SISTEMA E MÉTODO PARA ABSORVER ENERGIA

Abstract

The present invention relates to a system comprising: - a structural member of a vehicle and - a reinforcement member inserted into the structural member and comprising a hollow metal structure and a 3D-structure attached to the metal structure. The present invention further relates to a method to absorb energy, particularly impact energy.

Description

1 / 15 “SYSTEM AND METHOD FOR ABSORBING ENERGY”

[001] The present invention relates to a system comprising: - a structural element of a vehicle and -a reinforcing element inserted into the structural element, comprising a hollow metal structure and a three-dimensional structure coupled to the metal structure.

[002] The present invention also relates to a method for absorbing energy, particularly impact energy.

[003] Electric vehicles comprise a battery, which requires special protection against collisions.

[004] There is a constant need in industry, particularly in the automotive industry, to provide a system and method that absorbs energy, particularly impact energy, and that is capable of withstanding impact forces to protect passengers and certain elements of a vehicle, such as batteries.

[005] The problem is solved with a system comprising: - a structural element of a vehicle and - a reinforcing element inserted into the structural element and comprising a hollow metal structure and a three-dimensional structure fixed to the metal structure, wherein the hollow metal structure comprises at least one rib, each rib having a foldable section.

[006] Disclosure regarding this subject matter also applies to other subjects and vice versa. The information disclosed in relation to this embodiment of the invention may also be included in other embodiments and vice versa. Petition 870250084739, dated 09 / 19 / 2025, p. 15 / 76 2 / 15

[007] The present invention relates to a system comprising a structural element of a vehicle, for example, a rocker arm. The structural element is preferably an elongated element comprising a hollow cavity and having a longitudinal axis. Preferably, the structural element consists of two parts, for example, two shells, each preferably comprising flanges that preferably extend along the longitudinal axis. The parts are connected, preferably welded, more preferably along their flanges. The structural element is preferably made of metal, preferably sheet metal. The metal is preferably aluminum or steel. Preferably, a battery compartment is coupled to the structural element. The battery compartment is preferably protected by the vehicle's structural element.

[008] The system further comprises a reinforcing element that is inserted into the structural element. This reinforcing element comprises a hollow metal structure and a three-dimensional structure coupled to the hollow metal structure, preferably around its circumference, preferably around a portion of its circumference. The fixing can be done by means of adhesive and / or by form fitting and / or by interference (force fitting). The reinforcing element may include fastening means to fix it to the structural element.

[009] The three-dimensional structure, which preferably absorbs energy, particularly impact energy, is preferably composed of a polymeric material, more preferably nylon and / or polyamide, preferably polyamide and / or a metallic material, for example aluminum or steel. According to a preferred embodiment, the three-dimensional structure is composed of a composite material, preferably comprising multiple polymeric materials and / or a combination of one or more plastic materials with one or more metallic materials. The three-dimensional structure may Petition 870250084739, dated 09 / 19 / 2025, page 16 / 76 3 / 15 comprising at least a first layer. However, the element may comprise more than one layer, particularly two, three, four, six, or eight layers. An even or odd number of layers is preferred. More preferably, two layers of the three-dimensional structure, whose three-dimensional elements are fitted together, more preferably stacked, form an assembled unit, which is fixed to the hollow metal frame. Preferably, each layer of the three-dimensional structure comprises a multiplicity of three-dimensional elements, with the three-dimensional elements of two layers being fitted together in a stacking fashion. Preferably, the three-dimensional elements comprise an edge or flange. Two layers may be connected by the edge and / or by the flanges. One end of each three-dimensional element may be positioned in a plane, with the remainder of each three-dimensional element projecting outward from that plane.Three-dimensional elements are preferably hollow structures. Those skilled in the art understand that the plane does not need to be flat (in the geometric sense), and can be three-dimensional, for example, curved. [ 010] If the three-dimensional structure comprises more than one layer, for energy dissipation purposes; - The three-dimensional elements of the first layer are preferably inserted into the hollow three-dimensional elements of the second layer and / or vice versa and / or - The three-dimensional elements of the first layer are inserted into a hollow space formed between two or more three-dimensional elements of the second layer and / or vice versa.

[011] During impact, friction occurs preferentially between the three-dimensional elements of the two layers and / or elastic and / or plastic deformation and / or tangential stress in the three-dimensional elements, so that the energy is Petition 870250084739, dated 09 / 19 / 2025, page 17 / 76 4 / 15 dissipated. During plastic deformation, the cross-section of the three-dimensional elements and / or the openings of at least one layer are preferentially increased and / or reduced, reversibly and / or irreversibly, and / or the axial extension of the three-dimensional elements of one or both layers is reduced reversibly and / or irreversibly.

