Double Honeycomb Impact Absorber for Vehicle Energy Management
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Solution Overview
Problem
Existing impact absorbing elements for vehicles, typically with rectangular cross sections, face challenges in efficiently absorbing energy while maintaining a lightweight design and compliance with varying vehicle requirements and legal regulations, limiting their energy absorption capacity.
Innovation Solution
A tubular impact absorbing element with a double honeycomb-shaped cross section configured as a 10-faced polygon, featuring symmetrical honeycomb points and adjustable dimensions for optimal energy absorption, allowing for increased energy absorption without excessive weight, and produced using extruded aluminum sections without joining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional rectangular cross section impact absorbing elements are used, then manufacturing is simple, but energy absorption capacity is limited
Solution Approach 1:
The cross section is segmented into two separate honeycomb structures arranged side by side, each forming a complete honeycomb pattern. This segmentation allows each honeycomb to independently absorb impact energy through its cellular structure, significantly increasing total energy absorption capacity compared to a solid rectangular section, while maintaining manufacturability through extrusion processes.
Solution Approach 2:
The impact absorbing element utilizes a porous honeycomb structure instead of a solid rectangular section. The honeycomb geometry provides numerous cells that can collapse and deform during impact, absorbing kinetic energy through controlled crushing. This porous structure achieves superior energy absorption per unit weight and volume compared to traditional solid sections.
2Use of energy by moving object
If impact absorbing element weight is increased to improve energy absorption, then energy absorption capacity increases, but vehicle weight increases
Solution Approach 1:
The honeycomb structure provides high energy absorption capacity with reduced material usage. The cellular geometry allows the structure to absorb impact energy through progressive cell collapse, achieving high specific energy absorption (energy absorbed per unit weight). This porous architecture absorbs more energy per kilogram compared to solid sections, reducing the weight penalty.
Solution Approach 2:
The dual honeycomb configuration creates a composite structural system where two honeycomb patterns work together to absorb impact energy. This composite approach optimizes the strength-to-weight ratio by distributing stress across multiple cellular pathways, enhancing energy absorption capacity without proportionally increasing weight.
3Adaptability or versatility
If impact absorbing element dimensions are standardized, then manufacturing is simplified, but adaptability to different vehicle requirements is reduced
Solution Approach 1:
The extrusion process allows dynamic adjustment of the honeycomb parameters including cell size, wall thickness, and overall dimensions. These geometric parameters can be varied along the length of the extrusion or between different production batches, enabling customization for different vehicle types and impact requirements while maintaining the benefits of continuous extrusion manufacturing.
Solution Approach 2:
The honeycomb structure parameters (cell dimensions, wall thickness, spacing) can be changed to optimize performance for different vehicle applications. By adjusting these geometric parameters during the extrusion process, the same basic dual-honeycomb design can be adapted to meet varying energy absorption requirements, vehicle weights, and regulatory standards without requiring fundamentally different manufacturing processes.
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 double honeycomb structure enhances energy absorption capacity, enabling the element to effectively manage impact energy between the bumper and vehicle frame, offering improved deformation behavior and adaptability to different vehicle requirements while maintaining a lightweight profile.
Implementation Method 1
the impact absorbing elements absorb the kinetic energy which results from an impact, by said kinetic energy being converted into deformation energy
Data Source
AI summary
An impact absorbing element comprising a tubular body for absorbing the impact energy in a vehicle is proposed, the impact absorbing element having a double honeycomb-shaped cross section and being configured as a 10-face polygonal line, and honeycomb points being configured which are situated at a spacing (b2) from one another of approximately half the overall height (b1) of the impact absorbing element and define a width.