Monolithic Extrusion Bumper Crossmember for Simplified Assembly
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Solution Overview
Problem
The existing manufacturing process for vehicle bumpers with crossmember elements is complex due to the need for welding individually produced components, which complicates the production and increases weight, while seeking to enhance strength and crash characteristics.
Innovation Solution
The crossmember element is constructed as an extrusion with additional elements monolithically integrated, allowing for a lightweight and strong design with simplified production and additional functionalities like improved crash characteristics and fastening possibilities without additional installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual components are cut to length, provided with chamfers and welded together to form the crossmember element, then the bumper can be assembled from separate parts, but the manufacture becomes relatively complex and weight increases
Solution Approach 1:
The patent merges multiple separate components (crossmember sections and intermediate sections) into a single monolithic extrusion piece. This eliminates the need for welding individual parts together, thereby simplifying the manufacturing process and reducing production complexity while maintaining the structural integrity and functionality of the bumper crossmember element
2Adaptability or versatility
If additional elements are connected to the crossmember element by screw connections or similar fastening elements, then the additional functionality is achieved, but additional installation space is required
Solution Approach 1:
The patent integrates additional elements (such as fastening elements or reinforcing elements) directly into the crossmember element as monolithic integrations during the extrusion process. This eliminates the need for separate screw connections or fastening elements, thereby achieving additional functionality without requiring additional installation space
Solution Approach 2:
The crossmember element is designed with multi-functionality by incorporating various additional elements directly into its structure. The single extrusion piece serves multiple purposes: structural support, crash protection, and integrated fastening capabilities, thereby achieving adaptability without increasing installation space requirements
3Strength
If the crossmember element is constructed with vertically displaced sections to improve crash characteristics, then strength is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines multiple sections with different vertical positions into a single monolithic extrusion piece. The complex vertically displaced structure is achieved through the extrusion process itself, which can create intricate cross-sectional geometries in one continuous operation, thereby maintaining structural complexity for crash protection without requiring complex assembly processes
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
This approach results in a bumper with enhanced strength, crash performance, and adaptability, achieved through a monolithic construction that reduces weight and simplifies manufacturing, while maintaining or improving crash characteristics and providing additional fastening options.
Implementation Method 1
the crossmember element is constructed as an extrusion
Data Source
AI summary
The invention relates to a bumper (10) for a motor vehicle, with a crossmember element (20) which has preferably two homogeneous outer sections (12, 13) and a central section (11) differing from the outer sections (12, 13), wherein the central section (11) is displaced vertically downwards or upwards with respect to the two outer sections (12, 13). According to the invention, provision is made that the crossmember element (20) is constructed as an extrusion and in that at least one of the sections (11 to 13) has at least one additional element (35, 38, 39) arranged monolithically with the crossmember element (20).