Composite Crash Absorber Structure for Controlled Impact Deformation
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Solution Overview
Problem
Existing crash absorbers, such as those made of polymer foams or metal structures, suffer from sudden failure or complex designs when subjected to impacts, leading to inefficient energy absorption.
Innovation Solution
A component comprising a sheet profile and a foamed secondary component with a density of at least 0.2 g/cm³, connected to the sheet profile, which combines energy absorption types to allow for controlled deformation and increased energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a sheet profile is designed to absorb large amounts of energy, then energy absorption capacity is improved, but design complexity and sheet thickness increase
Solution Approach 1:
The invention combines a sheet profile with a foamed secondary component to create a composite energy absorption system. The sheet profile (metal or polymer) provides primary energy absorption through controlled deformation, while the foamed secondary component (density >0.2g/cm³) supplements energy absorption and maintains structural integrity, enabling high energy absorption without excessive thickness or complexity
2Use of energy by moving object
If a sheet profile is designed to absorb large amounts of energy, then energy absorption capacity is improved, but sheet thickness increases
Solution Approach 1:
The composite structure combines a thinner sheet profile with a foamed secondary component. The sheet profile absorbs energy through controlled deformation while the foamed component provides additional energy absorption and structural support, achieving high energy absorption capacity without requiring excessive sheet thickness
3Use of energy by moving object
If metal is used as sheet profile material, then energy absorption by controlled bending is improved, but weight increases
Solution Approach 1:
The invention allows changing the material parameter of the sheet profile from metal to polymer, altering the energy absorption mechanism from controlled bending to controlled destruction (tearing or breaking of fibers/compound). This provides flexibility in weight management while maintaining energy absorption performance
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 combined component design enables efficient and controlled energy absorption, allowing for a larger amount of energy to be absorbed without complex designs or excessive thickness, using materials like metals or polymers for the sheet profile and polymers or metals for the secondary component.
Implementation Method 1
A foamed secondary component usually absorbs energy by elastic deformation
Implementation Method 2
If a metal is used as material for the sheet profile, the sheet profile absorbs energy by controlled bending of the profile
Implementation Method 3
If a polymer is used as material for the sheet profile, the energy is absorbed by controlled destruction of the material, for example by tearing or breaking of fibers used for reinforcing the polymer or by tearing or breaking of the compound
Data Source
AI summary
The invention relates to a component for absorbing energy of an impact applied to the component (19), wherein the component (19) is plastically deformable by an impact and optionally can undergo at least some extent of destruction, the component (19) comprising a sheet profile (1) as a main component and a foamed secondary component (17), wherein the foamed secondary component (17) is connected to the sheet profile (1) and has a density of more than 0.2 g/cm3. The invention further relates to a composite unit (21) built from such components (17) and a process for producing the component (17).