Blow-Molded Impact Absorber With Variable Rib Density
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Solution Overview
Problem
Existing impact absorbing members, particularly those produced by blow-molding, face challenges in achieving uniform impact absorption due to limitations in thickness control and rib density distribution, leading to inconsistent performance across different portions and ineffective impact absorption when impact is concentrated on specific areas.
Innovation Solution
The development of a blow-molded impact absorbing member with a hollow body featuring low and high rib density portions, achieved through a manufacturing method involving split mold blocks and a plate member to cover ribs, allowing for varying rib density and thickness distribution to enhance impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If blow-molding is used to manufacture impact absorbing members, then production efficiency is improved, but thickness control precision deteriorates leading to inconsistent impact absorption performance
Solution Approach 1:
The patent applies local quality by creating regions with different rib densities within the hollow body. The hollow body includes a first region with a first rib density and a second region with a second rib density different from the first. This allows different portions of the impact absorbing member to have optimized properties for their specific functions, compensating for the lack of precise thickness control in blow-molding while maintaining high production efficiency.
2Ease of manufacture
If uniform rib density is used throughout the hollow body, then manufacturing simplicity is maintained, but impact absorption performance deteriorates when impact is concentrated on specific areas
Solution Approach 1:
The patent implements local quality by defining specific regions with different rib densities. The hollow body includes a first region with a first rib density and a second region with a second rib density. This regional differentiation ensures that areas experiencing concentrated impact have appropriate rib density for effective energy absorption, while maintaining a relatively simple blow-molding manufacturing process.
Solution Approach 2:
The patent applies segmentation by dividing the hollow body into distinct regions with different rib density characteristics. This segmentation allows each region to be optimized for its specific functional requirements regarding impact absorption, improving overall reliability without significantly complicating the manufacturing process.
3Reliability
If rib density is increased to improve impact absorption, then impact absorption performance is improved, but device complexity increases due to varying rib density distribution
Solution Approach 1:
The patent applies local quality by creating regions with different rib densities rather than uniformly increasing rib density throughout. This allows impact absorption performance to be improved in specific areas where it is most needed, while keeping other areas simpler, thereby limiting the overall increase in device complexity.
Solution Approach 2:
The patent resolves the contradiction by transitioning from a uniform one-dimensional rib structure to a two-dimensional regional structure with varying rib densities. This dimensional change allows the structure to achieve superior impact absorption performance through spatial distribution of rib densities without proportionally increasing overall structural complexity.
Data Source
AI summary
An impact absorbing member includes a hollow body having a plurality of ribs, and the hollow body includes a low rib density portion being a portion where density of the ribs is low, and a high rib density portion being a portion where density of the ribs is high. The hollow body may include a thin portion and a thick portion. In this case, the rib density of the thin portion and the rib density of the thick portion may be different from each other