Undulating Cast Crash Absorber for Progressive Impact Deformation
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Solution Overview
Problem
Existing crash-absorber structures in motor vehicles face challenges in achieving high component integration, cost-effective production, low weight, and high impact energy absorption, particularly with cast components that have limited ductility.
Innovation Solution
A crash-absorber structure with a deformation body made of a cast metal material featuring an undulating outer profile, allowing for high impact energy absorption through continuous bending modes and local deformation stabilization, which can be produced efficiently and is designed for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cast components are used for crash-absorber structures, then component integration and assembly efficiency are improved, but ductility and impact energy absorption capacity deteriorate
Solution Approach 1:
The deformation body is segmented into multiple deformation zones along its length, each capable of independent localized deformation. This segmentation allows the cast component to absorb impact energy through distributed plastic deformation across multiple zones, compensating for the inherently lower ductility of cast materials while maintaining high component integration.
Solution Approach 2:
The deformation body features a curved, undulating profile with alternating peaks and valleys along its length. This curved geometry promotes continuous bending modes during impact, enabling the cast component to undergo progressive deformation that maximizes energy absorption capacity despite the material's limited ductility.
2Strength
If joined metal sheets or extruded profiles are used, then impact energy absorption is improved, but component integration and assembly efficiency deteriorate
Solution Approach 1:
The invention merges multiple functions into a single cast deformation body component: impact energy absorption through controlled deformation, structural support, and crash force dissipation. This integration eliminates the need for separate joined sheets or extruded profiles, reducing assembly complexity while maintaining effective energy absorption capabilities.
Solution Approach 2:
The cast deformation body serves multiple functions simultaneously: it acts as a crash absorber, a structural element, and a force-dissipating component. This multi-functionality replaces traditional multi-component assemblies, achieving high component integration without sacrificing impact energy absorption performance.
3Device complexity
If cast components with undulating profile are used, then component integration and weight are improved, but manufacturing complexity increases
Solution Approach 1:
The invention employs parameter optimization in the cast deformation body design, including specific curvature radii, wall thickness distributions, and deformation zone dimensions. These parameter changes enable the complex undulating profile to be manufactured efficiently through casting processes while maintaining the desired deformation characteristics and component integration benefits.
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 structure achieves efficient impact energy absorption with moderate plastic strains and localized cracking, ensuring robust and continuous deformation behavior while maintaining low weight and cost-effectiveness.
Implementation Method 1
the deformation body can be deformed along the deformation axis
Implementation Method 2
a deformation body for absorbing impact forces
Implementation Method 3
the undulating outer profile of the invention basically provides a 'pre-bending,' which ensures that only moderate plastic strains occur in the bending zones
Implementation Method 4
The resulting folds interlock and jam into each other with further deformation and thus prevent a disruptive sliding of the deformed areas, which ultimately leads to a progressively continuing deformation behavior at a constant level
Data Source
AI summary
A crash-absorber structure for use in a motor vehicle, preferably for use in a side member of a motor vehicle, comprising a deformation body for absorbing impact forces, which deformation body extends along a deformation axis, and can be deformed along the deformation axis. The crash-absorber structure has a length and a material thickness, as well as a first and second opening having a height and a width. The openings are located at the ends of the deformation body. The deformation body is formed as a cast part made of a metal material and has a regular, undulating outer profile formed along the length thereof.