[012] Three-dimensional elements preferably have a circular, oval, and / or polygonal cross-section. The shape of the cross-section may vary along the axial extent of the three-dimensional elements. A layer may have three-dimensional elements with different cross-sections and / or different axial lengths. Preferably, the three-dimensional elements are tapered, with a larger cross-section, or the largest cross-section, located in the plane where the three-dimensional elements are interconnected. If the three-dimensional elements are tapered, the angle of inclination may be constant along the entire circumference or not. This angle of inclination may also vary along the axial length of the three-dimensional element. The side wall of one or more three-dimensional elements of a layer may include one or more steps.If the side wall is made of a laminated material, not all layers of the laminate need to include the aforementioned steps.

[013] Preferably, the shape and / or cross-sectional size of the three-dimensional elements, the axial extension, the length of the three-dimensional elements, the inclination of the side wall and / or the pattern in which they are distributed over the plane of two adjacent layers vary within the same layer or between two adjacent layers.

[014] Preferably, the three-dimensional elements of the layers each comprise a side wall, and the side wall of the three-dimensional elements of the first layer has, at least locally, Petition 870250084739, dated 09 / 19 / 2025, page 18 / 76 5 / 15 shape and / or dimension different from the side wall of the three-dimensional elements of the second layer.

[015] Each opening may have a circular, oval and / or polygonal cross-section.

[016] Preferably, at least one of the first or second layers comprises fastening means. By means of these fastening means, for example an adhesive layer, the layer can be connected to the structure of a vehicle and / or two or more layers can be interconnected by fastening means, preferably an adhesive layer.

[017] Two layers can also be connected to each other by means of fasteners before an impact or an energy absorption process. These fasteners can be, for example, an adhesive, such as an adhesive layer, a friction fastener, a conforming fastener and / or an interference fastener, for example a snap-fit ​​pressure fitting.

[018] Two layers, particularly the first and second layers, can be supplied as a single piece, preferably as a molded piece.

[019] According to another preferred embodiment of the present invention, the thickness of the side wall of the three-dimensional elements of at least one layer is not constant.

[020] According to the present invention, the system further comprises a hollow metal structure. The hollow metal structure is preferably a tube, preferably with a rectangular or square cross-section. The hollow metal structure can be an extruded piece or a piece made of bent sheet metal. Petition 870250084739, dated 09 / 19 / 2025, p. 19 / 76 6 / 15

[021] Preferably, the cross-section of the hollow metal structure is square or rectangular. Preferably, the shape of the cross-section of the hollow metal structure is adapted to the shape of the vehicle's structural element. Preferably, the hollow metal structure has two side walls, a first end and a second end. The side walls and the first and second ends preferably form the perimeter of a hollow metal structure with a rectangular cross-section. Preferably, the side walls are parallel to each other. The ends are also preferably parallel. Preferably, the ends connect the side walls, so as to form a rectangle or a square. The hollow metal structure preferably has a longitudinal axis, which extends parallel to the longitudinal axis of the vehicle's structural element.Preferably, one of the side walls is parallel to a wall of the vehicle's structural element and / or one side wall and / or one or both ends are adjacent to the vehicle's structural element. The ends are preferably parallel to the direction of impact against which protection is sought.

[022] According to the present invention, the hollow metal structure comprises at least one rib, and each rib has a bending section. Each rib preferably connects two side walls of the hollow metal structure. Preferably, each rib is parallel to at least one, and more preferably to both ends of the hollow metal structure. The ribs preferably extend along the longitudinal axis of the hollow metal structure. The bending section is preferably formed as an indentation, preferably a groove or channel, which preferably extends along the longitudinal axis of the hollow metal structure. The indentation preferably has a rounded cross-section, more preferably in the shape of an arc of a circle. Under impact load, the ribs begin to bend along the cross-section of Petition 870250084739, dated 09 / 19 / 2025, p. 20 / 76 7 / 15 bend. The bend section has the advantage of precisely defining the location where each rib begins to deform and the direction in which the rib bends. Through the ribs, it is possible to control how the reinforcing element and / or the vehicle's structural element deforms.

[023] Preferably, the bend section is located in the center of the rib extension, between the two side walls. However, if there is more than one rib, this location may be different.

[024] Each rib can be an extruded, folded, stamped or deep stamped piece.

