Integrated Composite Bumper Beam and Crush Member
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Solution Overview
Problem
Fiber-reinforced composite crush members in vehicles tend to detach from the bumper during non-parallel collisions, reducing the overall energy absorption capacity of the assembly.
Innovation Solution
The energy-absorbing structure integrates reinforcing fibers continuously between the bumper beam and the crush member, using a combination of polymers and fibers such as carbon, glass, or aramid fibers, and employing manufacturing methods like high-pressure resin-transfer molding or compression molding to form a unified composite component, ensuring the crush member remains attached during impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced composite crush members are used to reduce weight, then fuel efficiency is improved, but the crush members tend to detach from the bumper during non-parallel collisions, reducing energy absorption capacity
Solution Approach 1:
The patent merges the bumper beam and crush member into a single integrated component, eliminating the interface between separate parts that could detach. The continuous fiber reinforcement spans across what would have been the joint region, creating a unified structure that maintains integrity during angular collisions while preserving the weight benefits of composite materials.
Solution Approach 2:
The patent incorporates continuous fiber reinforcement that extends beyond the traditional component boundaries during manufacturing, pre-positioning the reinforcement to bridge the gap between bumper beam and crush member. This preliminary action ensures that when angular collision forces are applied, the fibers are already in place to prevent detachment, rather than requiring additional attachment mechanisms.
2Ease of manufacture
If traditional separate component design is used, then manufacturing is easier, but the overall energy absorption capacity is reduced due to detachment during impact
Solution Approach 1:
The patent combines the bumper beam and crush member into one molded component, which can be manufactured in a single injection molding operation. This merging approach maintains manufacturing simplicity while ensuring the continuous fiber reinforcement provides uninterrupted structural integrity throughout the impact zone, maximizing energy absorption capacity.
Solution Approach 2:
The patent utilizes fiber-reinforced polymer composite materials with continuous fibers that span the entire component length. This composite structure provides both the ease of molded manufacturing and the enhanced strength required for high energy absorption, as the continuous fibers distribute and transmit impact forces throughout the integrated structure.
3Stability of the object's composition
If continuous fiber reinforcement is used to prevent detachment, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the continuous fiber reinforcement directly into the molded component structure, eliminating the need for separate attachment mechanisms or complex assembly steps. The fiber reinforcement becomes an intrinsic part of the single molded piece, maintaining structural integrity while simplifying the overall manufacturing process compared to assembling multiple reinforced components.
Solution Approach 2:
The patent designs the mold and fiber placement system to automatically position and embed continuous fibers during the injection molding process itself. The manufacturing process serves its own reinforcement needs by integrating the fibers into the molten polymer before curing, eliminating the need for separate reinforcement installation steps and reducing overall manufacturing complexity.
Data Source
AI summary
An energy-absorbing structure includes first and second components. The first component includes a polymer and a plurality of reinforcing fibers disposed therein. The first component includes first bumper and crush member portions respectively defined by first and second walls. The second wall projects from and is integrally formed with the second wall. At least some of the fibers continuously extend between the first and second walls. The second component includes the polymer and a plurality of reinforcing fibers. The second component includes second bumper and crush member portions respectively defined by third and fourth walls. The fourth wall projects from and is integrally formed with the third wall. At least some of the fibers continuously extend between the third and fourth walls. The first and second components are joined. The first and third walls cooperate to define a bumper. The second and fourth walls cooperate to define a crush member.