Energy absorbing member with cone structure

Abstract

The invention relates to a component for absorbing energy, in particular impact energy. The invention also relates to a structure comprising such a component and to a method for absorbing energy, in particular impact energy.

Description

Technical Field

[0001] This invention relates to a component for absorbing energy, particularly impact energy. The invention also relates to a structure including the component and a method for absorbing energy, particularly impact energy. Background Technology

[0002] In industry, particularly in the automotive industry, there has always been a need for components that absorb energy, especially impact energy, in order to protect passengers and certain components of vehicles and / or structures. Summary of the Invention

[0003] This problem is solved by a component that absorbs energy, particularly impact energy, comprising at least a first layer and a second layer, each layer comprising a plurality of interconnected three-dimensional elements, wherein the three-dimensional elements of the first layer are inserted into the three-dimensional elements of the second layer and / or vice versa, and wherein the sidewalls of the three-dimensional elements of at least one layer have a varying thickness along the maximum extension of the three-dimensional element, preferably along the height of the three-dimensional element.

[0004] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0005] This invention relates to a component for absorbing energy, particularly impact energy. The component comprises at least a first layer and a second layer, each layer comprising a plurality of interconnected three-dimensional elements.

[0006] Preferably, the three-dimensional element is a hollow element. The three-dimensional element has sidewalls extending from its base to its top. The three-dimensional element preferably has a circular, elliptical, and / or polygonal cross-section. Each three-dimensional element is preferably a truncated cone. The shape of the cross-section of the three-dimensional element can vary with its axial extension. The axial extension is preferably the maximum extension of the three-dimensional element. A layer can have three-dimensional elements with different cross-sections and / or different axial lengths. Preferably, the three-dimensional elements are tapered, preferably having a larger or largest cross-section in the plane where the three-dimensional elements are interconnected, preferably through layers extending between the peripheries of two adjacent three-dimensional elements, preferably at the base of the three-dimensional elements. Additionally or alternatively, two adjacent three-dimensional elements of a layer can be directly connected at their bases. In the case of tapered three-dimensional elements, the tilt angle can be constant or not constant around their entire periphery. The tilt angle can also vary with the axial length of the three-dimensional element. The sidewalls of one or more three-dimensional elements in a layer can include one or more steps and / or shoulders. When the sidewalls are made of laminate, not all layers of the laminate need to include steps.

[0007] Preferably, the shape and / or size of the cross-section of the three-dimensional element of one or two layers varies with its axial extension, and / or preferably, the inclination angle of the sidewalls of the three-dimensional element of one or two layers varies with its axial extension.

[0008] According to the invention, the sidewalls of at least one layer of three-dimensional elements have a varying thickness along the maximum extension of the three-dimensional element, preferably along its height. Preferably, the three-dimensional elements of one layer have the maximum sidewall thickness near the bottom and / or base, while the three-dimensional elements of another layer have their maximum wall thickness at their top.

[0009] Each layer is preferably made of a polymeric material, more preferably of nylon. The polymeric material must be selected to ensure sufficient energy absorption within a temperature range of -20°C to 50°C. Preferably, each layer is manufactured individually. The layer is preferably manufactured by molding and / or injection molding.

[0010] A component may include at least a first layer and a second layer. However, a component may include more than two layers, particularly three, four, five, six, or seven layers.

[0011] Each layer comprises a plurality of interconnected three-dimensional elements. According to the invention, three-dimensional elements of one layer are inserted into three-dimensional elements of adjacent layers. One end of each three-dimensional element may be disposed in a plane, and the remainder of each three-dimensional element extends beyond that plane. The three-dimensional elements are preferably hollow structures. Those skilled in the art will understand that the plane need not be flat, but may be three-dimensional, for example, curved. In this plane, the three-dimensional elements of a layer are preferably interconnected, preferably according to a constant matrix (e.g., a Y×X matrix). Y is preferably 1 to 10. X is preferably 2 to 100.

[0012] The three-dimensional elements of two adjacent layers are preferably different in shape. A three-dimensional element or a layer is inserted into the three-dimensional elements of an adjacent layer, preferably such that, prior to impact, their tops and / or their bases are at least abutting each other, preferably in contact. Preferably, prior to impact, the sidewalls of the two inserted three-dimensional elements do not contact each other.

[0013] According to a preferred embodiment of the invention, the sidewalls of at least one layer of a three-dimensional element have regions of greater wall thickness and regions of lesser wall thickness. These regions preferably extend around the entire circumference of each three-dimensional element. Preferably, the region of greater wall thickness of a three-dimensional element in one layer is directly adjacent to the region of lesser wall thickness of a three-dimensional element in an adjacent layer.