[025] According to a preferred embodiment of the present invention, the hollow metal structure comprises two or more ribs, each preferably extending parallel to the longitudinal direction and / or parallel to each other and / or parallel to the ends of the hollow metal structure and / or perpendicular to the side walls and / or connecting the side walls.

[026] Preferably, the ribs are not distributed equidistantly along the height and / or in the z direction of the hollow metal structure. Preferably, the ribs are positioned at a height where it is desired to minimize the deformation of the vehicle's structural element.

[027] Preferably, the bending sections of the ribs have opposite bending directions, so that, during deformation, one rib bends in one direction while the other, preferably the adjacent rib, bends in the opposite direction. Preferably, two adjacent ribs bend in the same direction, while a third rib bends in the opposite direction. Petition 870250084739, dated 09 / 19 / 2025, p. 21 / 76 8 / 15

[028] In the case of two or more ribs, the ribs may be made of different materials and / or their thicknesses may vary. Alternatively or additionally, the design and / or orientation of the bend section may differ.

[029] In a preferred embodiment, the hollow metal structure has a first and a second end, and at least one of the ends comprises a bending section. Under impact load, the end will begin to bend along the bending section. A rib positioned adjacent to this end preferably has the same bending direction as the end with the bending section. Preferably, the system further comprises a battery compartment, intended to accommodate the batteries, particularly necessary for an electric or hybrid vehicle.

[030] According to a preferred embodiment of the present invention, the reinforcing element is located in the vehicle's structural element so that the three-dimensional structure faces the expected impact region. Preferably, the three-dimensional structure is oriented towards the outer periphery of the vehicle. The hollow metal structure is oriented more towards the center of the vehicle.

[031] Preferably, the hollow metal structure can be filled, at least partially, with a three-dimensional structure and / or a structural foam.

[032] The problem is also solved by a method for absorbing energy, particularly impact energy, using the system, in which the three-dimensional structure deforms before the hollow metal structure. Disclosure relating to this subject matter also applies to other subjects and vice versa. The matters disclosed relating to this embodiment of the invention may also be included in other embodiments and vice versa. Petition 870250084739, dated 09 / 19 / 2025, page 22 / 76 9 / 15

[033] The subject of the present invention relates to a method for absorbing energy, particularly impact energy that occurs during a collision in a motor vehicle, especially an electrically powered motor vehicle. The method in the present invention is particularly suitable for preventing or reducing damage to the battery compartment. The method in the present invention utilizes the system described above.

[034] According to the invention, while the hollow metal structure of the system is deforming by crushing, the three-dimensional structure deforms by crushing before the hollow metal structure. This embodiment of the present invention has the advantage that the deformation of the three-dimensional structure absorbs a significant amount of the impact energy without causing significant damage to the hollow metal structure.

[035] Preferably, the hollow metal structure bends while the three-dimensional composite structure deforms by crushing, more preferably around its longitudinal axis.

[036] Preferably, the hollow metal structure deforms asymmetrically with respect to its height or with respect to its z direction. Preferably, the deformation in the region of half the height is greater than in the vicinity of the ends.

[037] Preferably, in the region of the hollow metal structure and / or vehicle structural element where maximum protection is required, for example, the region where the battery compartment is located, the deformation of the hollow metal structure is less than in other regions. This applies to its longitudinal extent and / or its height extent.

[038] According to a preferred embodiment of the present invention, in the final stage of crushing the three-dimensional composite structure and / or shortly thereafter, the rib begins to bend. Petition 870250084739, dated 09 / 19 / 2025, p. 23 / 76 10 / 15

[039] If two or more ribs are provided, the ribs bend, at least partially, sequentially, differently and / or asymmetrically. Preferably, two ribs bend towards each other, so that the distance between the two bending sections is reduced. Preferably, one rib bends more than the other rib.

[040] Preferably, more than 40%, more preferably more than 50%, and preferably even more of the total impact energy is absorbed by the composite structure.

[041] Preferably, the maximum force in the system occurs after the onset of deformation of the hollow metal structure, particularly the ribs. During the deformation of the three-dimensional structure, the force in the system preferably increases to a peak and then is reduced to a plateau below that peak. During the deformation of the hollow metal structure, a peak load preferably occurs, which is then reduced to a plateau. Preferably, this plateau is lower than the plateau that occurs during the deformation of the three-dimensional structure.

[042] The inventions are explained below based on the figures. These explanations do not limit the scope of protection. The explanations apply equally to all embodiments of the present invention.

