Plastic Sandwich Bumper Structure for Simpler Crash Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crash management systems for motor vehicles are not entirely made of plastic material, limiting material compatibility and manufacturing efficiency.
Innovation Solution
A crash management system comprising two cover layers of continuous fiber-reinforced plastic material with a core element and rib sections made of the same plastic material, integrally connected by injection molding or extrusion, forming a sandwich structure with crash box elements for vehicle integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crash management systems use mixed metal and plastic materials, then structural strength and durability are improved, but manufacturing complexity and material compatibility issues arise
Solution Approach 1:
The patent merges the core element and rib sections into a single integrally connected plastic component through injection molding or extrusion processes. This eliminates the need for separate metal parts and complex assembly operations, reducing manufacturing complexity while maintaining structural integrity through the optimized plastic sandwich structure with fiber-reinforced cover layers
Solution Approach 2:
The patent employs composite plastic materials, specifically fiber-reinforced plastic for cover layers and thermoplastic materials for the core element and rib sections. These composite materials provide enhanced strength and stiffness comparable to metal constructions while enabling simpler manufacturing processes and better material compatibility within the plastic system
2Productivity
If crash management systems use entirely plastic materials, then manufacturing efficiency and material compatibility are improved, but structural strength may be compromised
Solution Approach 1:
The patent uses fiber-reinforced plastic materials for the cover layers to achieve high strength-to-weight ratio and structural performance comparable to metal. The continuous fiber reinforcement provides exceptional mechanical properties while maintaining the benefits of plastic material processing and integration
Solution Approach 2:
The patent applies different plastic materials with optimized properties to different functional zones: fiber-reinforced plastic for load-bearing cover layers, and thermoplastic materials with specific processing properties for the core element and rib sections. This local optimization ensures both structural strength and manufacturing efficiency in respective areas
3Adaptability or versatility
If multiple different materials are used in crash management systems, then functional performance is improved, but processing compatibility and manufacturing simplicity deteriorate
Solution Approach 1:
The patent combines the core element and rib sections into a single integrally molded plastic component, eliminating the need for separate processing of multiple materials. This integration simplifies manufacturing while maintaining functional performance through the optimized monolithic plastic structure
Solution Approach 2:
The patent uses homogeneous plastic materials for the core element and rib sections that are compatible with the same injection molding or extrusion processes. This material homogeneity enables simplified processing and manufacturing while the overall sandwich structure design provides the necessary functional versatility and performance
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
Enhances material compatibility and manufacturing efficiency by using entirely plastic materials, allowing optimal matching of plastic properties and simplified production processes.
Implementation Method 1
injecting an injection molding compound made of a second plastic material such that a core element is formed from the injection molding compound between the cover layers and rib sections are formed from the injection molding compound on one of the cover layers
Implementation Method 2
providing an extrusion compound made of a second plastic material on the first cover layer; pressing the two cover layers and the extrusion compound such that a core element is formed between the cover layers and rib sections are formed on one of the cover layers
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
A crash management system (1) for a motor vehicle (50) is described, having at least two outer layers (22h, 22v) made of a first endless-fibre-reinforced plastics material; a core element (24), arranged between the two outer layers (22h, 22v), made of a second plastics material, wherein the core element (24) and the outer layers (22h, 22v) are joined together via a material bond; a plurality of rib portions (18) made of the second plastics material, which are arranged on one of the outer layers (22v) and are joined thereto via a material bond; wherein the rib portions (18) and the core element (24) are joined together in one piece by means of injection moulding or extrusion. A motor vehicle having such a crash management system is also described, as are methods for producing such a crash management system.