Single-Sheet Metal Impact Absorber for Vehicle Bumper
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Solution Overview
Problem
Conventional impact absorbing members for vehicle bumpers require multiple parts and complex manufacturing steps, leading to increased part count and reduced mass productivity due to the need for extruded-shaped materials and precise press working, which complicates integration and buckling deformation.
Innovation Solution
An impact absorbing member configured entirely by bending a single sheet of metal plate material, including a fixing plate, side wall plates, flange plates, and bridge plates, which are integrated to form a square tube shape, reducing the part count and simplifying manufacturing while ensuring effective buckling deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extruded-shaped materials are used as impact absorbing members, then impact absorption capability is improved, but part count increases and manufacturing complexity increases
Solution Approach 1:
The patent combines the impact absorbing part, fixing plate, and flange plate into a single integrated component made from one sheet of metal plate material. This merging eliminates the need for separate parts and their corresponding connections, reducing part count while maintaining impact absorption capability through the integrated structure's buckling deformation
2Strength
If extruded-shaped materials are used as impact absorbing members, then impact absorption capability is improved, but manufacturing steps increase and mass production efficiency decreases
Solution Approach 1:
The patent changes the material form from extruded-shaped material to bent metal plate material. This parameter change enables the use of bending and joining processes that are more suitable for mass production, improving productivity while maintaining impact absorption capability through the integrated structure
3Shape
If deep drawing process is used to form impact absorbing member, then shape complexity is improved, but material surface restriction increases and processing precision requirement increases
Solution Approach 1:
Instead of using deep drawing to form the complex shape, the patent inverts the approach by using bending of metal plate material. This inversion replaces the restrictive deep drawing process with a more flexible bending process that achieves the desired shape complexity without stringent material or precision constraints
4Reliability
If multiple separate parts are used for impact absorbing member, then structural functionality is improved, but integration complexity increases and manufacturing cost increases
Solution Approach 1:
The patent merges multiple functional parts (impact absorbing part, fixing plate, flange plate) into a single integrated component. This merging maintains structural functionality through the integrated structure's design while eliminating the complexity of integrating multiple separate parts
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 solution reduces the part count and enhances mass productivity by simplifying manufacturing steps and ensuring favorable impact absorption properties through effective buckling deformation without lateral buckling, thus improving the overall performance of the bumper device.
Implementation Method 1
configured in its entirety by bending one sheet of a metal plate material
Implementation Method 2
an impact absorbing part which comprises two first side wall plates of an approximate square shape, which extend towards one side substantially perpendicularly from two opposite sides of the fixing plate
Data Source
AI summary
An impact absorbing member is formed by bending one sheet of a metal plate material and then joining adjacent end parts thereof. The impact absorbing member includes the following integrally-connected portions: a fixing plate, an impact absorbing part having two first side wall plates and two second side wall plates, two flange plates, and two bridge plates. The impact absorbing part overall has an approximate square or rectangular tube shape after being bent. Joining parts are provided at each opposing end parts of the first and second side wall plates. The adjacent end parts of the first and second side wall plates overlap and are joined. The end parts of the two flange plates are also joined to the end parts of the two bridge plates.