STRUCTURAL ANALYSIS AND DESIGN OF CARBON FIBER REINFORCED POLYETHERIMIDE AND GLASS EPOXY BUMPER FOR AUTOMOTIVE SAFETY

Abstract

A car bumper assembly incorporating carbon fiber reinforced polyetherimide (CFRPEI) and S-glass epoxy composites to enhance impact absorption and energy dissipation. The assembly is constructed using a multi-layered configuration that optimizes impact resistance while maintaining a lightweight profile. The method of manufacturing includes preparing CFRPEI and S-glass epoxy sheets, bonding them through a controlled curing process, and shaping the assembly for vehicle integration. This bumper design offers increased durability and fuel efficiency while meeting stringent safety standards.

Specification

Description:2. FIELD OF THE INVENTION:
The present invention relates to impact-resistant car bumper assemblies. More particularly, it concerns a novel car bumper design incorporating carbon fiber reinforced polyetherimide (CFRPEI) and S-glass epoxy composites, aimed at enhancing impact absorption and structural integrity under collision conditions. ________________________________________
3. BACKGROUND OF THE INVENTION:
Traditional automotive bumpers often utilize steel, aluminum, or unreinforced plastic materials, which may not provide optimal impact absorption and durability, especially under high-energy collisions. Modern advancements in material science have introduced reinforced composite materials such as carbon fiber-reinforced polymers, which provide enhanced strength-to-weight ratios, stiffness, and impact resistance.

Carbon fiber reinforced polyetherimide and S-glass epoxy composites present promising characteristics for automotive applications. However, current designs have not adequately incorporated these materials in a way that optimizes both impact resistance and lightweight properties essential for fuel efficiency. This invention seeks to address these limitations by providing a composite-based bumper assembly with improved impact absorption properties and weight efficiency. ________________________________________
4. OBJECTIVES OF THE INVENTION:
1. To provide a car bumper with improved impact absorption and energy dissipation properties.
2. To reduce the weight of the bumper assembly, enhancing vehicle fuel efficiency.
3. To provide a cost-effective solution using carbon fiber reinforced polyetherimide and S-glass epoxy composites.
4. To offer a car bumper with higher durability, reducing maintenance and replacement costs. ________________________________________
5. SUMMARY OF THE INVENTION:
The invention provides a car bumper assembly designed for enhanced impact resistance using carbon fiber reinforced polyetherimide (CFRPEI) and S-glass epoxy composites. This bumper assembly is specifically engineered to absorb energy more effectively in collisions while maintaining a lightweight structure that enhances vehicle efficiency. The bumper is structured with layers of CFRPEI and S-glass epoxy strategically arranged to distribute and absorb impact forces effectively. ________________________________________

6. DETAILED DESCRIPTION OF THE INVENTION:
The car bumper assembly described herein is made by integrating multiple layers of carbon fiber reinforced polyetherimide (CFRPEI) and S-glass epoxy to achieve an optimal balance between strength and weight. The CFRPEI layer provides primary structural integrity, offering high tensile strength and rigidity, while the S-glass epoxy layer enhances impact absorption. The bumper structure is strategically layered to maximize energy dissipation across the composite layers, minimizing deformation and damage upon impact.

Material Composition: The CFRPEI used in the bumper assembly is a high-strength composite with specific mechanical properties such as tensile strength, flexural modulus, and fracture toughness tailored for high-impact applications. S-glass epoxy, a type of fiberglass, is selected for its high impact resistance and lightweight characteristics.

Layering and Assembly: The bumper is constructed in a sandwich-style arrangement where multiple layers of CFRPEI and S-glass epoxy are bonded together. The thickness and arrangement of layers are determined based on finite element analysis (FEA) to ensure optimal performance under crash test conditions.

Impact Performance: The bumper assembly undergoes impact testing simulating real-world collision scenarios. Results demonstrate that the multi-layered composite structure efficiently absorbs and redistributes impact forces, reducing the risk of failure or major deformation.

Manufacturing Process: The manufacturing process includes a series of steps starting with preparing CFRPEI and S-glass epoxy sheets, followed by a curing process under controlled temperature and pressure to achieve a durable bond. The resulting assembly undergoes machining for precise fitment to different car models.
, Claims:1. A car bumper assembly comprising multiple layers of carbon fiber reinforced polyetherimide (CFRPEI) and S-glass epoxy composite material, wherein the layered configuration provides enhanced impact absorption and energy dissipation.

2. The car bumper assembly as claimed in Claim 1, wherein the CFRPEI layer provides structural rigidity and strength, while the S-glass epoxy layer enhances energy absorption and impact resistance.

3. The car bumper assembly as claimed in Claims 1 and 2, wherein the assembly has a sandwich-style configuration with alternating layers of CFRPEI and S-glass epoxy.

4. The car bumper assembly as claimed in Claim 1, further comprising a method of manufacturing that includes preparing CFRPEI and S-glass epoxy sheets, bonding them through curing, and shaping the assembly for specific vehicle models.

5. A method of improving impact resistance in car bumpers, comprising the steps of:

a. Layering CFRPEI and S-glass epoxy sheets;
b. Bonding the layers under controlled curing conditions;
c. Assembling the bonded structure to form a lightweight and impact-resistant car bumper.

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