Pultruded Polymer Impact Beam with Localized Fiber Orientation
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Solution Overview
Problem
Pultruded polymeric materials with high-density continuous fiber reinforcement have not been widely accepted for making vehicle bumper impact beams due to issues like premature catastrophic failure, low energy absorption, and difficulties in controlling fiber distribution and orientation, which affect their performance and manufacturing processes.
Innovation Solution
A vehicle bumper system comprising an impact beam with at least 40% continuous fiber reinforcement embedded in polymeric material, featuring strategically arranged reinforcements and a pultrusion process that allows for precise fiber placement and non-linear shaping, along with attachment structures for mounting to vehicle frame rails, to enhance impact strength and manage stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pultruded polymeric materials with high-density continuous fiber reinforcement are used, then tensile strength and bending strength are improved, but impact strength deteriorates due to premature catastrophic failure
Solution Approach 1:
The patent applies local quality by varying fiber orientation and density in different regions of the beam. Specifically, fibers are oriented at different angles (0°, 45°, 90°) in different sections to locally optimize for either tensile/bending strength or impact resistance. The fiber reinforcement is strategically placed with higher density in regions requiring tensile strength while incorporating angled fibers in impact-prone areas to prevent catastrophic failure.
Solution Approach 2:
The patent uses composite materials by combining polymeric matrix with continuous fiber reinforcement (glass, carbon, or aramid fibers) to create a pultruded beam that exhibits both high tensile strength and improved impact resistance. The composite structure allows the polymer to provide ductility and impact absorption while fibers provide tensile and bending strength.
2Productivity
If pultrusion process is used to manufacture impact beams, then manufacturing efficiency and material strength are improved, but process complexity and difficulty in controlling fiber distribution increase
Solution Approach 1:
The patent applies segmentation by dividing the fiber reinforcement into separate layers or sections within the pultrusion process. Different fiber orientations (0°, 45°, 90°) are placed in separate layers that are then consolidated during pultrusion. This segmentation allows independent control of fiber distribution in each layer while maintaining continuous production.
Solution Approach 2:
The patent uses parameter changes by varying fiber orientation angles, fiber density, and polymer composition during the pultrusion process to achieve desired beam properties. The pultrusion parameters (temperature, pressure, pull speed) are optimized to control fiber impregnation and distribution, reducing process complexity through systematic parameter optimization.
3Strength
If fiber reinforcement density is increased to improve strength, then tensile and bending strength are improved, but energy absorption capacity deteriorates
Solution Approach 1:
The patent applies local quality by creating regions with different fiber densities and orientations. Areas requiring high bending strength have higher fiber density with fibers aligned for maximum bending resistance, while impact-absorbing regions have lower fiber density or incorporate angled fibers that allow controlled deformation and energy absorption during impact events.
Solution Approach 2:
The patent uses composite materials to balance strength and energy absorption by optimizing the polymer-to-fiber ratio and selecting fiber types with different properties. The polymeric matrix provides energy absorption through viscoelastic deformation while fibers provide bending strength, creating a composite that achieves both objectives simultaneously.
Data Source
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AI summary
The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.