Crash Attenuator Living Hinge Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing crash attenuators are complex and costly due to multiple hinge points requiring precise welding and machining, making them difficult to assemble and deploy effectively for impact protection.

Innovation Solution

A collapsible crash attenuator design featuring a frame with a hinge assembly that acts as a living hinge, allowing for easy assembly and quick deployment, using a combination of rigid connections and angled frame members to absorb impact energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple hinge points with precise welding and machining are used, then the crash attenuator provides stable structural support, but the assembly complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improvestructural stabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple hinge points into a single integrated hinge assembly that connects the first and second frame members. This single assembly performs the function of multiple separate hinges while eliminating the need for precise welding and machining at multiple locations, thereby reducing assembly complexity while maintaining structural stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hinge assembly serves multiple functions simultaneously: it provides structural support, enables the living hinge mechanism for energy absorption, and allows for simplified assembly. By designing a universal component that performs multiple roles, the patent reduces the overall number of parts and assembly steps required.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple hinge points with precise welding and machining are used, then the crash attenuator provides stable structural support, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hinge assembly is designed as a replaceable component that can be manufactured more economically using simpler joining methods. Rather than requiring permanent welding and precision machining, the assembly can be manufactured and replaced more easily, reducing overall manufacturing costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If a rigid connection is used between frame members, then the frame maintains structural integrity during normal operation, but the ability to collapse during impact is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidcollapse capability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic hinge assembly that can transition between two states: a rigid locked position during normal operation that maintains structural integrity, and a flexible living hinge position during impact that allows collapse for energy absorption. This dynamic behavior allows the structure to adapt to different operational conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The hinge assembly changes its mechanical parameters (rigidity, degrees of freedom) based on the operational state. During normal operation, it maintains a rigid configuration with high structural integrity. During impact, it transitions to a more compliant configuration with reduced rigidity, allowing the frame to collapse and absorb energy.

Inventive Principle:

Principle #35Parameter changes

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 design enables efficient energy absorption during impacts, reducing the complexity and cost of assembly while providing effective protection for road workers and errant vehicle drivers.

Implementation Method 1

the hinge assembly comprises a living hinge when the hinge assembly is in the impact configuration

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

moving the first frame member relative to the second frame member about the hinge assembly to an impact configuration

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentEP3044074B1Crash attenuator

Publication Date: 2019.01.09 ENERGY ABSORPTION SYSTEMS INC

Figure 1
Figure 2~4
Figure 5

AI summary

A crash attenuator includes a frame having a first frame member and a second frame member rigidly connected with a hinge assembly in a pre-impact configuration. The first and second frames are hingedly connected with the hinge assembly in an impact configuration, wherein the hinge assembly comprises a living hinge when the hinge assembly is in the impact configuration. A method of using the crash attenuator is also provided.