] The present disclosure, in general, relates to automobile front bumper assembly and specifically relates to an energy absorber connected to a lower end of a front member provided on both the sides of the vehicle.
BACKGROUND
[0002] Automotive industry has always been known to be very competitive as far as its design and material usage are concerned. The automotive industry is always facing market pressure to develop high quality products more quickly at lower cost, and with reduced weight in order to improve fuel efficiency and cost.
[0003] In addition, a pedestrian protection has been a key focus of worldwide safety agencies and legislation for many years. Hence, the automotive industry is also taking this thing into consideration while designing the vehicle. Many of the structures in and around the engine compartment and front end of the vehicle are designed to maximize pedestrian protection in high speed impacts. While these agencies have been historically focused on pedestrian protection, they were also aware that there was a high fatality rate associated with or as a result of pedestrians being struck by motor vehicles. Such agencies have identified the need to reduce the number of fatalities and serious injuries to pedestrians without compromising occupant protection at a reasonable cost to the OEMs and ultimately the consumer.
[0004] New legislations—both enacted and proposed—require that the front end of motor vehicles in some markets be less rigid, so the severity of injuries sustained by pedestrians when struck by motor vehicles is minimal. Such legislations set forth the devices, test conditions, and performance criteria for protecting both the leg and the head of the pedestrian. Areas requiring this protection include a bumper system, a front grille, a cowl, lenses, a hood, fenders, wipers, pillars and other rigid structures behind these components which may pose a significant injury risk to a pedestrian in the event of an impact.
[0005] Said protection requirement had an effect on the design of energy absorbing systems—requiring new concessions and compromises in styling,
9

mass, aerodynamics, offsets, gaps, stiffness, system packaging, and other safety requirements. Conforming systems must work in concert to meet or exceed key criteria and obtain the legislated safety performance. The challenge lies in developing solutions which are highly efficient, easy to tune, low cost, lightweight, and occupy the smallest footprint and volume.
[0006] Some pedestrian requirement involves a relatively compliant exterior surface ("skin") that crushes in such a way that the forces experienced by the leg or the head of the pedestrian can be reduced. In addition, there is also a need to design the bumper assembly such that it reduces the chances of physical damage to the hood, trunk, grill, fuel, exhaust and cooling system as well as safety related equipment such as parking lights, headlamps, taillights, etc.
[0007] In order to overcome all the above-mentioned problems, there is need
to provide energy absorbers between the impacted object and the rigid structural member to act as energy absorbing countermeasures, as the structure of the current components and systems cannot be easily re-engineered to meet the criteria. It may also increase the production and the assembling cost as well as the production and the assembling time.
[0008] Generally, polyurethane and expanded polypropylene foam have been used in energy absorbing applications in vehicles. While these materials are easily moulded to the shape and contour of the energy absorbing volume, they are relatively inefficient, and costly. They also have a tendency to split or cleave when impacted against a weld flange or narrow reaction surface. In addition, their dimensional stability though the paint cycle may also be sub-optimal. Additionally, collapsible brackets are also used as energy absorbing means in vehicle. However, they are rigid and heavy in few scenarios based on the application areas in the vehicle.
[0009] Hence, this drives the need for high efficiency energy absorbers that can absorb the desired amount of energy in the shortest distance, with the lowest mass, and lowest assembly cost as the modification can only be expected in the energy absorber section.
[0010] In other words, there is need to design a bumper energy absorber which can well consider the requirements of pedestrian safety with evidently different

impact energy levels. Moreover, it is also important to determine the most appropriate design concept and material for the automotive bumper beam absorber at the early stage of product development process in order to reduce cost.
[0011] Hence, the present disclosure aims to design an energy-absorbing structure of the bumper system with composite materials i.e. by combining engineering resin and metallic reinforcement which can adaptively adopt different deformation modes according to the amount of impact energy to benefit the pedestrian.
OBJECTS OF THE DISCLOSURE
[0012] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0013] It is a general or primary object of the present disclosure to provide an energy absorber which is light in weight, compact, cost-effective and also comply with pedestrian protection regulation.
[0014] It is another object of present disclosure to provide the energy absorber that gives a better comprehensive performance by effectively controlling the force level and energy-absorbing rate.
[0015] It is further object of present disclosure to provide the energy absorber which can adaptively adopt different deformation modes according to the amount of impact energy to benefit the pedestrian.
[0016] It is yet another object of the present disclosure to provide the energy absorber that can easily be attached or detached with the front member of the vehicle.
[0017] It is another object of the present disclosure to provide the energy absorber having simplified structure, and easy to manufacture.
[0018] It is yet another object of the present disclosure to provide the energy absorber that retains its ability to absorb energy in varying ambient heat conditions.
[0019] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY
[0020] This summary is provided to introduce concepts related to an energy absorber connected to a lower end of a front member provided on both the sides of a vehicle. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0021] In accordance with an embodiment, the present disclosure provides a front side energy absorber of a vehicle, comprising a metallic reinforcement bracket extending in a lateral direction of the vehicle and, from one end, connected to a lower end of a front member of the vehicle; and a composite material structure extending in the lateral direction of the vehicle and, from one end, connected to the lower end of the front member of the vehicle, wherein a part of the composite material structure is supported on the metallic reinforcement bracket.
[0022] In accordance with an aspect, the present disclosure provides the metallic reinforcement bracket that includes a horizontal surface extending in the lateral direction of the vehicle and a mounting arm connected to the lower end of the front member of the vehicle.
[0023] In accordance with an aspect, the mounting arm of the metallic reinforcement bracket includes mounting holes corresponding to threaded holes formed on the lower end of the front member, for establishing a positive connection through fasteners.
[0024] In accordance with an aspect, the composite material structure includes a horizontal surface extending in the lateral direction of the vehicle and a mounting arm connected to the lower end of the front member of the vehicle.
[0025] In accordance with an aspect, the horizontal surface of the composite material structure is 3-4 times longer than a horizontal surface of the metallic reinforcement bracket.

