Compact Crash Structure With Deformable Members For Constant Energy Loading
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Solution Overview
Problem
Conventional vehicle crash structures require a large volume of space and transmit energy in a series of peaks and troughs during collisions, making them inefficient and complicating post-collision repairs.
Innovation Solution
A compact crash structure is interposed between the vehicle's bumper and side rail, featuring a hollow housing with deformable members and an actuator member that absorbs energy through deformation and friction, providing consistent loading and simplifying repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional crash structures use folding and bending mechanisms to absorb crash energy, then energy absorption capability is improved, but volume of space required increases
Solution Approach 1:
The patent changes the deformation mechanism from folding/bending to controlled crushing and densification. The cellular blocks are designed to undergo progressive collapse through cell wall buckling and material densification, which achieves comparable energy absorption in a more compact volume. This parameter change in the deformation mode resolves the contradiction between energy absorption and volume requirements.
Solution Approach 2:
The patent employs cellular blocks with composite structures consisting of multiple interconnected cells within each block, and multiple blocks arranged in arrays. This composite cellular structure increases the energy absorption density by utilizing both geometric cell collapse and material deformation, allowing effective energy absorption in a reduced volume compared to conventional single-structure folding mechanisms.
2Use of energy by moving object
If conventional crash structures use folding mechanisms to absorb crash energy, then energy absorption is achieved, but loading transmitted to passenger compartment becomes inconsistent with peaks and troughs
Solution Approach 1:
The patent segments the crash energy absorption function across multiple cellular blocks arranged in arrays, with each block containing multiple cells. This segmentation distributes the energy absorption process across many simultaneous deformation events, smoothing out the loading profile. The progressive collapse of individual cells and blocks creates a more continuous and consistent energy absorption pattern, eliminating the peaks and troughs associated with sequential folding mechanisms.
Solution Approach 2:
The patent utilizes the dynamic response of cellular structures under compression, where the collapse sequence of cells is controlled by stress wave propagation and cell wall buckling dynamics. This dynamic collapse process, governed by material properties and cell geometry, creates a more uniform energy absorption rate compared to predetermined folding paths, resulting in consistent loading transmission to the passenger compartment.
3Adaptability or versatility
If conventional crash structures are designed for both low-speed and high-speed collisions, then versatility is improved, but device complexity increases
Solution Approach 1:
The patent designs cellular blocks with universal applicability across different collision scenarios. By optimizing cell geometry, material properties, and block arrangement, the same cellular block structure provides appropriate energy absorption characteristics for both low-speed and high-speed collisions. The scalable cellular architecture allows the system to adapt to varying impact energies without requiring fundamentally different structural configurations, thereby maintaining simplicity while achieving versatility.
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 relatively constant energy loading during collisions, minimizing space requirements and simplifying post-collision repairs by using a combination of deformation and friction to absorb crash energy, ensuring safer and more efficient energy absorption.
Implementation Method 1
a plurality of deformable members that at least partially surround a first portion of the actuator member... designed to bend at a controlled rate, thereby absorbing crash energy
Implementation Method 2
uses a combination of friction and deformation to achieve a crash structure that yields relatively constant loading during a collision
Data Source
AI summary
A crash structure is provided that is interposed between a vehicle's bumper and a vehicle side rail, the crash structure providing relatively level loading in a compact structure that is easily removed and replaced during post-collision repairs. The structure includes an actuator member coupled to the bumper, the actuator member passing into, and slidably disposed within, a hollow housing of the crash structure. The hollow housing contains a plurality of deformable members that at least partially surround a first portion of the actuator member. A second portion of the actuator member, which is between the bumper and the first portion of the actuator member, has a larger diameter than that of the first portion of the actuator member and may be coupled to the first portion via a chamfered transition region.