Unitary Bumper Beam Assembly With Variable Thickness Crash Structure
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Solution Overview
Problem
The existing bumper beam assemblies in vehicles, comprising multiple components welded together, face issues with vulnerable seams, increased weight, and higher manufacturing complexity, which can lead to weaknesses during collisions.
Innovation Solution
A method for manufacturing a unitary bumper beam assembly by joining multiple blanks to form a combined blank, which is then deformed in a single operation, eliminating the need for post-forming welding and creating a structure with varying material thickness and microstructures to enhance strength and ductility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple components are welded together to form bumper beam assembly, then structural protection function is achieved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the bumper beam and pedestrian beam into a single unitary component formed from one blank, eliminating the need for welding and reducing the number of parts. This combining approach reduces assembly weight while maintaining structural protection functionality.
Solution Approach 2:
The unitary bumper beam is designed with segmented functional zones: a first portion with higher thickness for structural strength and a second portion with lower thickness for pedestrian safety. This segmentation allows different regions to fulfill different protective functions within a single component.
2Strength
If multiple components are welded together to form bumper beam assembly, then structural protection function is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single forming process, creating the entire bumper beam assembly from one blank without welding or post-assembly operations. This merging of operations significantly reduces manufacturing complexity.
Solution Approach 2:
The bumper beam is formed with integrated features including mounting brackets and reinforcement zones built into the single blank before forming. This preliminary integration of features eliminates subsequent assembly steps and reduces manufacturing complexity.
3Stability of the object's composition
If welding is used to join bumper beam and pedestrian beam, then structural integrity is achieved, but heat-affected zones create vulnerability to cracks
Solution Approach 1:
The patent merges the bumper beam and pedestrian beam into a single unitary component formed from one blank, completely eliminating welding joints and heat-affected zones. This approach maintains structural integrity while removing the vulnerability to cracks at weld seams.
4Ease of manufacture
If uniform thickness is used throughout the bumper beam, then manufacturing is simplified, but energy absorption and pedestrian safety are compromised
Solution Approach 1:
The patent applies local quality by varying the thickness of the bumper beam in different regions: a first portion with higher thickness for structural strength and energy absorption, and a second portion with lower thickness for pedestrian safety. This localized differentiation optimizes both protective functions.
Solution Approach 2:
The bumper beam is designed with dynamic deformation characteristics through varying thickness, allowing different regions to deform in a controlled sequence during impact. The thinner portion deforms first to absorb energy while protecting pedestrians, while the thicker portion maintains structural integrity.
5Strength
If thicker material is used throughout the bumper beam, then strength and energy absorption are improved, but weight increases
Solution Approach 1:
The patent uses local quality by providing thicker material only in the first portion where structural strength and energy absorption are critical, while using thinner material in the second portion where pedestrian safety is the primary concern. This localized thickness variation reduces overall weight while maintaining necessary strength.
Solution Approach 2:
The unitary construction allows optimized material distribution throughout the beam, placing material only where structurally necessary. This eliminates the need for uniform thick material throughout, reducing weight while maintaining energy absorption capacity in critical zones.
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 method results in a lightweight, robust bumper beam assembly with reduced risk of cracks and improved crash resistance by minimizing heat-affected zones and seam vulnerabilities.
Implementation Method 1
A blank to be hot formed may be heated to a predetermined temperature e.g. austenization temperature or higher (and particularly between Ac3 and an evaporation temperature of e.g. a coating of the blank). By heating the blank, the strength of the blank is decreased and deformability increases
Implementation Method 2
The blank may be made e.g. of a boron steel, coated or uncoated, such as Usibor® (22MnB5). In a HFDQ process, a blank to be hot formed may be heated to a predetermined temperature e.g. austenization temperature or higher (and particularly between Ac3 and an evaporation temperature)
Data Source
AI summary
The present disclosure relates to methods for manufacturing a unitary a bumper beam assembly of a vehicle. The method comprises providing a plurality of blanks, joining the blanks to each other to form a combined blank, and deforming the combined blank to form the unitary bumper beam assembly. The unitary bumper beam assembly includes a bumper beam, a pedestrian beam and at least one bracket connecting the bumper beam to the pedestrian beam. The plurality of blanks comprises a bumper beam blank and a pedestrian beam blank, and joining the blanks comprises forming one or more overlapping regions formed by partially overlapping the blanks with each other. The present disclosure further relates to unitary bumper beam assemblies obtainable by such methods.