Crash Energy Absorber Coating Gap for Buckling Strength
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Solution Overview
Problem
Existing automotive parts that absorb crashworthiness energy through axial crushing face issues with foam fillers detaching during collisions and CFRP materials fracturing easily, leading to inadequate energy absorption and increased production costs.
Innovation Solution
A tubular member with a coating part having a gap of 0.2 mm to 3 mm is coated with an electrodeposition paint to form a film, enhancing buckling strength and preventing fracture during axial crushing, while also acting as a vibration-damping material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foam filler is filled inside the automotive part, then strength against bending deformation and crashworthiness energy absorptive properties are improved, but adhesion force between the automotive part and foam filler is insufficient causing foam filler to blow out during collision
Solution Approach 1:
The patent combines foam filler with adhesive material to create a composite filling structure. The adhesive material is applied to the inner surface of the automotive part before filling with foam filler, creating a strong bond between the foam and the part structure. This composite approach maintains the energy absorption benefits of foam while solving the adhesion and blowout problems through the adhesive layer.
2Strength
If CFRP reinforcement material is adhered to metal member, then bending strength is improved, but residual shear stress causes fracture of CFRP during axial crushing
Solution Approach 1:
The patent modifies the physical and chemical parameters of the adhesive material to reduce residual shear stress. By selecting adhesive materials with appropriate viscosity, curing characteristics, and flexibility parameters, the patent reduces the stress concentration that causes CFRP fracture during axial crushing while maintaining the bending strength benefits of CFRP reinforcement.
3Reliability
If additional process of filling with foam resin without forming gap is required, then adhesion force is improved, but production cost increases
Solution Approach 1:
The patent employs adhesive material that automatically bonds the foam filler to the automotive part structure during the filling process itself. The adhesive is applied to the inner surface before foam injection, and the foam expansion and curing process naturally creates the bonding action without requiring separate adhesive application steps or gap-forming operations. This self-bonding approach improves adhesion while maintaining manufacturing efficiency and controlling costs.
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 method improves crashworthiness energy absorption and vibration-damping properties without additional processes, maintaining structural integrity and reducing production costs.
Implementation Method 1
a coating film of an electrodeposition paint formed in the gap
Data Source
AI summary
An automotive crashworthiness energy absorption part includes a tubular member formed by using a hat-shaped section part including a top portion and a side-wall portion; a coating part made of a material having a lower strength than the tubular member, the coating part being arranged on outer surfaces of the top portion and the side-wall portion at a portion including a corner portion configured to connect the top portion and the side-wall portion, with a gap of 0.2 mm or more and 3 mm or less from the outer surface of the top portion, the outer surface of the side-wall portion, and an outer surface of the corner portion; and a coating film of an electrodeposition paint formed in the gap.