Modular Bumper Beam with Crush Box Energy Absorber
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Solution Overview
Problem
Automobile manufacturers face challenges in developing cost-effective bumper beams and energy absorbers that meet varying global safety standards, are lightweight, and can be manufactured efficiently while maintaining aesthetic appeal.
Innovation Solution
A corner energy absorber design featuring an upper wall, lower wall, longitudinal rib, and lateral rib forming a crush box, which is configured as a single article for attachment to a vehicle, allowing for efficient energy absorption and aesthetic integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components are used to meet varying safety standards, then adaptability to different regulations is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bumper beam is designed with a universal modular structure that can satisfy multiple safety standards (FMVSS, ECE, RCAR, IIHS) through a single integrated design. The energy absorber geometry and material properties are optimized to meet the requirements of different collision tests simultaneously, eliminating the need for multiple variant designs for different markets.
Solution Approach 2:
The patent integrates the energy absorber and bumper beam into a single unified component rather than using separate parts. This merging reduces assembly complexity and enables the entire structure to be optimized as one system to meet various safety requirements, while the modular cross-member design allows for standardized manufacturing across different vehicle models.
2Strength
If heavier materials are used to meet safety standards, then strength and energy absorption are improved, but vehicle weight increases
Solution Approach 1:
The bumper beam utilizes composite material construction, combining materials with different properties to achieve optimal strength-to-weight ratio. The energy absorber is formed from materials that provide both structural integrity and controlled deformation characteristics, allowing the component to meet strength requirements while minimizing weight compared to solid metal constructions.
Solution Approach 2:
The bumper beam features varying wall thicknesses and rib configurations in different sections to provide localized strength where needed. The energy absorber has thicker walls and reinforced ribs in high-stress areas while maintaining thinner sections in low-stress regions, optimizing the distribution of material to achieve required strength with minimum weight.
3Shape
If complex geometries are used to meet aesthetic requirements, then appearance is improved, but manufacturing difficulty increases
Solution Approach 1:
The bumper beam is designed as an assembly of standardized modular cross-members that can be manufactured using simple extrusion or injection molding processes. These modular sections are then configured in different arrangements to create varied aesthetic appearances, allowing complex visual designs to be achieved through simple component assembly rather than complex single-piece manufacturing.
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 design effectively absorbs impact energy, meeting multiple safety standards while minimizing weight and manufacturing costs, and can be aesthetically integrated into vehicle design.
Implementation Method 1
energy absorbers can be used in conjunction with a vehicle frame and can absorb the energy to reduce vehicle damage
Data Source
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AI summary
An energy absorber for a vehicle, comprising: a continuous beam to extend across a width of vehicle, the beam defining a plurality of inward facing cavities in a center section, with adjacent inward facing cavities separated from one another by an inward facing rib, and at each end portion a plurality of outward facing cavities, with adjacent outward facing cavities separated from one another by an outward facing rib, wherein the center section includes a panel that is continuous on its outward side, and that forms a relative bottom of each of the plurality of inward facing cavities with its inward face.