Combined energy absorption box with hierarchical energy absorption

Abstract

The application provides a combined energy-absorbing box for a vehicle, wherein an upper end cover and a lower end cover are respectively fixed on a low-speed energy-absorbing box and a high-speed energy-absorbing box by welding; the low-speed energy-absorbing box and the high-speed energy-absorbing box are connected by rivets; the upper end cover is provided with bolt holes for connecting a crash beam and a vehicle frame; the low-speed energy-absorbing box is provided with two induction grooves along the circumference; the high-speed energy-absorbing box is respectively arranged with 4*4 pyramids on each surface; the low-speed energy-absorbing box is filled with 3*3*3 multi-cell aluminum structures; the single-cell structure of the multi-cell aluminum structure is composed of two groups of wave-shaped surfaces arranged in axial cross; the high-speed energy-absorbing box is filled with 3*3*3 three-period minimal surface aluminum structures; and the outer wall of the high-speed energy-absorbing box is filled with carbon fiber plates, and the lay-up angle of the carbon fiber plates is 0° and 90°.

Description

Technical Field

[0001] This invention is a novel automotive collision energy-absorbing box device, belonging to the field of automotive passive safety protection. Background Technology

[0002] With the widespread use of automobiles, vehicle collision safety has become one of the most important research areas in the field of automotive safety. Currently, vehicle collision safety is a mandatory requirement of laws and regulations in many countries around the world, and major automakers are constantly improving the collision safety performance of their vehicles.

[0003] During a car collision, the vehicle's kinetic energy needs to be absorbed, thus requiring devices to reduce the damage to occupants and the vehicle. These devices are known as automotive collision energy absorption systems, and mainly include the vehicle body structure, seats, airbags, and the automotive energy absorption box involved in this invention.

[0004] Existing automotive collision energy-absorbing boxes generally employ a single structure to absorb collision energy. However, these devices have relatively weak energy absorption capacity, cannot adapt to various collision intensities and types, and are prone to overall buckling during oblique impacts. Therefore, they are prone to failing to achieve the expected protective effect during collisions. Thus, there is a need for a more efficient and safer automotive collision energy-absorbing box that can provide different levels of energy absorption and protection in collisions of varying degrees, thereby improving the safety and reliability of vehicles during collisions. Summary of the Invention

[0005] The main technical problem to be solved by the present invention is to provide a combined automotive energy-absorbing box with graded energy absorption, which can provide different levels of energy absorption and protection in collisions of different degrees, thereby improving the safety and reliability of automobiles during collisions.

[0006] To solve the above-mentioned technical problems, the present invention proposes a combined automotive energy-absorbing box with graded energy absorption, including an upper cover, a low-speed energy-absorbing box, a high-speed energy-absorbing box, and a lower cover.

[0007] The upper end cover and the lower end cover are respectively fixed to the low-speed energy-absorbing box and the high-speed energy-absorbing box by welding; the low-speed energy-absorbing box and the high-speed energy-absorbing box are connected by rivets; the upper end cover is provided with bolt holes for connecting the anti-collision beam and the vehicle frame;

[0008] The low-speed energy-absorbing box has two circumferentially arranged induction grooves on its exterior; the high-speed energy-absorbing box has 4*4 pyramids arranged in an array on each of its exterior surfaces.

[0009] The interior of the low-speed energy-absorbing box is filled with a 3*3*3 multi-cell aluminum structure; the single-cell structure of the multi-cell aluminum structure is composed of two sets of corrugated surfaces arranged axially in a cross pattern, and its curve governing equation is: The high-speed energy-absorbing box is internally filled with a 3*3*3 three-period minimal curved aluminum structure, and the curve governing equation of its unit cell structure is:

[0010] The outer wall of the high-speed energy-absorbing box is filled with carbon fiber plates with layup angles of 0° and 90°.

[0011] In a preferred embodiment, the radius of the induction groove is 4.5 mm.

[0012] In a preferred embodiment: the pyramid has a length of 16mm, a width of 15mm, and a draft angle of 80°.

