Vehicle Bonnet Construction Using Energy Absorbing Layers

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Solution Overview

Problem

Existing vehicle panels lack effective energy absorption capabilities, leading to inadequate protection against impacts and increased risk of injury or damage, while also being heavy and costly to manufacture.

Innovation Solution

A vehicle panel construction featuring a top and bottom layer bonded together, with energy absorbing layers made of materials like polyurethane foam positioned between them, enhancing stiffness and energy absorption without the need for additional structural forms or heavy materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional vehicle panels are constructed without energy absorbing layers, then the structure is simpler and lighter, but the energy absorption capability and protection against impacts are inadequate

Engineering Contradiction:

Improveprotection against impactsVSAvoidpanel structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The vehicle panel is segmented into multiple functional layers: outer layers for structural integrity and inner energy-absorbing layers for impact mitigation. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between protection capability and structural simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The panel uses composite material construction combining outer structural layers with inner energy-absorbing materials (such as foam or honeycomb structures). This composite approach enhances impact protection while maintaining reasonable structural complexity through the integration of materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If heavy materials and complex structural forms are used to increase stiffness and energy absorption, then the protection capability improves, but the weight and manufacturing cost increase

Engineering Contradiction:

Improvestiffness and energy absorptionVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Energy-absorbing materials are strategically positioned in specific locations within the panel structure where impact forces are most likely to occur. This local quality approach provides enhanced strength and energy absorption exactly where needed, rather than uniformly throughout the entire panel, thereby reducing overall weight while maintaining protective capability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention employs porous or cellular energy-absorbing materials (such as foam or honeycomb structures) that provide high energy absorption per unit weight. These materials achieve superior strength-to-weight ratio compared to solid materials, allowing the panel to meet stiffness and protection requirements with reduced overall weight.

Inventive Principle:

Principle #31Porous materials

3Reliability

If additional structural forms and heavy materials are used to enhance energy absorption, then the protection capability improves, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveimpact protectionVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention merges the structural support function and energy absorption function into a single integrated panel assembly. The outer layers and energy-absorbing layers are combined in one manufacturable unit, eliminating the need for separate structural forms and reducing assembly steps, thereby simplifying manufacturing while maintaining protection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention changes the material parameters by selecting energy-absorbing materials with optimal properties (such as foam density, honeycomb cell structure) that can be directly incorporated into the panel manufacturing process. This parameter optimization allows achieving desired protection levels through material selection rather than complex structural design, simplifying manufacturing.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces the risk of injury and damage by absorbing more energy, achieves weight savings of up to 30%, and simplifies manufacturing by eliminating the need for complex forms and heavy materials, while maintaining or improving stiffness and torsional rigidity.

Implementation Method 1

one or more energy absorbing layers, wherein the one or more energy absorbing layers are comprised of one or more energy absorbing materials

Methodology Applied

Scientific EffectEnergy absorption: Deformation

Implementation Method 2

a top layer and a bottom layer, wherein the bottom layer is bonded to the top layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS9783236B1Vehicle bonnet constructions for reducing impact forces

Publication Date: 2017.10.10 WAYMO LLC

AI summary

The technology relates to vehicle panels. The vehicle panel may comprise a top layer and a bottom layer. The top and bottom layers may be bonded together. The bond of the top and bottom layer may be a weld. One or more energy absorbing layers may be positioned between the top layer and the bottom layer. The one or more energy absorbing layers may be comprised of one or more energy absorbing materials. The energy absorbing layers may be aluminum honeycomb and polyurethane foam.