Roll-Formed Bumper Beam With Local Internal Walls for Impact Absorption
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Solution Overview
Problem
Conventional bumper reinforcement beams for vehicles are complex and costly due to multiple separately formed components, which increases manufacturing time and weight, while aiming to balance strength and weight ratios for impact absorption.
Innovation Solution
A bumper reinforcement beam configured with a cross-sectional profile formed from a single metal sheet, featuring internal walls in the central section and omitted from end portions, with flanges extending along the edges for improved impact absorption, supported by crush cans at the vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separately formed components are used in conventional bumper reinforcement beams, then manufacturing flexibility and component functionality are improved, but manufacturing time, manufacturing cost, and device complexity increase
Solution Approach 1:
The patent merges multiple separately formed components (outer beam profile and inner beam profile) into a single integrated beam structure formed from one piece of sheet material. This consolidation maintains the functional benefits of having both outer and inner beam profiles while eliminating the complexity of assembling multiple separate components, reducing manufacturing steps and overall device complexity
2Adaptability or versatility
If multiple separately formed components are used in conventional bumper reinforcement beams, then component functionality is improved, but manufacturing time increases
Solution Approach 1:
The patent combines the formation of outer beam profile and inner beam profile into a single manufacturing process where both structures are formed simultaneously from one piece of sheet material. This eliminates the need for separate forming operations and assembly steps, significantly reducing manufacturing time while maintaining the functional integrity of both beam profiles
Solution Approach 2:
The patent performs preliminary forming of both outer and inner beam profiles during the initial sheet metal forming operation. By pre-forming the complex geometry including channels, flanges, and wall structures in the first manufacturing step, subsequent assembly operations are eliminated, thereby reducing total manufacturing time
3Strength
If internal walls are present throughout the entire bumper reinforcement beam, then impact absorption and stiffness are improved, but weight increases
Solution Approach 1:
The patent applies internal walls (inner beam profile) selectively only in the central portion of the bumper reinforcement beam rather than throughout the entire length. This local reinforcement strategy provides enhanced stiffness and impact absorption where it is most needed in the central impact zone while reducing overall weight by omitting internal walls from the end portions of the beam
4Ease of manufacture
If a single sheet metal configuration is used, then manufacturing cost and weight are minimized, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the single sheet metal configuration into distinct functional zones including outer beam profile sections, inner beam profile sections, flanges, and channels. This segmentation allows the forming process to create complex geometries through controlled folding and bending at specific locations, making the single-sheet construction feasible while maintaining manufacturing precision through defined forming zones
Data Source
AI summary
A reinforcement beam for a vehicle has an outer beam profile and an inner beam profile. The outer beam profile define an elongated hollow body and includes a front wall portion and a rear wall portion. The outer beam profile may include upper and lower flanges that formed in planar extension of the font wall portion. The inner beam profile may include a C-shape defining an upper shear wall and a lower shear wall that each extend between the front wall portion and the rear wall portion. The outer beam profile and the inner beam profile may be formed from a single sheet material through a roll-forming process. The inner beam profile may be present over a central section of the elongated hollow body and have a length that is less than half the length of the elongated hollow body.