Conformable Energy Absorber with Flexible Spine for Automotive Seats
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Solution Overview
Problem
Existing automotive seat energy absorbers, primarily using foam, are inefficient in managing impact forces due to slow load ramp-up and poor crush efficiency, necessitating a more effective second-stage energy absorber that can adapt to various impact scenarios and structural shapes while maintaining comfort and daily load resilience.
Innovation Solution
A multi-faceted energy absorber with a flexible spine that can bend up to 180 degrees about multiple axes, comprising energy absorbing modules with coalesced units and living hinges, allowing it to conform to complex shapes and provide gradient energy absorption characteristics, integrated into seat components through molding and attachment methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional foam energy absorbers are used, then comfort characteristics are maintained, but energy absorption efficiency and crush efficiency are poor
Solution Approach 1:
The energy absorber is divided into multiple energy absorbing modules, each comprising multiple energy absorbing units arranged in parallel. This segmentation allows each module to independently manage impact forces, improving overall energy absorption efficiency while maintaining structural reliability during crush events.
Solution Approach 2:
The energy absorber incorporates a flexible spine that can bend and deform during impact events. This dynamic flexibility allows the structure to adapt to various impact scenarios, optimizing energy absorption while maintaining the ability to withstand daily operational loads without permanent deformation.
2Volume of moving object
If seat assemblies decrease in thickness to increase interior space, then interior volume increases, but stroke for impact management decreases
Solution Approach 1:
The energy absorber transitions from a traditional linear compression approach to a multi-dimensional energy management system. The flexible spine can bend in multiple directions and the modular structure allows for complex deformation patterns, enabling effective energy absorption in shorter stroke distances by utilizing angular and rotational degrees of freedom.
Solution Approach 2:
The energy absorbing modules are designed with specific geometric parameters and material properties that allow for rapid energy dissipation over short distances. The gradient energy absorption characteristics enable the structure to provide high initial resistance that decreases progressively, maximizing energy absorption efficiency within limited stroke space.
3Loss of energy
If foam density is increased for energy management, then energy absorption improves, but comfort characteristics deteriorate
Solution Approach 1:
The energy absorber is segmented into multiple modules with gradient energy absorption characteristics. This allows the system to provide high energy absorption capacity during impact events while distributing the mechanical properties across multiple lighter-density units, preventing the need for uniformly high-density foam that would compromise comfort.
Solution Approach 2:
The energy absorber combines multiple energy absorbing materials with different mechanical properties in a composite modular structure. This allows optimization of each module for specific functions - some modules provide higher energy absorption while others maintain softer characteristics for comfort, achieving both goals simultaneously through material composition rather than density alone.
4Adaptability or versatility
If energy absorber is designed to conform to complex structural shapes, then adaptability improves, but manufacturing complexity increases
Solution Approach 1:
The energy absorber is divided into standardized modular units that can be independently manufactured using conventional molding processes. These modules are then assembled into complex configurations using the flexible spine system, allowing adaptation to various structural shapes without requiring complex custom manufacturing for each application.
Solution Approach 2:
The flexible spine acts as a adaptable connecting structure that allows the modular energy absorber assembly to conform to complex geometries. This flexibility enables a single standardized module design to be applied across multiple applications with different structural shapes, maintaining manufacturing simplicity while achieving high adaptability.
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 flexible energy absorber effectively cushions impacts, enhancing safety by improving energy absorption efficiency, reducing the risk of injury, and allowing for a more spacious interior design by adapting to various structural geometries, outperforming traditional foam systems.
Implementation Method 1
The flexible energy absorber effectively cushions impacts, enhancing safety by improving energy absorption efficiency
Implementation Method 2
energy absorbing modules with coalesced units and living hinges, allowing it to conform to complex shapes and provide gradient energy absorption characteristics
Data Source
AI summary
An energy absorber 10 that has a spine 12 which has a relaxed configuration and a deployment configuration. In the deployment configuration, the spine 12 lies proximate to a substrate 14 to protect the substrate 14 from an impacting object 16. Preferably, the spine 12 is bendable to conform to the substrate 14. The spine includes a number (N) of energy absorbing modules 18, 20, 22, 24, . . ., where 1<=N<=1000. At least some of the modules have a number (L) of mutually supporting energy absorbing vertebral members 30, where 1<=L<=100. Each vertebral member 30 includes a number (U) of coalesced energy absorbing units 32,34, were 2<=U<=10. At least some of the energy absorbing units 32, 34 have a base 36 that preferably but not necessarily is oriented toward the impacting object 16.