Multi-layered Composite Vehicle Bumper Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle bumpers face challenges in reducing weight for improved fuel efficiency, preventing delamination, achieving uniform coatings, resisting corrosion and denting, maintaining conductivity, and achieving a balance between weight reduction and durability, while also requiring complex shapes and multiple design considerations.
Innovation Solution
A multi-layered composite material comprising a core layer of filled polymeric material with a non-metallic conductive filler dispersed in a polymer matrix, sandwiched between two metal layers, which reduces weight, enhances conductivity, and improves durability, and can be processed to eliminate wrinkles and maintain a smooth surface during stamping and coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a multi-layered composite material is used to reduce weight, then fuel efficiency is improved, but delamination may occur during stamping
Solution Approach 1:
The patent uses a multi-layered composite material consisting of metal layers bonded to a polymeric core layer. This composite structure reduces bumper weight compared to solid metal while maintaining structural integrity. The specific gravity of the core layer (1.12 or less) is significantly lower than metal layers, achieving weight reduction. The layered composite design allows optimization of each layer's properties to prevent delamination during stamping operations.
2Weight of moving object
If a multi-layered composite material is used, then weight is reduced, but uniform coating application becomes difficult
Solution Approach 1:
The patent applies different materials and properties to different layers of the composite structure. The polymeric core layer provides a suitable substrate for coating adhesion, while metal layers provide structural support. This local differentiation of material properties enables uniform coating application on the outer surface while maintaining the benefits of the composite structure internally.
3Weight of moving object
If conventional composite materials are used, then weight reduction is achieved, but corrosion resistance is compromised
Solution Approach 1:
The patent combines metal layers with a polymeric core layer to create a composite structure where each material compensates for the other's weaknesses. The metal layers provide corrosion resistance and structural strength, while the polymeric core provides low density and damping properties. This composite approach achieves weight reduction without sacrificing corrosion resistance.
4Reliability
If a multi-layered composite material is used, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the bumper into distinct functional layers: metal layers for structural support and corrosion resistance, and a polymeric core layer for weight reduction and energy absorption. This segmentation allows each layer to be optimized independently for its specific function while simplifying the overall manufacturing process through standardized layering and bonding procedures.
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 results in a lightweight, durable, and conductive bumper that can withstand various manufacturing processes and environmental conditions, offering improved structural performance and resistance to corrosion and denting, while maintaining a smooth surface and uniform coatings.
Implementation Method 1
The non-metal filler preferably is a conductive filler that reduces the electrical resistance of the composite material
Implementation Method 2
There is a need for methods for stamping a multi-layered composite material into a bumper. There is a need for composite materials and/or methods that reduce or eliminate delamination of a multi-layered composite material after stamping into a bumper.
Implementation Method 3
There is a need for a multi-layered composite material that can be coated over an edge, including an edge of a polymeric layer (e.g., with chrome, e-coat, primer, base coat, top coat, or a combination thereof), preferably the coating is uniform.
Data Source
AI summary
The teachings herein are directed to light weight bumpers and methods for manufacturing a light weight bumper. The bumper is formed from a multi-layered composite material having a core layer that includes a non-metallic filler and preferably includes a conductive non-metallic filler, such as a carbon black filler.