3D Printed Composite Ribs for Crash Test Dummies
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Solution Overview
Problem
Current crash test dummies lack biofidelity in their rib structures, as they are typically made using 'free layer' damping with standard steel bands, which do not accurately replicate human mechanical properties and sensitivity during collisions.
Innovation Solution
The development of three-dimensional ribs using a combination of fibrous and polymer-based materials with a layer of damping material sandwiched between two layers of band material, printed using a 3D printer, incorporating materials like Kevlar and nylon or carbon fiber and nylon to enhance biofidelity and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard steel bands with free layer damping are used for ribs, then manufacturing simplicity is maintained, but biofidelity and human-like mechanical response are insufficient
Solution Approach 1:
The patent applies composite materials by combining fibrous materials (Kevlar, carbon fiber) with polymer-based materials (nylon) to create band material that replicates human rib mechanical properties. This composite construction provides both strength and damping characteristics similar to human tissue, directly improving biofidelity while maintaining structural integrity
Solution Approach 2:
The patent implements local quality by creating multi-layered rib structures with different materials positioned in specific locations. The damping material is sandwiched between layers of band material, with each layer serving a specific function: outer layers provide structural strength while inner damping layers provide energy absorption. This localized material placement optimizes both biofidelity and mechanical response
2Reliability
If multi-layer composite materials are used to improve biofidelity, then human-like mechanical response increases, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the material composition parameters of the ribs. Specific fiber types (Kevlar, carbon fiber) are combined with specific polymers (nylon) in controlled ratios and layer configurations. These parameter changes enable precise control over mechanical properties such as damping coefficient, tensile strength, and flexural rigidity to match human rib characteristics
Solution Approach 2:
The patent implements segmentation by dividing the rib structure into multiple discrete layers, each with specific material composition and function. The damping material is segmented into layers sandwiched between band material layers, allowing independent optimization of each layer's properties while maintaining overall structural coherence. This segmentation facilitates modular manufacturing and assembly
3Loss of energy
If damping material is added between band material layers, then energy absorption and hysteresis improve, but structural complexity increases
Solution Approach 1:
The patent applies beforehand cushioning by pre-positioning damping material layers between the band material layers during manufacturing. This damping material is strategically placed to absorb impact energy before it can cause damage, providing energy dissipation capability inherent to the rib structure. The damping layers act as pre-configured energy absorption zones that activate during collision events
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 new rib structure improves biofidelity and human-like interaction in crash tests by providing increased hysteresis and damping, allowing for more accurate simulation of human mechanical responses during collisions.
Implementation Method 1
The data referenced in order to create the layers is generated from a CAD system using thin, horizontal cross-sections of a CAD model
Implementation Method 2
at least two layers of a band material including a mixture of a fibrous based material and a polymer based material
Implementation Method 3
a layer of damping material sandwiched in between the at least two layers of the band material
Implementation Method 4
The new rib structure improves biofidelity and human-like interaction in crash tests by providing increased hysteresis and damping
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A three-dimensional rib for a crash test dummy includes at least two layers of a band material including a mixture of a fibrous based material and a polymer based material and a layer of damping material sandwiched in between the at least two layers of the band material.