[0026] In accordance with an aspect, a part, in the vicinity of the front member, of the horizontal surface of the composite material structure is fastened on the horizontal surface of the metallic reinforcement bracket.
[0027] In accordance with an aspect, the composite material structure includes a plurality of reinforcing ribs extending in a longitudinal direction and transverse direction of the composite material structure.
[0028] In accordance with an aspect, the composite material structure is formed from an engineering resin.
[0029] In accordance with an aspect, the composite material structure is formed from one or more materials selected from one of polyethylene, polypropylene, polycarbonate, polyoxymethylene, polybutylene terephthalate, or polyamide.
[0030] In accordance with an aspect, the composite material structure is formed as a plastic matrix to incorporate metallic elements.
[0031] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0032] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF FIGURES
[0033] The illustrated embodiments of the present disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein:

[0034] FIG.1 illustrates an automotive front bumper assembly in accordance with the present disclosure and the enlarged view of the same;
[0035] FIG. 2A illustrates a top view of an energy absorber in accordance with the present disclosure;
[0036] FIGS. 2B, 2C, and 2D illustrate various views of the energy absorber in accordance with the present disclosure;
[0037] FIG. 2E illustrates a side view of the energy absorber in accordance with the present disclosure;
[0038] FIG. 3A illustrates a connection between the energy absorber and the lower end of the front cross-member in accordance with the present disclosure; and
[0039] FIG.3B illustrates a connection between the composite material structure and a metallic reinforcement bracket of the energy absorber in accordance with the present disclosure.
[0040] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0041] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
DEFINITIONS
[0042] In the disclosure hereinafter, one or more terms are used to describe various aspects of the present disclosure. For a better understanding of the present

disclosure, a few definitions are provided herein for better understating of the present disclosure.
[0043] Composite material - A composite material (also called a composition material or shortened to composite, which is the common name) is a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or physical properties and are merged to create a material with properties unlike the individual elements.
[0044] In the present disclosure, the composite material used are the engineering resin, polyethylene, polypropylene, polycarbonate, polyoxymethylene, polybutylene terephthalate, or polyamide.
[0045] Nowadays, the thermoplastic matrix polymer composites have gained commercial success in the semi structural and structural applications. Polyethylene (PE) is one of the most versatile and widely used thermoplastics in the world because of its excellent properties like toughness, near-zero moisture absorption, excellent chemical inertness, low coefficient of friction, ease of processing and unusual electrical properties.
EXEMPLARY IMPLEMENTATIONS
[0046] While the present disclosure may be embodied in various forms, there are shown in the drawings, and will hereinafter be described, some exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the disclosure and is not intended to limit the disclosure to the specific embodiments illustrated. Not all of the depicted components described in this disclosure may be required, however, and some implementations may include additional, different, or fewer components from those expressly described in this disclosure. Variations in the arrangement and type of the components may be made without departing from the scope of the claims as set forth herein.
[0047] FIG. 1 illustrates an automotive front bumper assembly 100 in accordance with the present disclosure and the enlarged view of the same.

[0048] The front bumper assembly 100 consists of four basic components namely a bumper fascia 102, an energy absorber 200, a bumper beam 106 and bumper stay or mounting brackets (not shown).
[0049] The bumper beam 106 is a main structural component of the automotive bumper assembly 100 which is attached at the middle of the front members 104 provided on both the sides of the vehicle through bumper stay or mounting brackets. The energy absorber 200 is placed in between the bumper beam and the bumper skin or bumper fascia 102 to absorb impact energy. The energy absorber 200 are attached to the lower end of the front member 104 provided on both sides of the vehicle.
[0050] FIG. 2A-2E illustrate various views of the energy absorber in accordance with the present disclosure.
[0051] The energy absorber 200 as per the present disclosure consists of a composite material structure 202 extending in the lateral direction of the vehicle and, from one end, connected to the lower end of the front member 104 of the vehicle. The composite material structure 202 includes a horizontal surface extending in the lateral direction of the vehicle. The horizontal surface of the composite material structure 202 includes a plurality of reinforcing ribs 210 extending in a longitudinal direction of the composite material structure 202.
[0052] The composite material structure is either formed from an engineering resin or from one or more materials selected from one of polyethylene, polypropylene, polycarbonate, polyoxymethylene, polybutylene terephthalate, or polyamide. In addition, the composite material structure is formed as a plastic matrix to incorporate metallic elements.
[0053] The energy absorber 200 further consists of a metallic reinforcement bracket 204 extending in a lateral direction of the vehicle and, from one end, connected to a lower end of a front member 104 of the vehicle, wherein a part of the composite material structure 202 is supported over the metallic reinforcement bracket 204. Moreover, a part, that is in the vicinity of the front member, of the horizontal surface of the composite material structure 202 is fastened on the horizontal surface of the metallic reinforcement bracket 204 through fasteners such as nuts and bolts.

