Plastic Shock Absorber with Metal Inserts for Automotive Bumper Beams

Solution Overview

Problem

Existing shock absorbers for motor vehicles face challenges in balancing mass, cost, and energy absorption capacity, particularly for vehicles exceeding 1400 kilograms, with metal absorbers being too heavy and costly, and composite plastic absorbers having inadequate energy absorption.

Innovation Solution

A shock absorber comprising a plastic main body with integrated metal inserts that can be adjusted in dimensions and thickness, providing localized reinforcement and maintaining structural integrity during impacts, while reducing the load on the plastic component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If shock absorbers are made of metal, then strength and energy absorption capacity are improved, but mass increases

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidmass

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The shock absorber combines plastic material for the main body with metal inserts for localized reinforcement. This composite structure provides the strength and energy absorption capacity of metal where needed, while maintaining the mass advantages of plastic for the majority of the component volume.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Metal inserts are placed only in specific locations where reinforcement is needed, rather than making the entire shock absorber from metal. This allows localized strengthening at connection points and high-stress areas while keeping the overall mass low through the use of lighter plastic material elsewhere.

Inventive Principle:

Principle #3Local quality

2Weight of moving object

If shock absorbers are made of aluminium, then mass is reduced, but cost increases

Engineering Contradiction:

ImprovemassVSAvoidcost

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

Instead of making the entire shock absorber from expensive aluminum, the invention uses plastic for the main body and only incorporates metal inserts where structural reinforcement is necessary. This dramatically reduces the amount of expensive metal required while maintaining adequate strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses cheaper plastic material for the majority of the shock absorber volume, replacing expensive aluminum in non-critical areas. This cost-effective approach maintains acceptable performance while significantly reducing material costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Weight of moving object

If shock absorbers are made of thermoplastic material, then mass is reduced and cost is lowered, but energy absorption rate decreases

Engineering Contradiction:

ImprovemassVSAvoidenergy absorption rate

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The shock absorber combines plastic material for the main body with metal inserts for localized reinforcement. This composite structure provides the strength and energy absorption capacity of metal where needed, while maintaining the mass advantages of plastic for the majority of the component volume.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Metal inserts are placed only in specific locations where reinforcement is needed, rather than making the entire shock absorber from metal. This allows localized strengthening at connection points and high-stress areas while keeping the overall mass low through the use of lighter plastic material elsewhere.

Inventive Principle:

Principle #3Local quality

4Strength

If metal inserts are integrated into the shock absorber, then mechanical resistance is reinforced, but device complexity increases

Engineering Contradiction:

Improvemechanical resistanceVSAvoidstructural complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The shock absorber is divided into distinct functional zones: the plastic main body for mass absorption and the metal inserts for structural reinforcement. This segmentation allows each material to perform its optimal function while simplifying the design process through clear division of labor between materials.

Inventive Principle:

Principle #1Segmentation

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 offers improved impact resistance, economic efficiency, and broader vehicle compatibility by enhancing the mechanical characteristics of the absorbers, allowing for effective energy absorption and maintaining connection integrity during impacts.

Implementation Method 1

The shock absorber (10) comprises a main body (12) made of a plastic material and a metal insert (14)... the presence of the metal insert makes it possible to locally reinforce the mechanical resistance of the shock absorber

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

their purpose is to absorb energy by deformation when a shock occurs

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentEP3558758B1Shock absorber for automotive vehicle and bumper beam with such a shock absorber

Publication Date: 2021.02.10 COMPAGNIE PLASTIC OMNIUM SA

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AI summary

The present invention relates to an impact absorber for a motor vehicle and to an impact beam; this impact absorber is made of a plastic material; one of the ends of the impact absorber is attached to a crosspiece, the other end is attached to a box; the impact absorber is characterized in that at least one metal insert is integrated into the impact absorber and connects the crosspiece and the box.