Energy Absorbing Backshell With Honeycomb Core
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Solution Overview
Problem
Existing seat back designs fail to reliably absorb impact energy, leading to potential serious head injuries in vehicle collisions, and current solutions like airbags and restraints are costly, heavy, complex, and reduce passenger comfort.
Innovation Solution
An energy-absorbing backshell design featuring a non-metallic core and casing with a bent metallic tube, adhered by an adhesive and filled with self-expanding foam, allowing for local deformation and force absorption during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air bags and upper torso restraints are used to reduce head injury, then passenger safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the energy absorption function from complex active safety systems (airbags, restraints) and implements it passively within the seat backshell structure itself. The backshell is designed to deform and absorb impact energy directly at the impact location, eliminating the need for separate active restraint systems.
Solution Approach 2:
The backshell is pre-designed with energy-absorbing structural features (honeycomb core, collapsible geometry) that are prepared in advance to cushion impact forces. When impact occurs, these pre-configured structures immediately begin absorbing energy without requiring activation mechanisms.
2Reliability
If air bags and restraints are installed to prevent head trauma, then passenger protection is improved, but weight increases
Solution Approach 1:
The backshell structure performs multiple functions: it provides the necessary structural support for the seat while simultaneously serving as an energy-absorbing impact protection system. This multi-functionality eliminates the need for separate weight-bearing safety devices.
Solution Approach 2:
The backshell utilizes composite construction with a honeycomb core material that provides high energy absorption per unit weight. The combination of outer shell material and honeycomb core creates a lightweight yet highly effective impact absorption system.
3Ease of manufacture
If traditional seat back design is used, then manufacturing simplicity is maintained, but impact energy absorption capability is insufficient
Solution Approach 1:
The honeycomb core structure is a porous material configuration that provides exceptional energy absorption through controlled collapse of the cell structure. This porous geometry is manufactured using standard honeycomb bonding techniques that are well-established in the industry.
Solution Approach 2:
The backshell incorporates curved and rounded geometric features that facilitate progressive deformation during impact. The curved geometry allows for more gradual energy absorption compared to flat rigid structures, while remaining manufacturable using standard forming 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 design provides a lightweight, effective means to absorb impact forces, reducing injury risk while maintaining passenger comfort and reducing costs associated with heavier, more complex safety features.
Implementation Method 1
allowing for local deformation and force absorption during impacts
Implementation Method 2
The design provides a lightweight, effective means to absorb impact forces
Implementation Method 3
the non-metallic core is adhered to the non-metallic casing by an adhesive
Implementation Method 4
filled with self-expanding foam, allowing for local deformation and force absorption during impacts
Data Source
AI summary
An energy absorbing backshell including a non-metallic core, a non-metallic casing surrounding the non-metallic core, a tube on the top surface of the non-metallic core and non-metallic casing.