Modular Bumper End Modules for High Energy Absorption
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Solution Overview
Problem
Existing motor vehicle bumper arrangements face challenges in achieving a balance between cost, weight, and energy absorption capacity while meeting legal and safety requirements for pedestrian protection and crash performance.
Innovation Solution
A modular bumper arrangement featuring a crossbar with crash boxes and external end modules, where each end module includes a shell body with a crash box, and a shield that covers the shell body on the front, providing enhanced deformation behavior and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bumper assemblies with cross members and crash boxes are used, then energy absorption capacity is achieved, but weight increases and cost increases
Solution Approach 1:
The bumper is divided into modular end modules (each with shell body, shield, and crash box) and a central cross member section. This segmentation allows optimized placement of high-strength materials only where needed for energy absorption, reducing overall weight while maintaining energy absorption capacity.
Solution Approach 2:
Different material qualities are applied locally: high-strength steel is used for crash boxes and shell bodies where impact forces occur, while lighter materials can be used for the cross member and shield areas experiencing lower stresses, optimizing the weight-strength balance.
2Strength
If high-strength materials and complex structures are used to meet safety requirements, then energy absorption and pedestrian protection are improved, but manufacturing cost increases
Solution Approach 1:
The bumper system is segmented into separate modules (end modules with integrated crash boxes and shell bodies, central cross member, shields) that can be manufactured independently using cost-effective processes and then assembled, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The crash box is integrated within the shell body of each end module, with the shield covering the shell body. This nested arrangement combines multiple protective functions into a single compact unit, reducing the total number of separate components and assembly steps, thereby lowering manufacturing cost.
3Adaptability or versatility
If a modular structure with end modules is implemented, then adaptability to different vehicle models is improved, but device complexity increases
Solution Approach 1:
The bumper is segmented into standardized end modules and a central cross member section. The end modules serve as interchangeable units that can be configured in different numbers and arrangements to suit various vehicle models, providing adaptability while keeping the basic module design relatively simple.
Solution Approach 2:
The end modules are designed as universal units that can be applied across different vehicle models. Each end module contains integrated functions (structural support, energy absorption via crash box, pedestrian protection via shield), reducing the need for model-specific customizations and simplifying the overall system.
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 achieves a high level of energy absorption with a weight-saving construction, improving crash performance and reducing the risk of injury from impacts, while being cost-effective and adaptable to different vehicle models.
Implementation Method 1
The cross member serves to direct the energy resulting from an impact into the crash boxes, where the impact energy is converted into deformation energy
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A bumper assembly 1 for a motor vehicle comprises a cross member 2 and crash boxes 3 arranged at each end of the cross member 2, as well as outer end modules 14. According to the invention, each end module 14 has a shell body 15 and a shield 16 that covers the shell body 15 at least partially on its front side, wherein the shell body 15 is joined to a crash box 3 and each end 17 of the cross member 2 is joined to a shell body 15. The bumper assembly 1 exhibits a functionally high energy absorption capacity despite its modular design.