Steel Bumper Beam Insert for SOL Crash Energy Distribution
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Solution Overview
Problem
Current vehicle frame designs face challenges during small overlap rigid barrier (SOL) frontal crashes, where the aluminum bumper beam experiences high shear and tends to tear off, leading to excessive cabin deformation and increased risk of injury due to inadequate engagement of structural members.
Innovation Solution
The introduction of steel members into the hollow bumper beam at the end caps, which are fixedly attached to the frame rails, enhances the bumper's strength, reduces shearing, and allows for more effective energy absorption through frame crushing, preventing the unsupported end from shearing off and improving force transfer to the vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If an aluminum bumper beam is used to span the front ends of the high strength frame rails, then the bumper assembly achieves lightweight construction, but the unsupported end of the bumper beam easily deforms and tears away under high shear during SOL collision
Solution Approach 1:
The patent employs a composite structure combining aluminum bumper beam with steel reinforcement members. The aluminum beam provides lightweight construction while the steel members (inserted into the hollow aluminum beam and attached to frame rails) provide high shear strength. This composite approach resolves the contradiction by integrating materials with complementary properties - the lightweight aluminum for mass reduction and the high-strength steel for structural integrity during SOL collision.
Solution Approach 2:
The steel reinforcement members are inserted into the hollow interior of the aluminum bumper beam, creating a nested structure. The steel members are positioned within the aluminum beam's hollow section and extend to engage with the frame rails, providing internal reinforcement without significantly increasing external dimensions. This nesting approach allows the lighter aluminum beam to contain the stronger steel members, achieving both weight reduction and enhanced shear resistance.
2Loss of energy
If the bumper beam is designed to engage structural members during SOL collision, then energy absorption improves, but the unsupported end of the bumper beam is more susceptible to shearing and tearing
Solution Approach 1:
The steel reinforcement members act as intermediaries between the aluminum bumper beam and the vehicle frame rails. During SOL collision, these steel members transfer and distribute the shear forces that would otherwise concentrate at the unsupported end of the aluminum beam. The intermediaries (steel members) enable effective energy absorption through frame engagement while protecting the aluminum beam from direct shearing and tearing forces.
Solution Approach 2:
The composite aluminum-steel structure enables simultaneous achievement of energy absorption and shear resistance. The aluminum beam engages with crushable structural members to absorb energy, while the embedded steel reinforcement members provide the necessary shear strength to prevent tearing. This material composite allows the system to perform both functions - energy absorption through controlled deformation and structural integrity through high-strength reinforcement.
Data Source
AI summary
Disclosed is a device for distributing crash energy within a vehicle. The device includes a member insertable into an end of a bumper beam of a vehicle, where a first portion of the inserted member occupies an unsupported end of the bumper beam. A second portion of the inserted member is fixedly attached to the bumper beam and to a left frame rail or a right frame rail of the vehicle, and a third portion of the inserted member occupies a portion of the bumper beam between the left frame rail and the right frame rail.