[043] Figure 1 shows one embodiment of reinforcement element 1.

[044] Figure 2 reveals details of reinforcement element 1.

[045] Figure 3 shows the system in the present invention.

[046] Figure 4 shows an example of the load distribution during the deformation of reinforcement element 1. Petition 870250084739, dated 09 / 19 / 2025, page 24 / 76 11 / 15

[047] Figures 5 and 6 show a sequence of the system's deformation during an impact in the present invention.

[048] Figure 1 shows an example of the reinforcing element 1, which comprises a hollow metal structure 4 and a three-dimensional structure 5. The reinforcing element 1 has a longitudinal axis 10 and the hollow metal structure 4 and the three-dimensional structure 5 preferably extend along the entire longitudinal axis 10. The longitudinal axis 10 is preferably parallel to the longitudinal axis of a structural element 8 of a vehicle, in which the reinforcing element 1 is inserted. The length of the reinforcing element 1 along the longitudinal axis 10 is preferably chosen according to the partial or total length of the structural element 8 that is to be reinforced.

[049] Figure 2 shows a detail of the reinforcing element 1. The representation according to Figure 2 is a section perpendicular to the longitudinal axis 10. In the present invention, the three-dimensional structure 5 comprises a first layer 2 and a second layer 3. However, the person skilled in the art understands that a single layer or three, four, five or more layers may be preferred. Each layer preferably comprises a multiplicity of three-dimensional elements, in this case cones, which are connected to each other at the base. If there is more than one layer, the layers are preferably stacked. This can be achieved by inserting the three-dimensional elements into each other, as illustrated in Figure 2. Alternatively or additionally, one layer, here the second layer 3, may have openings into which the three-dimensional elements of the first layer 2 are inserted.The first layer 2 and the second layer 3 can be connected by means of adhesive and / or by fitting by shape or by friction. During an impact, the three-dimensional structure 5 is compressed, as will be explained. Petition 870250084739, dated 09 / 19 / 2025, page 25 / 76 12 / 15 with more details in Figures 5 and 6. During compression and deformation, the three-dimensional elements of the layers preferentially interconnect.

[050] The three-dimensional structure 5 is fixed to the hollow metal structure 4, for example, by means of mechanical fastening, but, according to a preferred embodiment, the three-dimensional structure is glued to the hollow metal structure 4.

[051] The hollow metal structure 4, in the present case, is designed as a tube, here with an essentially rectangular cross-section. However, the cross-section may be different, for example, square or hexagonal. Preferably, the hollow metal structure 4 has two side walls, which are preferably parallel, and a first and second end 13, 14, which are also preferably parallel. The hollow metal structure 4 has a height 11 in the z direction, which in this case corresponds to the height. Innovatively, the hollow metal structure 4 comprises at least one rib 6, in this case two. Each rib 6 may connect two side walls 15, 18. Each rib 6 comprises a bend section 7, here an indentation. During compression of the hollow metal structure 4, each rib 6 begins to collapse at its respective bend section 7, as will be explained in more detail in Figures 5 and 6.As can be seen in Figure 2, the bend section 7 of one of the ribs 6, here the upper rib 6, is oriented in one direction, while the bend section 7 of the other rib 6, here the lower rib 6, is oriented in the opposite direction. This mirror orientation of the bend sections 7 has the advantage that the hollow metal structure 4 maintains, at least essentially, its shape during an impact. Preferably, the ribs 6 are not arranged equidistantly along the height 11 of the hollow metal structure 4, but rather distributed along the height direction, so as to provide minimal deformation in the region where maximum protection of a component is sought. Petition 870250084739, dated 09 / 19 / 2025, p. 26 / 76 13 / 15 example, battery compartment 9. In the present case, rib 6 at the bottom is positioned at a height 11 from the hollow metal structure 4 adjacent to a crossbeam of the battery structure, while rib 6 at part 6 is positioned adjacent to a crossbeam near a passenger seat. In this example, one of the lower ends 13, here the lower end 13, has a bending section 7.