[0054] In addition, the horizontal surface of the composite material structure 202 is 3-4 times longer than a horizontal surface of the metallic reinforcement bracket 204.
[0055] The composite material structure 202 further includes a mounting arm 206 that helps in building up the connection with the lower end of the front member 104 of the vehicle as shown in FIG. 3A. The mounting arm 206 of the composite material structure 202 includes multiple mounting holes corresponding to threaded holes formed on the lower end of the front member, for establishing a positive connection through fasteners.
[0056] Further, the metallic reinforcement bracket 204 also comprises a mounting arm 208 that is also used for building up the connection with the lower end of the front member 104 of the vehicle as shown in FIG. 3B. Here also, the mounting arm 208 of the metallic reinforcement bracket 204 includes multiple mounting holes corresponding to threaded holes formed on the lower end of the front member, for establishing a positive connection through fasteners. The front bumper facia 102 (lower side) is connected with the energy absorber 200 through the composite material 202 using positive mounting i.e. using nut and bolt connection.
[0057] Through the above-mentioned procedure, the composite material structure 202 placed above the metallic reinforcement bracket 204 and in combination called as an energy absorber 200. This energy absorber 200 are further connected to the lower end of the front member 104 provided on both sides of the vehicle through mounting arms 206, 208 of the composite material structure 202 and the metallic reinforcement bracket 204.
WORKING OF THE DISCLOSURE
[0058] When a pedestrian is hit by an impacting object, such as an automotive vehicle, the technical configuration and the material of the proposed energy absorber restricts the bumper movement by effectively controlling the force level

and energy-absorbing rate. In this manner, the impact on the pedestrian leg is restricted and also the chances of distortion of the bumper is reduced to the great extent.
ADVANTAGES
[0059] The proposed energy absorber is light in weight, compact, cost-effective and also comply with pedestrian protection regulation. It gives a better comprehensive performance by effectively controlling the force level and energy-absorbing rate. It can easily adapt with the different deformation modes according to the amount of impact energy to benefit the pedestrian. It can easily be attached or detached with the front member of the vehicle. It is also simplified in structure, and easily manufactured as per requirements. It also retains its ability to absorb energy in varying ambient heat conditions.
EQUIVALENTS
[0060] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0061] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0062] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and

substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0063] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

We claim:

1. A front side energy absorber (200) of a vehicle, comprising:
a metallic reinforcement bracket (204) extending in a lateral direction of the vehicle and, from one end, connected to a lower end of a front member (104) of the vehicle; and
a composite material structure (202) extending in the lateral direction of the vehicle and, from one end, connected to the lower end of the front member (104) of the vehicle, wherein a part of the composite material structure (202) is supported on the metallic reinforcement bracket (204).
2. The front side energy absorber (200) as claimed in claim 1, wherein the metallic reinforcement bracket (202) includes a horizontal surface extending in the lateral direction of the vehicle and a mounting arm (208) connected to the lower end of the front member (104) of the vehicle.
3. The front side energy absorber (200) as claimed in claim 2, wherein the mounting arm (208) of the metallic reinforcement bracket (204) includes mounting holes corresponding to threaded holes formed on the lower end of the front member (104), for establishing a positive connection through fasteners.
4. The front side energy absorber (200) as claimed in claim 1, wherein the composite material structure (202) includes a horizontal surface extending in the lateral direction of the vehicle and a mounting arm (206) connected to the lower end of the front member (104) of the vehicle.
5. The front side energy absorber (200) as claimed in claim 4, wherein the horizontal surface of the composite material structure (202) is 3-4 times longer than a horizontal surface of the metallic reinforcement bracket (204).
6. The front side energy absorber (200) as claimed in claim 5, wherein a part, in the vicinity of the front member (104), of the horizontal surface of the composite material structure (202) is fastened on the horizontal surface of the metallic reinforcement bracket (204).

7. The front side energy absorber (200) as claimed in claim 1, wherein the composite material structure (202) includes a plurality of reinforcing ribs (210) extending in a longitudinal direction and transverse direction of the composite material structure (202).
8. The front side energy absorber (200) as claimed in claim 1, wherein the composite material structure (202) is formed from an engineering resin.
9. The front side energy absorber (200) as claimed in claim 1, wherein the composite material structure (202) is formed from one or more materials selected from one of polyethylene, polypropylene, polycarbonate, polyoxymethylene, polybutylene terephthalate, or polyamide.
10. The front side energy absorber (200) as claimed in claim 1, wherein the composite material structure (202) is formed as a plastic matrix to incorporate metallic elements.