Vehicle Crash Box with Deformable Elongate Members
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Solution Overview
Problem
Existing energy-absorbing materials for crash boxes in vehicles are expensive, heavy, and have longevity issues, limiting their effectiveness in absorbing impact energy and protecting occupants during collisions.
Innovation Solution
A crash box design featuring deformable elongate members of variable lengths and thicknesses, made from high ductile and high-strength materials, with enhanced strength and ductility properties through chemical and physical processes, and a container with specific cross-sectional shapes and fastening plates for controlled energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional energy-absorbing materials are used in crash boxes, then impact energy absorption capability is improved, but vehicle weight increases and production cost increases
Solution Approach 1:
The patent changes the material parameters by using high-strength steel (with yield strength ≥600 MPa and elongation ≥20%) instead of traditional energy-absorbing materials. This parameter change allows the crash box to achieve excellent energy absorption capability while significantly reducing material density and vehicle weight.
Solution Approach 2:
The patent employs composite structural design by combining high-strength steel material properties with an optimized geometric configuration (container with deformable elongate members). This composite approach integrates material strength with structural efficiency to achieve superior energy absorption per unit weight.
2Loss of energy
If traditional energy-absorbing materials are used in crash boxes, then impact energy absorption capability is improved, but production cost increases
Solution Approach 1:
The patent changes the material parameters by using high-strength steel (with yield strength ≥600 MPa and elongation ≥20%) instead of traditional energy-absorbing materials. This parameter change allows the crash box to achieve excellent energy absorption capability while significantly reducing material density and vehicle weight.
Solution Approach 2:
The patent adopts a design philosophy where the crash box is optimized to be replaced after impact events. By using high-strength steel with predictable deformation characteristics, the system provides cost-effective protection without requiring expensive, long-lasting materials that maintain performance after deformation.
3Strength
If high-strength materials are used to enhance container strength, then energy absorption capability is improved, but material ductility may be reduced
Solution Approach 1:
The patent carefully selects high-strength steel materials that meet specific parameter thresholds: yield strength ≥600 MPa and elongation ≥20%. This parameter specification ensures that the material maintains both high strength for energy absorption and sufficient ductility for controlled deformation without brittle failure.
Solution Approach 2:
The patent applies local quality enhancement through chemical and physical processes to specific regions of the container and deformable members. These localized treatments optimize material properties where needed while preserving overall ductility and energy absorption characteristics.
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 effectively absorbs impact energy, reducing the transmission of force to the vehicle cabin and passengers, while minimizing weight and maintaining structural integrity, thereby lowering the risk of injury and enhancing the vehicle's passive safety system.
Implementation Method 1
the crash box collapses and absorbs impact first, prior to other structural components in the vehicle absorbing the impact. In effect, the crash box converts the impact energy of the collision into deformation work
Implementation Method 2
The strength and ductility properties of the container are enhanced by at least one of a chemical process and a physical process. At least one of a chemical process and physical process may include at least one of a mechanical treatment, laser sintering, a temperature treatment, a pH changing treatment, solvent swelling, a magnetic technique, the application of an electric current, light and a chemical oxidation technique.
Data Source
AI summary
An energy absorbing device includes a deformable elongate member that is arranged such that the device, in use, deforms in a controlled manner upon the absorption of impact energy. The invention also provides a chassis and a vehicle incorporating the energy absorbing device.