[0014] Preferably, regions of different wall thicknesses in a three-dimensional element of a layer are separated by shoulders or undercuts. When two three-dimensional elements are inserted into each other and both have shoulders or undercuts, the shoulders / undercuts of the two elements are preferably directly adjacent to or in contact with each other.

[0015] Preferably, the three-dimensional elements in each layer are connected by connecting layers and / or by contact with each other. Preferably, in one layer, the three-dimensional elements are connected by connecting layers. Preferably, the three-dimensional elements of this layer (the so-called "male element") are inserted into hollow three-dimensional elements (the so-called "female element") in adjacent layers. The connecting layer is preferably flexible, such that it is bendable, and preferably, if held as a single unit, it can be bent under its own weight. In adjacent layers, the female elements are preferably directly connected, preferably connected at their periphery and / or along a longer section of their periphery, and preferably connected along their entire height. It is even possible for two adjacent three-dimensional elements to locally have shared sidewalls. The layer with the female three-dimensional element has less flexibility than the layer with the male three-dimensional element. Two female three-dimensional elements can be connected by ribs, which even more preferably extend across the entire height of the three-dimensional element.

[0016] According to another inventive or preferred embodiment of the invention, a layer, preferably a layer having common three-dimensional elements (preferably the region between two adjacent three-dimensional elements), is bendable and / or flexible, preferably bendable under its own weight if held at one end.

[0017] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0018] Due to this flexibility, male three-dimensional elements can be inserted into female three-dimensional elements even if the components are large and / or the three-dimensional elements are elongated at their maximum extension.

[0019] Preferably, the layer can be bent around two axes that are orthogonal to each other.

[0020] Two adjacent three-dimensional elements are preferably connected by a layer. This layer is preferably disposed at the base of the three-dimensional element and is preferably made of the same material as the three-dimensional element itself. The layer is preferably thin and / or includes notches to allow for flexibility between the elements.

[0021] A layer of the component, preferably a layer containing a parent three-dimensional element, is preferably more rigid than a bendable layer. This can be achieved by connecting one or more ribs of two adjacent three-dimensional elements. Alternatively or additionally, two adjacent three-dimensional elements are directly connected, for example, by contacting sidewalls and / or sharing sidewalls. The connection between the sidewalls of two adjacent three-dimensional elements may be located only at the bottom, but it may also extend along a larger section of the sidewall, preferably along the entire height of the three-dimensional element from the base to the top.

[0022] Another inventive or preferred embodiment of the invention is an energy-absorbing component, particularly impact energy, comprising at least a first layer and a second layer, each layer comprising a plurality of interconnected three-dimensional elements, wherein the three-dimensional elements of the first layer are inserted into the three-dimensional elements of the second layer and / or vice versa.

[0023] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0024] According to this embodiment, the layers are connected by a connection means, preferably at the top and / or base of the three-dimensional element, preferably by clips and / or by adhesives.

[0025] This embodiment of the invention reduces the vibration of the layers, particularly at their resonant frequencies. This, in turn, reduces component damage and / or fatigue.

[0026] Preferably, at least one layer, preferably two layers, of the three-dimensional element has an opening on its top and / or in the connecting layer between two adjacent three-dimensional elements. This embodiment, for example, improves the molding of the layers and / or the flow of coating material through the component.

[0027] Preferably, or creatively, the three-dimensional element in at least one layer is a hollow frustocone. Preferably, the three-dimensional elements in both layers are frustocones. Preferably, the cross-section of the frustocone is polygonal, such as quadrilateral and / or hexagonal. The shape of the cross-section of the three-dimensional element in at least one of the two layers may vary along the height of the three-dimensional element, for example, between the base and the top of the three-dimensional element.

[0028] Another preferred or inventive embodiment of the invention is an energy-absorbing component, particularly impact energy, comprising at least a first layer and a second layer, each layer comprising a plurality of interconnected three-dimensional elements, wherein the three-dimensional elements of the first layer are inserted into the three-dimensional elements of the second layer and / or vice versa.

[0029] According to this embodiment, the two layers are in partial contact with each other before the impact.

[0030] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0031] In contrast to existing technologies, the three-dimensional elements of one layer are inserted, preferably completely, into the three-dimensional elements of the adjacent layer from the beginning and before impact. Preferably, the three-dimensional elements are in contact or nearly in contact at their tops and / or their bases before impact.

