Multi-Chamber Crash Box With Internal Deformable Energy Absorber

Solution Overview

Problem

Current crash management systems face challenges in efficiently absorbing varying levels of energy without significant weight increase or modification of the crash box, necessitating a solution that enhances energy absorption and force resistance without altering the hollow profile or increasing production costs.

Innovation Solution

Incorporating a deformable element within the crash box's hollow profile, which absorbs additional impact energy by folding under compressive force, allowing for improved energy absorption without changing the external geometry or weight, and can be adapted to meet different performance levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the hollow profile wall thickness is increased to improve energy absorption, then the energy absorption capacity is improved, but the weight of the crash box increases

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidweight of crash box

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The hollow profile is divided into multiple chambers (at least two chambers) separated by partition walls, creating distinct deformation zones. This segmentation allows each chamber to contribute to energy absorption through controlled folding patterns, achieving enhanced energy absorption capacity without increasing overall wall thickness or weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A deformable element is inserted inside one of the chambers of the hollow profile. This nested configuration allows the deformable element to absorb additional impact energy through its own deformation mechanisms, effectively adding energy absorption capacity within the existing structural envelope without increasing weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Use of energy by moving object

If the crash box structure is modified to increase energy absorption, then the performance is improved, but the production cost increases

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidproduction cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The hollow profile is divided into multiple chambers (at least two chambers) separated by partition walls, creating distinct deformation zones. This segmentation allows each chamber to contribute to energy absorption through controlled folding patterns, achieving enhanced energy absorption capacity without increasing overall wall thickness or weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A deformable element is inserted inside one of the chambers of the hollow profile. This nested configuration allows the deformable element to absorb additional impact energy through its own deformation mechanisms, effectively adding energy absorption capacity within the existing structural envelope without increasing weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Use of energy by moving object

If the hollow profile geometry is changed to improve energy absorption, then the energy absorption capacity is improved, but the external dimensions and design are modified

Engineering Contradiction:

Improveenergy absorption capacityVSAvoidexternal geometry

Core Design Contradiction:

Use of energy by moving objectVSShape

Solution Approach 1:

A deformable element is inserted inside one of the chambers of the hollow profile. This nested configuration allows the deformable element to absorb additional impact energy through its own deformation mechanisms, effectively adding energy absorption capacity within the existing structural envelope without increasing weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The hollow profile is divided into multiple chambers (at least two chambers) separated by partition walls, creating distinct deformation zones. This segmentation allows each chamber to contribute to energy absorption through controlled folding patterns, achieving enhanced energy absorption capacity without increasing overall wall thickness or weight.

Inventive Principle:

Principle #1Segmentation

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 deformable element enhances the crash box's energy absorption capacity and resistance to higher forces, allowing it to meet increased performance requirements without modifying the crash box's design or increasing weight, thus offering a flexible and cost-effective solution.

Implementation Method 1

the deformable element is subjected to a compressive force in a longitudinal direction X of the hollow profile extending from the front side to the rear side of the crash box and the deformable element has a deformed shape in the longitudinal direction X resulting from a folding of the deformable element

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS12097817B2Crash box containing a deformable element to extend the capacity of a crash box to absorb impact energy

Publication Date: 2024.09.24 CONSTELLIUM SINGEN GMBH

AI summary

A crash box (3) comprising a hollow profile (38) extending along a longitudinal direction (X) and having a crush length (LCB), said hollow profile (38) having at least two chambers (4) characterized in that it comprises at least a deformable element (7, 7′, 7″) contained into at least one chamber (4) contributing to the energy absorption capability of said crash box (3).