[0013] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0014] 1. This invention proposes a staged energy-absorbing composite automotive energy-absorbing box. The low-speed energy-absorbing box consists of an outer thin-walled aluminum square tube and an inner corrugated deformable polycellular aluminum tube. The axial corrugation design reduces the peak force of the structure, allowing the energy-absorbing box to generate corresponding folded waves according to the wave number controlled by its parametric equations during a collision, resulting in stable accordion-like deformation. This increases its energy absorption efficiency while enabling it to absorb energy during low-speed collisions. Furthermore, the corrugated deformable polycellular aluminum tube exhibits a more stable deformation mode under lateral load collisions. The corrugations on the side closer to the lateral load bend, while the corrugations on the side farther from the lateral load are stretched and straightened. By controlling the amplitude of its parametric equations, the corrugated deformable polycellular aluminum tube can maintain an accordion-like deformation mode on one side even under lateral load collisions, absorbing a large amount of energy. The high-speed energy-absorbing box consists of an outer thin-walled aluminum-carbon fiber composite square tube and an inner three-period minimal curved surface cell. Because the three-period minimal curved surface aluminum structure is composed of multiple continuous curved surfaces, its surface area is larger than that of traditional linear structures, allowing for more efficient energy absorption and enabling it to play an energy-absorbing role in high-speed collisions. Furthermore, the three-period minimal curved surface aluminum structure is composed of curved surfaces in multiple directions, allowing for energy absorption in multiple directions. This allows the energy-absorbing box to adapt to different impact directions, thereby improving its overall impact resistance. The graded design of this energy-absorbing box can adjust its energy absorption method according to different collision intensities and types to achieve better protective effects. Simultaneously, the high-speed energy-absorbing box's outer shell is designed using aluminum-carbon fiber composite materials, which effectively reduces the weight of the energy-absorbing box and improves its energy absorption effect. Carbon fiber composites have superior energy absorption and density compared to aluminum, but their energy absorption deformation mode involves fiber tearing and outward flipping, resulting in a petal-like shape. The torn fibers scatter, potentially causing secondary injuries. Therefore, this invention uses an external aluminum plate to constrain the deformation of the carbon fiber plate. The pyramidal structure on the outside of the high-speed energy-absorbing box expands outward during a collision, creating a gap between the outer aluminum plate and the carbon plate. The internal carbon fibers tear and flip outward, with fiber fragments encased and stored within the gap by the outer aluminum plate. Simultaneously, the outer aluminum plate folds at thinner sections, inducing progressive tearing of the carbon fibers. In low-speed collisions, the front low-speed energy-absorbing box deforms first to absorb energy, collapsing progressively from the upper induction groove. The external square tube constrains the internal filling structure, preventing the filling structure from scattering and causing secondary injuries to the occupants. When a vehicle experiences a high-speed collision, the energy absorbed by the low-speed energy-absorbing box is insufficient to resist the kinetic energy brought by the high-speed impact. After the low-speed energy-absorbing box collapses into a compact state, the high-speed energy-absorbing box will take over the energy absorption function of the low-speed energy-absorbing box. Through its internal three-period minimal curved surface cell structure, the external pyramidal induced structure and composite material reinforcement plate, it effectively absorbs the energy brought by the high-speed collision, thereby preventing the risk of overall buckling or failure.This multi-stage energy-absorbing modular automotive energy-absorbing box design can adapt to different collision degrees and types, improving overall impact resistance. Simultaneously, the use of aluminum-carbon fiber composite materials effectively reduces the weight of the energy-absorbing box, improving energy absorption efficiency and vehicle fuel economy. This multi-stage energy-absorbing modular automotive energy-absorbing box effectively solves the technical problems of existing energy-absorbing boxes, such as excessively high peak force leading to difficulty in triggering at low speeds, insufficient energy absorption capacity and adaptability, and a high risk of overall buckling or failure. It improves automotive collision safety performance and is expected to be widely used in the automotive manufacturing industry.

[0015] 2. This invention proposes a multi-layered, energy-absorbing automotive energy-absorbing box with different energy-absorbing structures designed for varying impact velocities. This ensures that impact forces at different speeds are absorbed separately during a collision, protecting both the colliding object and the occupants. Since collision conditions differ at different vehicle speeds, the multi-layered energy-absorbing design can adapt to various collision scenarios. Furthermore, for low-speed impacts, the deformed low-speed energy-absorbing box can be directly removed from the energy-absorbing box, facilitating installation and reducing maintenance costs.

[0016] 3. This invention proposes a staged energy-absorbing composite automotive energy-absorbing box. Both the inner and outer surfaces of the energy-absorbing box are designed with induced deformation structures, deforming step-by-step, resulting in stable energy absorption. By designing the staged deformation energy-absorbing structure, this invention can gradually release energy during a collision, thereby reducing the risk of occupant injury. Simultaneously, because the energy-absorbing box has induced deformation structures both inside and outside, it can stably absorb and disperse energy during a collision, thereby improving the vehicle's stability performance.