[0032] The component may include a metal structure, preferably a hollow metal structure, more preferably a hollow beam, and even more preferably a hollow beam with one or more ribs. The layer having the three-dimensional component is attached to, and preferably glued to, the metal structure. During impact, the metal structure is the last part to deform. Preferably, the metal structure is not part of the vehicle's structure, but rather the component is preferably inserted into the vehicle's structure. The metal structure is preferably an extruded or pultruded part. Preferably, the metal structure is made of aluminum.

[0033] Preferably, at least one of the first or second layers includes a connecting means. The layer can be connected to a structure, such as the structure of a vehicle, via these connecting means (e.g., an adhesive layer), and / or two or more layers can be connected by the connecting means (preferably, an adhesive layer).

[0034] Each adhesive layer is preferably applied after the three-dimensional layer has been formed, or the adhesive layer is part of the material of the three-dimensional layer, such as an adhesive layer.

[0035] Before impact or energy absorption, the two layers can also be connected to each other by means of bonding. These means of bonding can be, for example, adhesives (e.g., adhesive layers), friction fits, form fits, and / or force fits (e.g., snap-fit ​​fits).

[0036] Preferably, at least one layer of the three-dimensional element includes a reinforcing element. This reinforcing element, such as one or more ribs and / or foam layers (preferably structural foam), is preferably disposed in hollow sections of the three-dimensional element and / or between the three-dimensional elements. The reinforcing element may be disposed within the structure of the three-dimensional element and / or adjacent to the three-dimensional element.

[0037] Each layer of the component can be molded into a single part. Other methods of manufacturing these layers include, for example, pultrusion, injection molding and / or thermoforming and / or compression molding, and / or blow molding.

[0038] Another subject of the invention is a system comprising structural and inventive components.

[0039] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0040] The structure can be any structure, such as a collision barrier, body armor, or vehicle. The structure can be a metallic and / or plastic structure. Inventive components are disposed at or within the structure to reduce its deformation, for example, during an impact. Preferably, the structure includes a cavity in which the component is located. More preferably, at least one layer of the component is attached to the structure. Additionally or alternatively, the inventive component can be disposed at a structure without a cavity.

[0041] The problem is also solved by utilizing the energy absorption, particularly impact energy, of the components of the present invention, wherein different regions of the sidewalls of the three-dimensional element collapse, at least temporarily and sequentially.

[0042] The disclosure relating to this subject matter also applies to other subjects, and vice versa. The disclosed subject matter relating to this embodiment of the invention may also be included in other embodiments, and vice versa.

[0043] According to the subject matter of the invention, two layers and their three-dimensional elements are provided such that they collapse sequentially. For example, the three-dimensional elements of one or two layers comprise regions with different wall thicknesses. The regions of the three-dimensional elements with thinner sidewalls will collapse first, while other regions of the three-dimensional elements remain intact and preferably collapse in a later stage.

[0044] Preferably, the three-dimensional element is irreversibly expanded and / or irreversibly compressed and / or irreversibly subjected to tangential stress. More preferably, the cross-section of the three-dimensional element in the first layer and (optionally) its axial extension is irreversibly compressed, while the cross-section of the three-dimensional element in the second layer is reversibly / irreversibly increased and its axial extension is reversibly and / or irreversibly widened and / or compressed.

[0045] The three-dimensional elements of the first layer are inserted into the three-dimensional elements of the second layer, preferably until the tops of the two layers and / or the three-dimensional elements are close to or even in contact.

[0046] Preferably, the three-dimensional elements of the two layers interlock during their plastic deformation. Attached Figure Description

[0047] The invention is explained below with reference to the accompanying drawings. These explanations do not limit the scope of protection. These explanations also apply to all embodiments of the invention.

[0048] Figure 1 An implementation of the creative component is shown.

[0049] Figure 2 A creative system is shown.

[0050] Figure 3 It shows that according to Figure 1 The details of the creative components.

[0051] Figure 4 The two layers of the creative component are shown.

[0052] Figures 5a to 5d The behavior of the innovative component during impact is shown. Detailed Implementation

[0053] Figure 1 A first embodiment of the inventive component 1 is shown, comprising at least a first layer 2 and a second layer 3. Each layer 2, 3 includes a plurality of three-dimensional elements 5, which are interconnected at the base. The three-dimensional elements are arranged in an X×Y array, here 2×15. The component has a length of 10, which can reach 3 meters, preferably 1 to 2 meters. Preferably, the two layers are connected to each other, for example by clips, to reduce vibration of layers 2, 3, thereby reducing fatigue and / or noise. In the present case, the component comprises an optional hollow metal structure, preferably an aluminum structure. At least one layer 2, 3 is connected, for example, glued to a structure 4. The entire component 1 is preferably inserted into the structure of a vehicle, preferably into a cavity (e.g., a rocker). The component improves the impact resistance of the vehicle structure during impacts. The inventive component is particularly suitable for electric vehicles to specifically protect their batteries.

