Cantilevered Sensor Energy Absorber for Bumper Impact Protection
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Solution Overview
Problem
Vehicles' sensors, such as radar and emergency braking sensors, are prone to damage and dislocation during low-force impacts due to unabsorbed forces, which can lead to malfunction and increased maintenance costs.
Innovation Solution
The integration of an energy absorber positioned alongside the sensors on the bumper beam, which absorbs energy during impacts, protecting the sensors and preventing dislocation by utilizing materials like expanded polypropylene foam and metallic components with varying cross-sectional configurations to effectively absorb forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are mounted on the bumper beam, then the vehicle can detect external objects and perform safety functions, but the sensors are vulnerable to damage and dislocation during low-force impacts
Solution Approach 1:
An energy absorber is positioned between the external environment and the sensor mounted on the bumper beam. This energy absorber is specifically designed to cushion and absorb low-force impacts before they reach the sensor, preventing damage and dislocation while allowing the sensor to remain mounted in its operational position on the bumper beam.
2Reliability
If the energy absorber is positioned outwardly of the sensor, then the sensor is protected from direct impact, but the energy absorber must be precisely aligned with the sensor to be effective
Solution Approach 1:
The energy absorber is designed with an asymmetric configuration where its width extends beyond the width of the sensor in at least one direction. This asymmetric design provides a larger tolerance zone for alignment during manufacturing and installation, making it easier to position the energy absorber correctly relative to the sensor while maintaining effective protection.
Solution Approach 2:
The energy absorber is positioned in general alignment with the sensor, with its width extending beyond the sensor width in at least one direction. This creates a localized protection zone that encompasses the sensor, providing enhanced protection while accommodating manufacturing tolerances through the extended width configuration.
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 energy absorber effectively mitigates sensor damage and dislocation, reducing the likelihood of malfunction and maintenance needs, while ensuring compliance with safety regulations by absorbing and distributing impact forces.
Implementation Method 1
The energy absorber includes a foam body that is configured and positioned to absorb energy during a low-force impact between the vehicle and an external object to protect the electronic sensor and reduce dislocation of the electronic sensor
Data Source
AI summary
A vehicle includes: a bumper assembly defining opposite lateral ends and an overall width extending therebetween, the bumper assembly defining a recessed area located between the opposite lateral ends thereof; an electronic sensor supported by the bumper assembly in cantilevered relation; and an energy absorber positioned within the recessed area to protect the electronic sensor and reduce dislocation of the electronic sensor by absorbing energy resulting from an impact between the vehicle and an external object. The energy absorber defines opposite lateral ends and an overall width extending therebetween less than that the overall width of the bumper assembly such that the opposite lateral ends of the energy absorber are spaced inwardly from the opposite lateral ends of the bumper assembly.