Bumper Assembly And Method

• US 20130001964A1
• Filed: 06/20/2012
• Published: 01/03/2013
• Est. Priority Date: 06/29/2011
• Status: Active Grant

• Current Assignee: Magna International Incorporated
• Original Assignee: Magna International Incorporated
• Inventors: Mellis, Jeffery Jay, Freundl, Thomas James
• Granted Patent: US 8,919,834 B2
• Time in Patent Office: Days
• US Class Current: 293/133
• CPC Class Codes: B60R 19/18 characterised by the cross-section; Means within the bumper to absorb impact
• CPC Class Codes: B60R 19/34 destroyed upon impact, e.g. one-shot type
• CPC Class Codes: B60R 2019/1813 made of metal
• CPC Class Codes: Y10T 29/4978 Assisting assembly or disassembly

Abstract

A bumper assembly includes a bumper beam having a bumper beam surface extending along a bumper plane X and a crash box including a crash box surface extending along a crash box plane Y. One of the bumper beam and the crash box includes an alignment joint to mate the bumper beam and the crash box and dispose the surfaces in abutting and aligned relationship relative to one another for establishing a linear load path extending linearly along the planes X, Y. A method of assembling a bumper assembly includes the steps of mating the bumper beam and the crash box about the alignment joint and connecting the bumper beam and the crash box together along the alignment joint. The step of connecting the bumper beam and the crash box includes friction stir welding the bumper box and the crash box together along the alignment joint.

Claims

1. A bumper assembly comprising:

a bumper beam including a bumper beam surface extending along a bumper plane X;

a crash box including a crash box surface extending along a crash box plane Y; and

one of said bumper beam and said crash box including an alignment joint to mate said bumper beam and said crash box and dispose said surfaces in abutting and aligned relationship relative to one another for establishing a linear load path extending linearly along said planes X, Y.

2. A bumper assembly as set forth in claim 1 wherein said alignment joint defines an alignment surface for engaging said other of said bumper beam and said crash box to establish said aligned relationship of said surfaces.

3. A bumper assembly as set forth in claim 2 wherein said alignment joint includes a flange extending from one of said surfaces to a flange end to define said alignment surface extending in parallel relationship to said planes X, Y for overlapping said other of said surfaces in said mated position of said bumper beam and said crash box.

4. A bumper assembly as set forth in claim 2 wherein said bumper beam includes said flange.

5. A bumper assembly as set forth in claim 3 further comprising a connector disposed adjacent said flange end and extending through said flange and penetrating said other of said surfaces to secure said bumper box and said crash box in said mated position.

6. A bumper assembly as set forth in claim 5 wherein said connector includes a frictional stir welding joint.

7. A bumper assembly as set forth in claim 2 wherein said other of said crash box and said bumper beam defines an internal surface and said alignment joint includes a shoulder extending inwardly from one of said surfaces to define the alignment surface extending in parallel relationship to said planes X, Y for underlaying said internal surface in said mated position of said bumper beam and said crash box.

8. A bumper assembly as set forth in claim 7 wherein said bumper beam includes said shoulder.

9. A bumper assembly as set forth in claim 7 further comprising:

said shoulder defining a seam extending along said abutting and aligned surfaces; and

a connector disposed along said seam and penetrating each of said surfaces to secure said bumper beam and said crash box in said mated position.

10. A bumper assembly as set forth in claim 9 wherein said connector includes a frictional stir welding joint.

11. A bumper assembly comprising:

a bumper beam including a top bumper beam surface extending along a bumper beam plane X and a bottom bumper beam surface extending in parallel and equidistant relationship to said top bumper beam surface along a second bumper beam plane X₂;

a crash box including a top crash box surface extending along a crash box plane Y and a bottom crash box surface extending in parallel and equidistant relationship to said top crash box surface along a second crash box plane Y₂; and

one of said bumper beam and said crash box including a plurality of alignment joints to mate said bumper beam and said crash box and dispose said top surfaces and said bottom surfaces in abutting and aligned relationship relative to one another for establishing linear load paths extending linearly along said respective planes X, Y and X₂, Y₂.

12. A bumper assembly as set forth in claim 11 wherein each of said alignment joints includes an alignment surface for engaging said other of said bumper beam and said crash box to establish said aligned relationship of said surfaces.

13. A bumper assembly as set forth in claim 12 wherein each of said alignment joints includes a flange extending from said surfaces of one of said bumper beam and said crash box to flange ends to define the alignment surfaces extending in parallel relationship to said planes X, Y and X₂, Y₂ for overlaying said other of said surfaces in said mated position of said bumper beam and said crash box.

14. A bumper assembly as set forth in claim 12 wherein said other of said crash box and said bumper beam defines a plurality of internal surfaces and each of said alignment joints includes a shoulder extending inwardly from one of said surfaces to define the alignment surface extending in parallel relationship to said planes X, Y and X₂, Y₂ for underlaying said internal surfaces in said mated position of said bumper beam and said crash box.

15. A bumper assembly as set forth in claim 11 further comprising a frictional stir welding joint extending along each of said alignment joints to secure said bumper box and said crash box in said mated position.

16. A method of assembling a bumper assembly including a bumper beam having a bumper beam surface extending along a bumper plane X and a crash box having a crash box surface extending along a crash box plane Y comprising the steps of:

mating the bumper beam and the crash box about an alignment joint disposed on one of the bumper beam and the crash box to dispose the surfaces in abutting and aligned relationship relative to one another along the planes X, Y; and

connecting the bumper box and the crash box together adjacent the alignment joint.

17. A method as set forth in claim 16 wherein said step of connecting includes frictional stir welding the bumper beam and the crash box together along the alignment joint.

18. A method as set forth in claim 16 wherein said step of mating the bumper beam and the crash box includes underlaying an alignment surface of the alignment joint under an internal surface of the other of the bumper beam and the crash box.

19. A method as set forth in claim 16 wherein said step of mating the bumper beam and the crash box includes overlaying an alignment surface of the alignment joint over the surface of the other of the bumper beam and the crash box.