Monolithic Plastic Energy Absorption Member for Automobile Bumper
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Solution Overview
Problem
Conventional multi-piece energy absorption members in automobiles are complex to assemble, excessively heavy, and exhibit unreliable collapsing characteristics during collisions, which can lead to inefficient energy absorption and potential damage to the vehicle frame.
Innovation Solution
A monolithic plastic energy absorption member with a crushable body and integrated mounting portions that attach to both the bumper and rail, featuring a honeycomb structure for enhanced stability and energy absorption, allowing for lighter weight and improved performance in oblique impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional multi-piece metallic energy absorption members are used, then sufficient energy absorption capability is achieved, but the weight of the component increases
Solution Approach 1:
The patent changes the material parameter from metal to plastic, fundamentally altering the density and weight characteristics while maintaining energy absorption functionality. The plastic material enables the component to be approximately 35% lighter than conventional metallic members while achieving comparable or superior energy absorption performance through controlled deformation mechanisms.
Solution Approach 2:
The energy absorption member utilizes a composite structure combining plastic material with optimized geometric features including hollow sections, ribs, and controlled thin-walled structures. This composite approach integrates multiple functional elements (crushable zones, mounting portions, reinforcement features) into a unified plastic component that achieves both weight reduction and reliable energy absorption.
2Ease of manufacture
If conventional multi-piece energy absorption members are used, then adequate strength is achieved, but the assembly process becomes complex
Solution Approach 1:
The patent merges multiple separate components (crushable body, mounting portions, reinforcement elements) into a single monolithic plastic energy absorption member. This integration eliminates the need for assembly operations between multiple metallic parts, simplifying both manufacturing and installation while maintaining structural integrity and strength requirements.
Solution Approach 2:
The monolithic plastic component performs multiple functions simultaneously: energy absorption through controlled crushing, structural strengthening via integrated ribs and hollow sections, and mounting to the vehicle frame through built-in attachment features. This multi-functionality in a single component reduces the overall part count and assembly complexity.
3Reliability
If conventional energy absorption members are used, then energy absorption occurs during collision, but the collapsing characteristics become unreliable
Solution Approach 1:
The patent applies local quality variations within the plastic component by incorporating hollow sections, ribs, and strategically positioned thin-walled zones. These localized structural features create controlled deformation pathways that ensure reliable and predictable collapsing characteristics during collision, directing the crush progression through specific zones designed for optimal energy absorption.
Solution Approach 2:
The energy absorption member is designed with dynamic deformation characteristics where the plastic material transitions from rigid to progressively collapsing states during impact. The hollow sections and rib structures enable controlled dynamic crushing behavior that adapts to impact forces, ensuring reliable energy absorption across varying collision scenarios.
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 provides a lightweight, efficient energy absorption system that maintains the same footprint as conventional members, absorbs energy effectively in both normal and oblique collisions, and reduces the risk of damage to the vehicle frame by isolating absorbed energy from the rail, while being approximately 35% lighter than traditional metallic counterparts.
Implementation Method 1
The energy absorption members are configured to collapse in response to the collision energy. As the energy absorption members collapse, they absorb energy that would otherwise be transferred to the rail.
Implementation Method 2
by defining a geometry of the crushable body that increases the lateral stability of the crushable body during instances of oblique impact
Data Source
Figure 1
Figure 2A~2B
Figure 2C~3D
AI summary
A plastic energy absorption member (28) for an automobile bumper assembly (22) is disclosed. The plastic energy absorption member (28) includes a plastic crushable body (34) defining a first end and a second end opposite the first end along a length of the crushable body (34). The plastic energy absorption member (28) further includes a plastic first mounting portion (30) disposed proximate to the first end and monolithic with the plastic crushable body (34), the first mounting portion defining at least one first attachment member (38) configured to attach to the bumper (24), and a plastic second mounting portion (32) disposed proximate to the second end and monolithic with the plastic crushable body (34), the second mounting portion defining at least one second attachment member (42) configured to attach to the automobile rail (26). The energy absorption member (28) defines a plurality of voids (44) that each extend along at least a portion of the length of the crushable body (34).