Side Extension Structure for Lightweight Crash Intrusion Control
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Solution Overview
Problem
Existing crash management systems are heavy and complex, failing to absorb impact energy without fracturing and causing deep intrusions into the vehicle, necessitating a simpler and more efficient solution.
Innovation Solution
A crash management system with bumper cross members and side extensions that deform into a flat surface during impact, absorbing energy and minimizing intrusion by connecting to the vehicle's components, using lightweight materials like aluminum alloys and polymers, and incorporating openings for air passage and reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel panel assemblies are used to extend bumper cross members for side impact protection, then the rigidity and impact resistance are improved, but the system becomes heavy and structurally complex
Solution Approach 1:
The patent changes the material parameter from traditional steel panels to aluminum alloy extrusions, achieving weight reduction while maintaining structural integrity. The extruded aluminum profiles are designed with optimized cross-sections that provide sufficient strength for side impact protection without the mass of steel assemblies
Solution Approach 2:
The solution employs composite construction by integrating the side extension as a multi-functional element that combines structural support, impact absorption, and aerodynamic considerations in a single aluminum alloy component, replacing multiple separate steel panels and fasteners
2Stability of the object's composition
If complex multi-panel steel assemblies are used to achieve rounded contours for wheel strike protection, then the impact distribution is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple functions (side impact protection, wheel strike protection, structural bracing) into a single integrated side extension element. The extruded profile is designed to perform multiple protective roles simultaneously, eliminating the need for separate steel panels and their complex fastening systems
Solution Approach 2:
The extruded aluminum profile incorporates rounded contours and curved surfaces that distribute impact forces uniformly during wheel strikes and side collisions. The curved geometry is achieved through extrusion tooling, providing smooth impact surfaces without requiring multiple assembled panels
3Strength
If heavy extruded elements with cut-off parts are used to extend bumper cross members, then the structural integrity is improved, but the weight and manufacturing complexity increase
Solution Approach 1:
The side extension is designed as a modular extruded element that can be produced separately and then integrated into the bumper assembly. The extrusion process creates a standardized component with consistent cross-section along its length, simplifying manufacturing compared to cutting and welding heavy steel sections
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (welding, bolting, riveting of heavy steel sections) with an extrusion-based solution. The aluminum extrusions are designed to be attached using simpler fastening methods, reducing both manufacturing complexity and assembly time
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 system effectively absorbs impact energy, preventing deep intrusions and fractures while maintaining a lightweight design, enhancing safety and reducing vehicle damage.
Implementation Method 1
side extensions on each side of the crash management system, which are superimposed on the outer face of the bumper cross members and that is subjected to bend in the event of a deformation of the end portion of the crash management system following a collision of the vehicle
Data Source
AI summary
A crash management system for a vehicle comprising an assembly of bumper cross members with at least a first bumper cross member and a second bumper cross member being substantially vertically spaced and located one above the other and at least one connecting means to attach the first bumper cross member and the second bumper cross member to the motor vehicle, and a two essentially side extensions positioned on each side of the crash management system. Each side extension comprises, a first vertical segment, a first and a second horizontal segment and at least one opening. The first horizontal segment overlaps the first bumper cross member and the second horizontal segment overlaps the second bumper cross member.