[052] Figure 2 illustrates the system in the present invention, which comprises a structural element, for example, a reinforcing crossbar, which in this case is composed of two plates connected along two flanges. The structural element extends along a longitudinal axis 10. The vehicle's structural element 8 has a cavity into which the reinforcing element 1 is inserted so that its longitudinal axis 10 is parallel to the longitudinal axis of the vehicle's structural element 8. The three-dimensional structure 5 of the reinforcing element 1 is preferably oriented in the direction of the expected impact 19 and / or facing outwards from the vehicle. The extension of one of the side walls of the hollow metal structure 4 in the z direction preferably corresponds to the extension of the adjacent side wall of the vehicle's structural element. The reinforcing element 1 is preferably fixed to the vehicle's structural element 8 by means of adhesive and / or mechanical fastening element.Adjacent to structural element 8 of the vehicle is, in the present example and / or preferably connected to it, a battery compartment 9, which houses the battery of an electric vehicle. Structural element 8 of the vehicle protects the battery compartment 9 against impact, as symbolized by the arrow. This figure also shows that the upper and lower ribs 6 are aligned with two crossbeams, to which the load resulting from an impact is transferred, as represented by the arrows.

[053] With reference now to Figures 4 to 6, the deformation and load distribution during an impact are illustrated. After the impact, as can be seen Petition 870250084739, dated 09 / 19 / 2025, page 27 / 76 14 / 15 observed in Figure 5, initially the three-dimensional structure 5 collapses and the impact energy is dissipated. The hollow metal structure 4 undergoes only a slight deformation. The situation at a later point in the impact is illustrated in Figure 6. After the complete collapse of the three-dimensional structure 5, the hollow metal structure 4 deforms, especially in the z direction, in the central region. The upper rib 6 deforms more than the lower one. In the region where the lower rib 6 is located, the hollow metal structure 4 deforms very little, so the battery compartment 9 remains well protected.

[054] Figure 4 shows a force versus strain graph. During the deformation of the three-dimensional structure, the force increases to a peak, here of 19 kN, and then plateaus, here of 13 kN. After the complete collapse of the three-dimensional structure, the force increases to a second peak, here of 23 kN, during the deformation of the hollow metal structure 4, and then decreases to a lower plateau, here of 7 kN. More than 50%, here 60%, of the energy is absorbed by the three-dimensional structure. Reference signs: first layer reinforcing element second layer hollow metal structure three-dimensional (3D) structure rib bend section structural element Petition 870250084739, dated 09 / 19 / 2025, page 28 / 76 15 / 15 battery compartment longitudinal axis (extension in the x direction) height (extension in the z direction) main protection region first end second end first side wall vehicle component direction of load second side wall direction of impact. Petition 870250084739, dated 09 / 19 / 2025, page 29 / 76

Claims

1 / 2 CLAIMS 1. System comprising: - a structural element (8) of a vehicle and - a reinforcing element (1) inserted in the structural element (8) and comprising a hollow metal structure (4) and a three-dimensional structure (5) connected to the hollow metal structure (4), characterized in that the hollow metal structure (4) comprises at least one rib (6), each rib (6) having a bending section (7).

2. System according to claim 1, characterized in that the three-dimensional structure (5) comprises at least a first layer (2) and a second layer (3), each layer (2, 3) comprising a multiplicity of interconnected three-dimensional elements.

3. System according to claims 1 and 2, characterized in that the hollow metal structure (4) comprises two or more ribs (6), each preferably extending parallel to the longitudinal axis (10) and / or parallel to each other.

4. System according to claim 3, characterized in that the ribs (6) are not distributed equidistantly along the height (11) and / or z direction of the hollow metal structure (4).

5. System according to any of the preceding claims, characterized in that the rib (6) connects two side walls of the hollow metal structure (4).

6. System according to claims 3 to 5, characterized in that the bending section (7) of the rib (6) has a counter-bending direction. Petition 870250092345, dated 09 / 10 / 2025, p. 12 / 13 2 / 2 7. System according to any of the preceding claims, characterized in that the hollow metal structure (4) has a first end (13) and a second end (14), wherein at least one of the ends comprises a bending section (7).

8. System according to any of the preceding claims characterized by further comprising a battery compartment (9).

9. Method for absorbing energy, particularly impact energy, using a system as defined by any one of claims 1 to 4, characterized by comprising the following steps: a) breaking the three-dimensional structure (5) comprising at least one rib (6) in the event of an impact; b) bending at least one rib (6) of the three-dimensional structure (5) by the force of the impact; and c) crushing the hollow metal structure (4) in the event of an impact after the collapse of the three-dimensional structure (5).

10. Method according to claim 9, characterized in that the ribs (6) fold at least partially in a sequential and / or asymmetrical manner.

11. Method according to claims 9 and 10, characterized in that more than 40%, preferably more than 50%, of the total impact energy is absorbed by the composite three-dimensional structure (5). Petition 870250092345, dated 09 / 10 / 2025, p. 13 / 13

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