Composite Crush Can Structure for Post-Crash Bumper Retention
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Solution Overview
Problem
Existing energy management systems in vehicles face challenges with composite materials shattering under high-energy impacts, leading to detachment of bumper beams from the vehicle, which complicates crash recovery and increases weight.
Innovation Solution
Incorporating a composite crush can with frangible and non-frangible portions, where the non-frangible portion maintains the bumper beam's attachment to the vehicle by withstanding higher energy absorption, while the frangible portion deforms to absorb energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used for crush cans to reduce weight, then vehicle weight is reduced, but the composite materials shatter under high-energy impacts causing bumper beam detachment
Solution Approach 1:
The crush can is divided into two distinct portions: a frangible portion made of composite material for energy absorption, and a non-frangible portion made of metal for maintaining attachment reliability. This segmentation allows each portion to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different portions of the crush can are assigned different material properties: the frangible portion uses lightweight composite material with lower energy absorption capacity, while the non-frangible portion uses stronger metal material with higher energy absorption capacity to ensure attachment security at critical locations.
2Loss of energy
If frangible portion deforms to absorb energy, then energy absorption is improved, but the portion may be destroyed leading to detachment
Solution Approach 1:
The crush can is segmented into frangible and non-frangible portions, allowing the frangible portion to safely deform and absorb energy while the non-frangible portion remains intact to maintain attachment.
Solution Approach 2:
The non-frangible portion acts as an intermediary between the frangible portion and the vehicle body, absorbing excess energy that the frangible portion cannot handle and ensuring the attachment remains secure even when the frangible portion is destroyed.
3Reliability
If non-frangible portion withstands higher energy absorption, then attachment reliability is improved, but the portion cannot deform to absorb energy
Solution Approach 1:
The crush can is divided into frangible and non-frangible portions, with the frangible portion designed to deform and absorb energy while the non-frangible portion maintains attachment reliability.
Solution Approach 2:
Different portions have different material properties optimized for their specific functions: the frangible portion uses composite material for energy absorption, while the non-frangible portion uses metal for attachment security.
4Ease of manufacture
If composite crush can is used, then ease of manufacture is improved, but the frangible portion may shatter causing debris
Solution Approach 1:
The crush can is segmented into frangible and non-frangible portions, containing the shattering to the frangible portion while the non-frangible portion maintains structural integrity and reduces debris.
Solution Approach 2:
The potential harmful shattering of composite material is converted into a beneficial energy absorption mechanism, where the controlled destruction of the frangible portion absorbs crash energy while the non-frangible portion prevents harmful debris dispersion.
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 system ensures the bumper beam remains attached post-crash, allowing easier recovery and reduces vehicle weight by using lighter composite materials effectively.
Implementation Method 1
If a sufficiently high-energy crash occurs then the crush can is plastically deformed and crushed
Implementation Method 2
the non-frangible portion of the at least one crush can is capable of absorbing a higher amount of energy (per unit mass) upon impact than the frangible portion
Data Source
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AI summary
An energy management system for a vehicle which includes a bumper beam (106, 206, 1602) and at least one crush can (102A-B, 202A-B, 400, 500, 600, 700, 1000, 1400, 1818, 1900) made from composite materials. The crush can includes at least one frangible portion (410, 510, 518, 610, 710, 810, 1910), and at least one non-frangible portion (412, 512, 612, 712A-D, 812, 1908). The crush can further includes at least one fixing aperture (416A-B, 516A-B, 616A-B, 716A-D, 816, 1916) configured to receive a fixing, the at least one fixing aperture extending through the at least one frangible portion and through the at least non-frangible portion of the crush can.