[0054] Figure 2An inventive component 1 is depicted within a cavity (e.g., a side beam) of a vehicle structure 8. A cross-section extending axially in the x-direction, perpendicular to the side beam, is depicted. Those skilled in the art will understand that component 1 need not be placed within the cavity of the vehicle structure 8, even though this embodiment is preferred. The cross-section shows two layers 2, 3, each having a tapered three-dimensional element 5. The tapered element of layer 2 is inserted into the tapered three-dimensional element of layer 3. Thus, the three-dimensional element of layer 2 is the so-called "male" three-dimensional element, and the three-dimensional element of layer 3 is the so-called "female" three-dimensional element. The male three-dimensional element is preferably inserted into the female three-dimensional element to extend such that their tops and / or their bases are abutting or even contacting each other. One, preferably both, three-dimensional elements of layers 2, 3 have an extension 19 in their longest direction (here, their height). Preferably, the cross-sectional shape of the three-dimensional element of one or both layers is polygonal. The cross-sectional shape of at least one three-dimensional element of layer 2, 3 may vary along its height, for example, from hexagonal to quadrilateral. Preferably, the cross-section of the female three-dimensional element varies along its height. Prior to the impact, a space 16 preferably exists between the sidewalls 20 of the male and female three-dimensional elements 5, which serves as a volume for deformation. The impact direction is exemplarily depicted by arrow 12, such as a side impact on a vehicle.

[0055] Figure 3 Exemplary details of two three-dimensional elements, layers 2 and 3, are depicted. Each three-dimensional element extends between a base 22 and a top 21. Each three-dimensional element is hollow and includes sidewalls 20 extending around the entire circumference of each three-dimensional element. In this case, the thickness of the sidewalls 20 is not constant throughout the height of the three-dimensional element. The male three-dimensional element has a larger wall thickness 7 near its base and a thinner wall thickness 9 near the top. With respect to the female three-dimensional element, the sidewall thickness 11 near the top is larger and the sidewall thickness 9 near the bottom 9 is smaller. A region of a certain sidewall thickness extends around the entire circumference of the three-dimensional element and is, in this case, separated by shoulders 17 provided in the two three-dimensional elements. The hollow metal structure 4 here has ribs with recesses; the hollow metal structure is optional in all embodiments.

[0056] Figure 4Further details of male layer 2 and female layer 3 are shown. It can be seen that the top of the male three-dimensional element of layer 2 is inserted into the female three-dimensional element of layer 3 until their tops 21 and their bases 22 are at least adjacent, preferably in contact with each other in contact area 13. Layer 3 has a more rigid design than layer 2. Therefore, two adjacent three-dimensional elements are connected, for example, by ribs 6. Optionally or additionally, the three-dimensional elements of layer 3 may be designed such that the sidewalls of two adjacent three-dimensional elements are in contact at least along a certain degree of height of the three-dimensional elements, or even at the same height. Layer 2 is preferably flexible, preferably bendable under its own weight if held at one end. This can be achieved through a flexible connection area 15 between two adjacent three-dimensional elements. The two layers preferably have planar connection areas 14, 15 that contact each other after assembly.

[0057] The plane where the three-dimensional elements of layers 2 and 3 are connected can have openings between two or more, for example, four three-dimensional elements. These openings can be bridged by one or more ribs.

[0058] Figures 5a to 5d The behavior of the innovative component 1 during the impact depicted by the arrows is shown, along with a force / displacement diagram. The force was measured on the left-hand side of the metal structure 4. The sidewall design of the three-dimensional element of the layer is based on... Figure 3 The design is described. Sidewall regions with smaller sidewall thicknesses are so-called fusible regions in this example because they preferably melt during deformation. When the impact begins (Figure a), the load increases to a peak accompanied by structural compression. Once this peak load is reached (Figure a), the load increases to a peak value. Figure 5b The sidewall regions (melted regions) of the two three-dimensional elements, with a smaller sidewall thickness 9, begin to collapse. Each region 9 preferably folds and slides along adjacent regions 7 and 11 with a larger sidewall thickness. As can be seen from the corresponding figures, the load decreases to a stable region while deformation continues. Then ( Figure 5c Regions with larger sidewall thicknesses 7 and 11 also collapsed, while region 9 remained collapsed until it reached a state of complete collapse under peak load, as shown in the attached figure. Figure 5c As can be seen in the text. Finally, as... Figure 5d As depicted, the metal structure 4 preferably collapses through the folding of its ribs. This reduces the forces on the vehicle parts to be protected to an acceptable level. In the absence of the metal structure being part of component 1, no force is applied according to... Figure 5d The deformation.

