Profiled Crash Box Vertical Extent for Low Bumper Compatibility
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Solution Overview
Problem
Vehicles with high-positioned bumper rails face challenges in collisions with vehicles having low-positioned bumper rails or barriers, as existing crash boxes are not adequately designed to absorb and distribute forces effectively in such scenarios.
Innovation Solution
The crash box features a profiled cross-section with upper and lower longitudinal portions and a raised profile portion that changes to a downward-pointing profile near the outer end, increasing its vertical extent, allowing it to absorb and distribute collision forces more effectively by folding rearwards and preventing bending at the attachment point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the crash box is positioned high relative to the bumper rail, then the bumper can meet collision requirements with high-positioned vehicles, but it fails to function satisfactorily when colliding with low-positioned vehicles or barriers
Solution Approach 1:
The crash box incorporates a downward-pointing profile portion that extends vertically downward from the main body, increasing the vertical extent of the energy-absorbing structure. This allows the high-positioned crash box to reach down and engage with low-positioned bumpers or barriers, effectively bridging the vertical gap between different vehicle heights while maintaining the high mounting position for compatibility with tall vehicles.
2Ease of manufacture
If the crash box has a standard profile, then the manufacturing is simple, but it cannot effectively absorb and distribute forces in collisions with low-positioned vehicles
Solution Approach 1:
The crash box profile is segmented into distinct portions: an upper longitudinal portion for engagement with high-positioned vehicles, a downward-pointing profile portion extending vertically downward to reach low-positioned vehicles, and a lower longitudinal portion. This segmentation allows each portion to serve its specific function while maintaining a relatively simple overall structure that can be manufactured using standard processes.
3Reliability
If the crash box vertical extent is increased to reach low-positioned vehicles, then collision functionality improves, but the structural complexity increases
Solution Approach 1:
The downward-pointing profile portion is strategically positioned only at the specific location where vertical extension is needed to reach low-positioned vehicles, rather than uniformly increasing the complexity throughout the entire crash box structure. This localized modification maintains simplicity in areas where it is not needed while providing the necessary functionality where required.
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 design ensures the bumper arrangement functions satisfactorily in collisions with both low-positioned vehicles and barriers, preventing the crash box from bending at its attachment and maintaining structural integrity, thus ensuring effective energy absorption and distribution during impacts.
Implementation Method 1
allowing it to absorb and distribute collision forces more effectively by folding rearwards and preventing bending at the attachment point
Data Source
AI summary
A crash box (11,12) is positioned high relative to the bumper beam (13) on, for example, an SUV. The underside (22) of the crash box has a profiled cross-section with upper (25,26) and lower (24) longitudinal portions. At least one upward profile portion (25,26) changes to being a downward-pointing profile portion (27,28) near to the outer end of the crash box, thereby increasing the vertical extent of the crash box. The underside of the crash box may have a hat profile which at its outer end changes to an inverted hat profile.