[0017] 4. This invention proposes a staged energy-absorbing composite automotive energy-absorbing box with a multi-material hybrid design, which enhances energy absorption and reduces the weight of the energy-absorbing box. Multi-material hybrid design is a common engineering design method that combines the advantages of different materials to achieve better performance and effects. Compared with traditional metal energy-absorbing boxes, this invention combines the high energy absorption and lightweight properties of carbon fiber reinforced resin with the deformation stability of aluminum through the combined action of carbon fiber plates and aluminum plates. This reduces the weight of the energy-absorbing box while absorbing more impact energy and exhibiting a better staged deformation mode. Attached Figure Description

[0018] Figure 1 This is a 3D view of the energy-absorbing box;

[0019] Figure 2 This is a top view of the energy-absorbing box;

[0020] Figure 3 This is a side view of the energy-absorbing box;

[0021] Figure 4 This is a cross-sectional view of the energy-absorbing box;

[0022] Figure 5 This is a schematic diagram of the unit cell structure of a corrugated deformation unit cell.

[0023] Figure 6 This is a schematic diagram of a three-period minimal surface unit cell structure. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0027] The overall structure of this embodiment is as follows: Figure 1-3 As shown, the system includes a low-speed energy-absorbing box 101, an upper end cover 102, a high-speed energy-absorbing box 103, and a lower end cover 104. The upper end cover 102 and the lower end cover 104 are respectively welded to the low-speed energy-absorbing box 101 and the high-speed energy-absorbing box 103. The low-speed energy-absorbing box 101 and the high-speed energy-absorbing box 103 are connected by rivets. The overall structure is fastened to the anti-collision beam and the vehicle frame bolts through bolt holes on the end covers, forming a stable anti-collision system. The design and manufacture of this structure fully consider various factors, such as material strength, deformation mode, and energy absorption efficiency, to ensure maximum protection of passengers and the vehicle during a collision.

[0028] The low-speed energy-absorbing box 101 has two circumferentially arranged guide grooves with a radius of 4.5 mm surrounding its exterior. The high-speed energy-absorbing box 103 has a pyramidal design with a length of 16 mm, a width of 15 mm, and a draft angle of 80°. Each face of the high-speed energy-absorbing box 103 has an array of 4*4 identical pyramids. The design of the guide grooves and pyramids controls the direction and manner of deformation of the energy-absorbing box under stress, thereby improving its energy absorption efficiency. The internal structure of the energy-absorbing box is as follows. Figure 4 As shown, the low-speed energy-absorbing box 101 is filled with a 3*3*3 multi-cell aluminum structure 201, and its single-cell structure is as follows: Figure 5 As shown, it consists of two sets of corrugated surfaces arranged axially in an intersecting pattern, and its curve governing equation is: The high-speed energy-absorbing box 103 is internally filled with a 3*3*3 three-period minimal curved aluminum structure 202, whose unit cell structure is as follows: Figure 6 As shown, its curve control equation is The outer wall of the high-speed energy-absorbing box 103 is filled with carbon fiber plates with layup angles of 0° and 90°. Two layers of aluminum plates restrict the direction of carbon fiber tearing deformation, achieving better energy absorption. The use of this composite material improves the strength and toughness of the energy-absorbing box, enabling it to better absorb impacts.

