Integrated Front Bumper Beam and FEM Carrier

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Solution Overview

Problem

Conventional manufacturing processes for impact absorbing members in vehicles are inefficient, leading to increased weight, cost, and quality issues due to separate components and complex assembly requirements.

Innovation Solution

A combined front bumper beam and front end module (CFF unit) with a dual sectional crash box structure, where the impact energy absorbing space and chassis component mounting space are formed integrally, reducing the need for separate components and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate components (bumper back beam, crash box, FEM carrier) are manufactured and assembled, then impact energy absorption capability is maintained, but manufacturing complexity and assembly time increase

Engineering Contradiction:

Improveimpact energy absorption capabilityVSAvoidmanufacturing and assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the bumper back beam, crash box, and FEM carrier into a single integrated component manufactured via injection molding. This merging eliminates the need for separate manufacturing processes and assembly operations, directly reducing manufacturing complexity while maintaining the structural integrity needed for impact energy absorption.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component performs multiple functions simultaneously: it serves as the bumper back beam for structural support, the crash box for impact energy absorption, and the FEM carrier for mounting chassis components. This multi-functionality reduces the number of parts without compromising any individual function's performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate components are used, then impact energy absorption can be achieved, but overall weight increases

Engineering Contradiction:

Improveimpact energy absorptionVSAvoidoverall weight of impact absorbing members

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

By merging multiple components into one integrated part, the patent eliminates redundant materials and overlapping structures that would exist in separate components. The single molded part achieves the same or better impact energy absorption with reduced overall weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component features locally optimized structures including hollow sections and varying wall thicknesses in different regions. This allows material to be concentrated where needed for impact absorption while minimizing material in non-critical areas, reducing overall weight while maintaining protective functionality.

Inventive Principle:

Principle #3Local quality

3Reliability

If separate components are manufactured and assembled, then impact protection is provided, but manufacturing cost increases

Engineering Contradiction:

Improveimpact protection capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent consolidates three separate manufacturing processes into a single injection molding operation. This eliminates multiple manufacturing steps, reduces tooling requirements, and simplifies quality control, directly lowering manufacturing costs while maintaining impact protection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The design incorporates hollow sections and optimized material distribution that reduce material consumption without compromising protective functionality. This efficient material usage reduces raw material costs while maintaining the required impact protection level.

Inventive Principle:

Principle #34Discarding and recovering

4Adaptability or versatility

If multiple separate components are assembled, then chassis components can be mounted, but assembly time and productivity decrease

Engineering Contradiction:

Improvechassis component mounting capabilityVSAvoidassembly efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The integrated component provides mounting capabilities for chassis components directly as part of its structure. The FEM carrier functionality is built-in, allowing chassis components to be mounted without requiring separate assembly of multiple parts, thereby improving assembly efficiency while maintaining versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10899395B2Unit of combined front bumper beam and front end module including crash box having dual-sectional structure

Publication Date: 2021.01.26 HYUNDAI MOTOR CO LTD

AI summary

A unit of a combined front bumper beam and front end module (“CFF unit”) is provided with a configuration in which an impact energy absorbing space formed is as a closed space and a chassis component mounting space is formed as an open space. The impact energy absorbing space and the chassis component mounting space are formed as an integrally formed structure. This structure is divided into a bumper back beam to which impact energy is transmitted, a crash box molded integrally with the bumper back beam to form the impact energy absorbing spaces at both sides of the bumper back beam, respectively, and a front end module carrier (“FEM carrier”) molded integrally with the crash box to form the chassis component mounting space at the inward side of the crash box. The bumper back beam, the crash box and the FEM carrier form the CFF unit.