Corrugated Joint Composite Energy Absorber
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Solution Overview
Problem
Fiber-reinforced composite crush members in vehicles face interface failure during collisions, particularly when impacted at angles other than head-on, leading to reduced energy absorption due to separation of components, which compromises their lightweight advantage and fuel efficiency benefits.
Innovation Solution
An energy-absorbing assembly comprising two components with complementary corrugated surfaces joined by an adhesive layer, forming a mechanical interlock to resist interface failure, enhancing the assembly's resistance to non-parallel impacts and improving energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced composite crush members are used to reduce weight, then fuel efficiency is improved, but interface failure occurs during angled collisions reducing energy absorption
Solution Approach 1:
The corrugated joint structure is pre-formed during manufacturing with interlocking ridges and valleys that create mechanical engagement between components. This preliminary structural configuration ensures that during angled collisions, the components maintain interface stability through the pre-established mechanical interlock, preventing separation and maintaining energy absorption capability.
Solution Approach 2:
The corrugated joint introduces curved, wave-like surfaces with ridges and valleys between components. This curvature creates a mechanical interlock that resists separation forces during angled impacts, allowing the lightweight composite structure to maintain interface stability and energy absorption performance without increasing component weight.
2Ease of manufacture
If components are joined with simple adhesive bonding, then manufacturing is simplified, but interface failure occurs under non-parallel impact loads
Solution Approach 1:
The joint combines adhesive bonding with a corrugated mechanical interlock structure. This composite joining approach integrates the simplicity of adhesive application with the strength of mechanical engagement, creating a joint that resists interface failure under angled impact loads while maintaining ease of manufacture through a streamlined bonding process.
Solution Approach 2:
The corrugated joint introduces curved, wave-like surfaces with ridges and valleys between components. This curvature creates a mechanical interlock that resists separation forces during angled impacts, allowing the lightweight composite structure to maintain interface stability and energy absorption performance without increasing component weight.
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 solution effectively reduces interface failure and enhances the energy-absorbing capacity of the assembly, maintaining lightweight characteristics while improving fuel efficiency and crash performance by ensuring components remain engaged during impacts, thereby maximizing energy absorption.
Implementation Method 1
an adhesive layer disposed between the first corrugated surface and the second corrugated surface to fix the first component to the second component
Implementation Method 2
energy-absorbing assembly for a vehicle... enhances the energy-absorbing capacity of the assembly
Data Source
AI summary
An energy-absorbing assembly includes a first component and a second component. The first component includes a first polymer and a first plurality of reinforcing fibers. The first component includes a first peripheral wall defining a first interior compartment. A first interior portion of the first peripheral wall includes a first corrugated surface. A second component includes a second polymer and a second plurality of reinforcing fibers. The second component includes a second peripheral wall. A second interior portion of the second peripheral wall includes a second corrugated surface. The first corrugated surface is complementary to the second corrugated surface. The first corrugated surface is joined to the second corrugated surface.