[0029] The aforementioned staged energy-absorbing composite automotive energy-absorbing box comprises a low-speed energy-absorbing box consisting of an outer thin-walled aluminum square tube and an inner corrugated deformable polycellular aluminum tube. The axial corrugation design reduces the peak force of the structure, allowing the energy-absorbing box to generate corresponding folded waves according to the wave number controlled by its parametric equations during a collision, resulting in stable accordion-like deformation. This increases its energy absorption efficiency while enabling it to absorb energy during low-speed collisions. Furthermore, the corrugated deformable polycellular aluminum exhibits a more stable deformation mode under lateral load collisions; the corrugations on the side closer to the lateral load bend, while those on the side farther from the lateral load are stretched and straightened. By controlling the amplitude of its parametric equations, the corrugated deformable polycellular aluminum can maintain an accordion-like deformation mode on one side even under lateral load collisions, absorbing a large amount of energy. The high-speed energy-absorbing box consists of an outer thin-walled aluminum-carbon fiber composite square tube and an inner three-period minimal curved surface cell. Because the three-period minimal curved surface aluminum structure is composed of multiple continuous curved surfaces, its surface area is larger than that of traditional linear structures, allowing for more efficient energy absorption and enabling it to play an energy-absorbing role in high-speed collisions. Furthermore, the three-period minimal curved surface aluminum structure is composed of curved surfaces in multiple directions, allowing for energy absorption in multiple directions. This allows the energy-absorbing box to adapt to different impact directions, thereby improving its overall impact resistance. The graded design of this energy-absorbing box can adjust its energy absorption method according to different collision intensities and types to achieve better protective effects. Simultaneously, the high-speed energy-absorbing box's outer shell is designed using aluminum-carbon fiber composite materials, which effectively reduces the weight of the energy-absorbing box and improves its energy absorption effect. Carbon fiber composites have superior energy absorption and density compared to aluminum, but their energy absorption deformation mode involves fiber tearing and outward flipping, resulting in a petal-like shape. The torn fibers scatter, potentially causing secondary injuries. Therefore, this invention uses an external aluminum plate to constrain the deformation of the carbon fiber plate. The pyramidal structure on the outside of the high-speed energy-absorbing box expands outward during a collision, creating a gap between the outer aluminum plate and the carbon plate. The internal carbon fibers tear and flip outward, with fiber fragments encased and stored within the gap by the outer aluminum plate. Simultaneously, the outer aluminum plate folds at thinner sections, inducing progressive tearing of the carbon fibers. In low-speed collisions, the front low-speed energy-absorbing box deforms first to absorb energy, collapsing progressively from the upper induction groove. The external square tube constrains the internal filling structure, preventing the filling structure from scattering and causing secondary injuries to the occupants. When a vehicle experiences a high-speed collision, the energy absorbed by the low-speed energy-absorbing box is insufficient to resist the kinetic energy brought by the high-speed impact. After the low-speed energy-absorbing box collapses into a compact state, the high-speed energy-absorbing box will take over the energy absorption function of the low-speed energy-absorbing box. Through its internal three-period minimal curved surface cell structure, the external pyramidal induced structure and composite material reinforcement plate, it effectively absorbs the energy brought by the high-speed collision, thereby preventing the risk of overall buckling or failure.

[0030] This multi-stage energy-absorbing modular automotive energy-absorbing box design can adapt to different collision degrees and types, improving overall impact resistance. Simultaneously, the use of aluminum-carbon fiber composite materials effectively reduces the weight of the energy-absorbing box, improving energy absorption efficiency and vehicle fuel economy. This multi-stage energy-absorbing modular automotive energy-absorbing box effectively solves the technical problems of existing energy-absorbing boxes, such as excessively high peak force leading to difficulty in triggering at low speeds, insufficient energy absorption capacity and adaptability, and a high risk of overall buckling or failure. It improves automotive collision safety performance and is expected to be widely used in the automotive manufacturing industry.

[0031] The above description is merely a preferred embodiment of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention by those skilled in the art within the scope of the technology disclosed in the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.

Claims

1. A modular automotive energy-absorbing box with graded energy absorption, characterized in that... Includes the top cover, low-speed energy absorption box, high-speed energy absorption box, and bottom cover; The upper end cover and the lower end cover are respectively fixed to the low-speed energy-absorbing box and the high-speed energy-absorbing box by welding; the low-speed energy-absorbing box and the high-speed energy-absorbing box are connected by rivets; the upper end cover is provided with bolt holes for connecting the anti-collision beam and the vehicle frame; The low-speed energy-absorbing box has two circumferentially arranged induction grooves on its exterior; the high-speed energy-absorbing box has 4*4 pyramids arranged in an array on each of its exterior surfaces. The interior of the low-speed energy-absorbing box is filled with a 3*3*3 multi-cell aluminum structure; the single-cell structure of the multi-cell aluminum structure is composed of two sets of corrugated surfaces arranged axially in a cross pattern, and its curve governing equation is: The high-speed energy-absorbing box is internally filled with a 3*3*3 three-period minimal curved aluminum structure, and the curve governing equation of its unit cell structure is: The outer wall of the high-speed energy-absorbing box is filled with carbon fiber plates with layup angles of 0° and 90°.

2. The combined automotive energy-absorbing box with graded energy absorption according to claim 1, characterized in that: The radius of the induction groove is 4.5 mm.

3. The combined automotive energy-absorbing box with graded energy absorption according to claim 1, characterized in that: The pyramid has a length of 16mm, a width of 15mm, and a draft angle of 80°.

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