Wave-Structured Bumper Crossbeam for Bending and Torsional Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bumper crossbeams in vehicles face challenges in withstanding torsional loads and maintaining structural integrity during crashes, particularly in high-speed collisions, while also requiring weight and cost optimization, and efficient force transmission to connected longitudinal members.
Innovation Solution
A bumper crossbeam design featuring a wave structure oriented in the vertical direction with inverted vertex structures in transition sections, additional vertex-forming structures, and a higher number of vertex structures in transition areas to enhance bending and torsional strength, allowing for efficient force absorption and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional U-shaped profile with strike plate is used to stiffen the bumper crossbeam, then bending strength is improved, but device complexity and weight increase
Solution Approach 1:
The patent integrates the strike plate function and stiffening structure into a single U-shaped carrier profile component. The carrier profile itself provides the stiffening effect through its geometry, eliminating the need for separate strike plates while maintaining structural integrity and reducing overall component count.
Solution Approach 2:
The U-shaped carrier profile acts as a thin-walled stiffening structure that provides significant bending strength through its geometric configuration. The profile's shape creates structural rigidity without requiring thick walls or additional components, achieving strength-to-weight optimization.
2Strength
If additional beads are introduced into the U-shaped carrier profile to stiffen the bumper crossbeam, then bending strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs beads with specific curvature radii (R1 and R2) that are at least 5 mm to create smooth transitions and stress distribution. These curved features provide stiffening effect while maintaining manufacturability through standard forming processes, avoiding sharp corners that would complicate manufacturing.
3Device complexity
If a one-piece design without strike plate is used, then weight and complexity are reduced, but torsional strength and connection robustness deteriorate
Solution Approach 1:
The patent applies local stiffening features (beads with specific curvature radii) at critical locations along the U-shaped carrier profile. These localized geometric modifications provide enhanced torsional strength and connection robustness only where needed, without requiring additional components throughout the entire structure.
4Force
If the connection area is designed for high-speed crash loads, then force transmission is improved, but the risk of kinking and tearing increases
Solution Approach 1:
The patent incorporates beads with specific curvature radii (R1 ≥ 5 mm, R2 ≥ 5 mm) in advance of potential stress concentration points. These pre-designed geometric features cushion and distribute high crash loads smoothly, preventing kinking and tearing at the connection area between the bumper crossbeam and longitudinal members during high-speed collisions.
Data Source
AI summary
A bumper crossmember comprising a wave structure oriented in the vertical direction (z direction), wherein the wave structure comprises at least three apex structures which extend in the bumper crossmember longitudinal direction and are adjacent in the vertical direction. This crossmember comprises a first length section that follows its longitudinal extent, at least one second length section that follows its longitudinal extent, and at least one transition section that is arranged respectively between these length sections. In the second length section, the wave structure is inverted with respect to the first length section, in that the opening direction of the apex structures switches in the transition section. In the transition section, there is at least one additional apex-forming structure, the apex of which is offset in the frontal direction (x direction) with respect to a frontal plane (yz-plane) in which at least two apex structures that are adjacent in the longitudinal sections lie.