Bumper system

• US 8,276,954 B2
• Filed: 03/08/2010
• Issued: 10/02/2012
• Est. Priority Date: 03/18/2009
• Status: Active Grant

• Current Assignee: Benteler Automobiltechnik GmbH (Benteler International AG)
• Original Assignee: Benteler Automobiltechnik GmbH (Benteler International AG)
• Inventors: Handing, Christian, Wibbeke, Michael
• Primary Examiner(s): Dayoan, Glenn
• Assistant Examiner(s): Blankenship, Gregory
• Application Number:
  US12/719,087
• Publication Number:
  US 20100237639A1
• Time in Patent Office: 939 Days
• Field of Search: 293/102, 293/132, 293/133, 293/155, 296/203.01, 296/29, 296/30
• US Class Current: 293/133
• CPC Class Codes: B60R 19/03 characterised by material, e.g. composite B60R19/18 takes precedence
• CPC Class Codes: B60R 19/34 destroyed upon impact, e.g. one-shot type
• CPC Class Codes: B60R 2019/182 of light metal, e.g. extruded
• CPC Class Codes: B60R 2019/1826 of high-tension steel
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/49986 Subsequent to metal working

Abstract

A bumper system for motor vehicles has a cross-member and two crush boxes. The cross-member is made from steel and the crush boxes are made from aluminum, or vice versa. The bumper member that is made from steel has a zinc coating on at least the joint area thereof. A braze weld fixedly connects the crush boxes to the cross-member along associated joints.

Claims

1. A bumper system for motor vehicles, comprising:

a cross-member having a joint area, and being constructed from one of a steel material and an aluminum material;

at least one crush box having inner and outer ends and a peripheral edge extending around the entire inner end and defining a joint area, and being constructed from the other one of said steel material and said aluminum material; and

wherein

said one of said cross-member and said crush box that is constructed from said steel material has a zinc coating on at least said joint area thereof; and

including

a braze weld extending around substantially the entire peripheral edge and fixedly connecting said joint area of said cross-member with said joint area of said crush box.

2. The bumper system as set forth in claim 1, wherein:

said zinc coating has a thickness in the range of 5 μ

m to 50 μ

m.

3. The bumper system as set forth in claim 1, wherein:

said one of said cross-member and said crush box that is constructed from said steel material has a thickness in the range of 1 mm to 3 mm; and

said one of said cross-member and said crush box that is constructed from said aluminum material has a thickness in the range of 1 mm to 4 mm.

4. The bumper system as set forth in claim 1, wherein:

said cross-member is constructed from said steel material having a tensile strength Rm in the range of 800 MPa to 1,800 MPa; and

said crush box is constructed from said aluminum material having a tensile strength in the range of 85 MPa to 350 MPa.

5. The bumper system as set forth in claim 1, wherein:

said zinc coating comprises either a thermal diffusion layer or a powder coating.

6. The bumper system as set forth in claim 1, including:

mounting plates constructed from said other one of said steel material and said aluminum material connected with an end of said crush box facing away from said cross-member by a material bond.

7. A bumper system for motor vehicles, comprising:

a cross-member having an elongated rear surface, the rear surface defining a joint area that faces generally rearwardly, and wherein the cross-member is constructed from one of a steel material and an aluminum material;

at least one crush box having an outer edge and an outer surface immediately adjacent the outer edge facing transversely relative to the rear surface of the cross-member, the outer surface defining a joint area, and wherein said crush box is constructed from the other one of said steel material and said aluminum material; and

wherein

said one of said cross-member and said crush box that is constructed from said steel material has a zinc coating on at least said joint area thereof; and

including

a braze weld fixedly connecting said joint area of said cross-member with said transversely facing joint area of said outer surface of said crush box.

8. The bumper system as set forth in claim 7 wherein:

said outer edge of the crush box forms a portion of the joint area and includes a vertically-extending portion, and a portion extending transverse relative to said vertically-extending portion.

9. The bumper system as set forth in claim 8 wherein:

said vertically-extending portion is substantially linear.

10. The bumper system as set forth as claim 7, wherein:

the outer surface is substantially planar.

11. A bumper system for motor vehicles, comprising:

a cross-member having a non-planar joint area, and being constructed from one of a steel material and an aluminum material;

at least one crush box having an edge defining a non-planar joint area having a shape that closely corresponds to said non-planar joint area of the cross-member, and being constructed from the other one of said steel material and said aluminum material; and

wherein

said one of said cross-member and said crush box that is constructed from said steel material has a zinc coating on at least said joint area thereof; and

including

a braze weld fixedly connecting said non-planar joint area of said cross-member with said non-planar joint area of said crush box.

12. The bumper system as set forth in claim 11, wherein:

said crush box defines a peripheral outer surface, and said braze weld extends around substantially the entire peripheral outer surface.

13. The bumper system as set forth in claim 11, wherein:

said cross-member has a generally curved shape in plan view and an upright elongated generally convex rear surface having end portions that extend outwardly and rearwardly adjacent said joint areas.