Non-Parallel Bi-Rectangular Cellular Beam for Crash Energy Absorption
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Solution Overview
Problem
Vehicle beams and structural members face a challenge in achieving weight reduction for improved fuel economy while maintaining or enhancing energy absorption and bending strength to meet stringent safety and crash performance standards.
Innovation Solution
The implementation of non-parallel bi-rectangular cellular beams with inner and outer tubes and a plurality of ribs, arranged to form triangular cells, which provide increased energy absorption and bending strength while minimizing weight, achieved through specific orientations and configurations of the tubes and ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vehicle beams are strengthened to increase energy absorption and improve crash performance, then safety and crash performance are improved, but weight increases which reduces fuel economy
Solution Approach 1:
The beam cross-section is segmented into multiple cells formed by inner and outer tubes with transverse ribs dividing the space between them. This cellular structure increases energy absorption capacity while maintaining lightweight construction through efficient material distribution across multiple compartments.
Solution Approach 2:
The patent employs non-parallel bi-rectangular tube configurations where inner and outer tubes have different orientations and dimensions. This asymmetric design optimizes structural efficiency and energy absorption characteristics while minimizing material usage and overall weight compared to conventional symmetric sections.
Solution Approach 3:
The invention transitions from conventional two-dimensional cross-sectional designs to a three-dimensional cellular structure with multiple layers and orientations. The non-parallel arrangement of inner and outer tubes creates a complex spatial configuration that enhances strength and energy absorption in multiple directions simultaneously.
2Strength
If conventional square, octagonal or circular cross-sections are used, then manufacturing is simple, but energy absorption capacity is limited
Solution Approach 1:
The complex non-parallel bi-rectangular cellular structure is segmented into manageable components including inner tubes, outer tubes, and transverse ribs that can be manufactured separately and assembled. This segmentation enables production of complex high-performance sections using conventional manufacturing processes.
Solution Approach 2:
The design employs nested tube configurations where inner tubes are positioned within outer tubes, creating a compact hierarchical structure. This nesting approach maximizes energy absorption within constrained space while simplifying manufacturing through concentric assembly processes.
Data Source
AI summary
A vehicle structural beam includes four inner walls, four outer walls, and a plurality of ribs. The four outer walls and the four inner walls respectively form outer and inner rectangular tubes. The inner tube is disposed within the outer tube such that the outer walls are non-parallel with the inner walls. Each of the plurality of ribs are disposed between the outer and inner walls. The plurality of ribs is arranged to define a plurality of triangular and/or quadrilateral cells between the outer and inner tubes.