Staggered Vertical Lobes for Vehicle Bumper Energy Absorption
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Solution Overview
Problem
Current energy absorbers for vehicles face challenges in meeting global regulatory standards due to height mismatch impacts and are non-optimal in terms of weight and material usage, failing to efficiently absorb energy across varying impact positions at low speeds while adhering to stringent test requirements.
Innovation Solution
A thermoplastic energy absorber with vertically oriented lobes arranged in staggered rows, capable of extending above and below the bumper beam, providing energy absorption capabilities regardless of impact height and meeting stringent test standards such as FMVSS part 581, while reducing material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional energy absorbers are used, then they can absorb impact energy, but they fail to efficiently absorb energy across varying impact positions at low speeds while adhering to stringent test requirements
Solution Approach 1:
The energy absorber transitions from conventional horizontal crush lobes to vertically oriented lobes arranged in multiple rows. This dimensional reorientation allows the structure to effectively absorb impact energy across varying impact positions (different heights), thereby improving adaptability while maintaining compliance with regulatory standards such as FMVSS part 581 and ECE 42
2Use of energy by moving object
If bumper systems are tuned for particular energy absorption profile, then impact energy can be absorbed, but packaging space occupied by the bumper system increases
Solution Approach 1:
The invention changes the geometric parameters of the energy-absorbing structure by using vertically oriented lobes with specific aspect ratios (height to width ratio between 1.5:1 and 3:1). This parameter optimization allows efficient energy absorption within a compact packaging space, reducing the overall volume occupied by the bumper system while maintaining the required energy absorption profile
3Object-affected harmful factors
If bumper beam flexure is limited, then rear intrusion into the space behind the bumper beam is reduced, but energy absorption capability is compromised
Solution Approach 1:
The energy absorber is segmented into multiple rows of vertically oriented lobes that can deform independently during impact. This segmentation allows the structure to absorb energy through controlled deformation of individual lobes while limiting the overall flexure of the bumper beam, thereby reducing rear intrusion into the space behind the bumper beam while maintaining energy absorption capability
4Weight of moving object
If material usage is reduced, then weight of energy absorber decreases, but energy absorption efficiency may be compromised
Solution Approach 1:
The energy absorber utilizes thermoplastic materials with optimized mechanical properties to achieve high energy absorption efficiency with reduced material usage. The vertically oriented lobe structure creates an efficient load path that maximizes the energy absorption capability per unit mass, allowing weight reduction while maintaining or improving energy absorption efficiency
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 thermoplastic energy absorber effectively absorbs impact energy across varying heights, meets stringent regulatory standards, and achieves a significant reduction in weight and intrusion levels compared to conventional systems, demonstrating high efficiency and compliance with global safety requirements.
Implementation Method 1
A thermoplastic energy absorber having a horizontal axis and a vertical axis comprising: an array of energy absorbing lobes protruding from a base... configured to be installed on a vehicle for absorption of impact energy
Data Source
AI summary
A thermoplastic energy absorber having a horizontal axis and a vertical axis, and comprise: an array of energy absorbing lobes protruding from a base, the lobes arranged in two or more rows. The energy absorbing lobes can have a vertical length (L) and a horizontal width (D), and wherein a ratio of L:D is greater than 1. The energy absorbing lobes in each row can be disposed in a staggered manner with respect to energy absorbing lobes in an adjacent row. The energy absorber can be configured to be installed on a vehicle for absorption of impact energy. An energy absorbing system can comprise the thermoplastic energy absorber disposed between a bumper beam and a fascia. The fascia can optionally be configured to envelope the thermoplastic energy absorber and the bumper beam. This system passes EuroNCAP lower-leg impact requirements, version 5.1, June 2011, for lower leg impact requirement.