Vehicle bumper assembly
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Solution Overview
Problem
Existing vehicle bumper assemblies have high dead weight, are prone to corrosion, and require complex assembly processes, which can lead to weak points and increased damage in collisions.
Innovation Solution
A one-piece U-shaped crash box design with integral tabs for connection to the bumper cross bar and vehicle structure, featuring an open profile to prevent corrosion and simplify assembly, allowing for targeted deformation during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If closed hollow section crash boxes are used, then structural strength is improved, but dead weight increases and corrosion risk increases
Solution Approach 1:
The crash box is designed as a U-shaped profile consisting of two side walls and a web, forming an open hollow section rather than a closed tube. This segmentation of the closed profile into an open U-shape reduces material usage and dead weight while maintaining structural strength through the triangular configuration of the side walls and web.
Solution Approach 2:
One side of the closed hollow section is removed to create an open U-shaped profile. This extraction of material not only reduces weight but also eliminates the interior cavity that would otherwise be prone to moisture and dirt accumulation, thereby reducing corrosion risk while preserving crash absorption capabilities.
2Adaptability or versatility
If multi-part crash boxes are used, then structural flexibility is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The two side walls and the web are joined to form a single-integral U-shaped crash box component. This merging of multiple parts into one piece eliminates the need for separate manufacturing and assembly steps, reducing manufacturing complexity and assembly time while maintaining the structural flexibility needed for crash deformation.
Solution Approach 2:
The single-integral U-shaped crash box serves multiple functions simultaneously: it provides structural flexibility for crash energy absorption, maintains rigidity through its triangular configuration, and eliminates the need for separate joining components. The design achieves multi-functionality in a single component, reducing overall assembly complexity.
3Stability of the object's composition
If closed profile crash boxes are used, then structural integrity is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The closed profile is segmented into an open U-shaped configuration with two side walls and a web. This segmentation simplifies the manufacturing process by eliminating the need to form and seal closed ends, allowing for easier stamping and forming operations while maintaining structural integrity through the triangular geometry.
Solution Approach 2:
The closed end of the hollow section is removed to create an open profile. This extraction simplifies manufacturing by eliminating welding or bonding operations required for closed sections, reduces assembly time, and lowers manufacturing cost while the U-shape with web bridging maintains sufficient structural integrity for crash protection.
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 design achieves low dead weight, reduces corrosion risk, simplifies manufacturing, and enhances energy absorption and pedestrian protection by controlling deformation direction.
Implementation Method 1
a transversely projecting integral tab that is folded over from the web and with which the crash box is fastened to the cross bar
Implementation Method 2
in the event of an impact, the components of the bumper assembly deform in such a way that particularly low damage is caused to the vehicle structure
Implementation Method 3
the crash boxes absorbs or part of the energy acting on the vehicle so that damage to the vehicle structure or the vehicle occupants resulting from the collision can be reduced
Data Source
AI summary
A bumper assembly for a motor vehicle has a first bumper subassembly having a first cross bar and two first U-section crash boxes spaced apart from one another and each fastened by a respective outer end to a respective one of two regions of the cross bar close to ends thereof and each fastened by a respective inner end to the structure of the vehicle, Each crash box is of U-section with a web bridging two side walls, and each crash box further has at least at the respective outer end a transversely projecting integral tab that is folded over from the web and with which the crash box is fastened to the cross bar.