[0059] Figure label:

[0060] 1. Reinforcing Components

[0061] 2. The first layer of the composite structure, the male structure

[0062] 3. The second layer and parent structure of the composite structure

[0063] 4. Hollow metal structure

[0064] 5 3D components

[0065] 6 ribs, ribs connecting the parent structure

[0066] 7. Areas with thicker walls and harder public areas

[0067] 8. Structural components and side beams of the vehicle

[0068] 9. The region with the smaller wall thickness during the first deformation, and the fusible region.

[0069] 10. Longitudinal axis, extension along the x-direction

[0070] 11. Areas with thicker walls and harder parent regions.

[0071] 12. Direction of impact

[0072] 13 Contact Area

[0073] 14 Connecting the 3D structural parent layer and regions

[0074] 15 Connecting the 3D structural parent layer and regions

[0075] 16. Volume used for deformation between male and female structures

[0076] 17. Shoulders, steps

[0077] 18 Openings

[0078] 19 Maximum extension, height

[0079] 20 sidewalls

[0080] 21 Top of 3-D Component

[0081] 22 Base of 3-D Component

Claims

1. An energy-absorbing component (1), the energy being particularly impact energy, the component comprising at least a first layer (2) and a second layer (3), each layer (2, 3) comprising a plurality of interconnected three-dimensional elements (5), wherein the three-dimensional elements (5) of the first layer (2) are inserted into the three-dimensional elements (5) of the second layer and / or vice versa, characterized in that, The sidewall (20) of at least one layer (2, 3) of the three-dimensional element (5) has a thickness that varies along the maximum extension (19) of the three-dimensional element (5) and preferably along its height.

2. The component (1) according to claim 1, wherein the sidewall (20) of the three-dimensional element (5) of at least one layer (2, 3) has a region with a larger wall thickness (7, 11) and a region with a smaller wall thickness (9).

3. The component (1) according to claim 2, characterized in that, The region of the three-dimensional element with a larger wall thickness (7, 11) in a layer (2) is directly adjacent to the region of the three-dimensional element with a smaller wall thickness (9) in the adjacent layer (3).

4. The component (1) according to any one of the preceding claims, characterized in that, The areas with different wall thicknesses (7, 11, 9) are separated by the shoulder (17) or the undercut.

5. The component (1) according to any one of the preceding claims, characterized in that, The three-dimensional elements (5) of each layer (2, 3) are connected by connecting layers (14, 15) and / or by contact with each other.

6. The component (1) according to any one of the preceding claims or the preamble of claim 1, characterized in that, Layer (2), preferably the region (14, 15) between two adjacent three-dimensional elements (5) is bendable.

7. The component (1) according to claim 6, characterized in that, The layer (3) is rigid, wherein two adjacent three-dimensional elements (5) are preferably connected by ribs (6).

8. The component (1) according to any one of the preceding claims or the preamble of claim 1, characterized in that, The layers (2, 3) are connected by a connection means, preferably at the top (21) and / or base (22) of the three-dimensional element (5), preferably by a clip.

9. The component according to any one of the preceding claims, characterized in that, The three-dimensional element (5) of at least one, preferably two layers (2, 3) has an opening (18) at its top (21).

10. The component (1) according to any one of the preceding claims or the preamble of claim 1, characterized in that, The three-dimensional element (5) is a hollow truncated cone.

11. The component (1) according to claim 10, characterized in that, The shape of the cross section of the three-dimensional element (5) of at least one layer (2, 3) changes, preferably with the cross section at the base and top of the three-dimensional element (5) being different.

12. The component (1) according to any one of the preceding claims or the preamble of claim 1, characterized in that, Prior to the impact, the two layers (2, 3) were in partial contact with each other.

13. A system comprising a structure (9) and a component according to any one of the preceding claims.

14. The system according to claim 13, characterized in that, The structure (9) includes a cavity, and the component (1) is located in the cavity.

15. The system according to claim 8 or 9, characterized in that, At least one layer (2, 3) is attached to the structure (9).

16. A method for absorbing energy, particularly impact energy, using a component according to any one of claims 1 to 12, characterized in that... 。 17. The method according to claim 16, characterized in that, The three-dimensional elements (5) can all expand and / or compress and / or be subjected to tangential stress in a reversible and / or irreversible manner.

18. The method according to any one of claims 16 to 17, characterized in that, The three-dimensional element (5) of the two layers (2, 3) is interlocked during its plastic deformation.

Images