deforms during energy absorption.
3Device complexity
If conventional attachment methods are used to connect shock absorbers to the crossmember, then the structure remains simple, but the connection area is limited, reducing resistance to pull-out under tensile stress
Solution Approach 1:
The attachment mechanism extends the connection area by utilizing the longitudinal dimension of the crossmember. Instead of relying solely on transverse attachment points, the reinforcement ribs and extended attachment surfaces spread the connection along the length of the crossmember, increasing the effective attachment area and improving pull-out resistance without significantly increasing structural complexity.
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 solution enhances the robustness of the connection between the crosspiece and shock absorbers, improving resistance to traction and compression, thereby maintaining the impact beam's efficiency and reducing damage during different impact scenarios.
Implementation Method 1
the strap-like shape increases the contact area between the crossmember and the shock absorber, which also strengthens the bond through surface adhesion
Data Source
Figure 1~4
Figure 5~6
AI summary
According to the invention, both the cross-member (1) and the shock absorber (2) include an upper surface (1s, 2s) and a lower surface (1i, 2i), and the bumper beam comprises an element (3) for attaching the cross-member (1) to the shock absorber (2), said attachment element including a strap (3i, 3s) connecting the lower (1i, 2i) and/or upper (1s, 2s) surfaces of the cross-member (1) and the shock absorber (2).