Vehicle Crash Box Geometrical Freedom via Sheet Blank Bending
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Solution Overview
Problem
Existing crash box designs for vehicles lack geometrical flexibility and depth without increasing manufacturing costs, limiting design options and efficiency.
Innovation Solution
A crash box design where a sheet blank is bent into a U shape to form overlapping flaps that are joined together, allowing for greater depth and flexibility without increasing production costs, with the front plate attached to a bumper beam and rear fastening plates bolted to the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional crash box designs are used, then manufacturing costs are controlled, but geometrical freedom and depth are limited
Solution Approach 1:
The crash box is divided into multiple functional zones including front plate, top side, bottom side, and rear fastening plates, each formed from specific regions of the sheet blank. This segmentation allows independent optimization of each zone's geometry while maintaining manufacturing efficiency through a single-blank construction approach.
Solution Approach 2:
The invention transitions from conventional three-dimensional shaping to a predominantly two-dimensional sheet blank configuration that is later formed into 3D structures. The sheet blank is designed with predetermined bend lines and flap configurations that enable complex geometries to be achieved through bending operations rather than expensive 3D forming processes.
2Length of stationary object
If greater depth is achieved in crash box design, then geometrical freedom improves, but manufacturing complexity increases
Solution Approach 1:
The sheet blank is pre-configured with all necessary bend lines, flap positions, and connection points before the forming process. The rear fastening plates are positioned and oriented in advance on the blank, allowing them to be folded into place during a single forming operation rather than requiring separate assembly steps.
Solution Approach 2:
Multiple components that would traditionally be manufactured and assembled separately (front plate, top side, bottom side, rear fastening plates) are merged into a single integrated structure formed from one sheet blank. The overlapping flaps that join these components are built into the blank's geometry, eliminating the need for separate fastening operations.
3Strength
If overlapping flaps are joined together, then structural integrity improves, but manufacturing steps increase
Solution Approach 1:
The overlapping flaps are designed to self-align and self-join during the forming process. The geometry of the flaps and their attachment points on the sheet blank ensures proper positioning without requiring additional alignment operations or complex tooling, allowing the structure to form its own connections during a single forming operation.
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
This design provides enhanced geometrical freedom and depth in crash box design without escalating manufacturing costs, enabling more efficient attachment to vehicle components.
Implementation Method 1
a sheet blank is bent in a U to form the front plate, a top side and a bottom side, and the top side and bottom side are bent to form overlapping flaps
Implementation Method 2
the flaps are joined together, preferably by welding
Data Source
Figure 1~3
Figure 4
AI summary
A crash box for a vehicle is made from a sheet blank (10) which is bent in a U to form the front plate (11), a top side (12) and a bottom side (13), and the top side and bottom side are bent to form overlapping flaps (16-19) which are joined together at the overlapping, and to form rear fastening plates (14,15).