Extruded Deformation Element for Vehicle Crash Management

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Solution Overview

Problem

Current deformation elements in crash management systems for motor vehicles either increase weight or require a large number of components, compromising energy absorption efficiency and passenger safety.

Innovation Solution

A deformation element made from an extruded hollow profile with a larger outer surface area than inner surface area, designed to connect a bumper beam to a side rail, enhancing the support of the bumper beam and improving energy absorption by spreading impact load over a larger area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If deformation elements are designed with larger outer surface area than inner surface area, then energy absorption efficiency is improved and bumper beam support is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy absorption efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The deformation element is divided into two distinct sections: an outer section with larger surface area for energy absorption and an inner section with smaller surface area for structural support. This segmentation allows each section to be optimized for its specific function while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different surface areas are assigned to different locations of the deformation element. The outer section has a larger surface area to maximize energy absorption during impact, while the inner section has a smaller surface area to maintain structural support. This local differentiation of properties optimizes overall performance.

Inventive Principle:

Principle #3Local quality

2Strength

If deformation elements use additional reinforcement parts, then structural strength is improved, but vehicle weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The reinforcement function is merged into the deformation element itself by creating an integrated structure with varying surface areas. The outer section with larger surface area provides both structural strength and energy absorption capability, eliminating the need for separate reinforcement parts and reducing overall weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The deformation element serves multiple functions simultaneously: it provides structural support through its inner section, absorbs energy through its outer section, and reinforces the bumper beam connection. This multi-functionality eliminates the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If deformation elements require multiple components for assembly, then installation flexibility is improved, but assembly time and complexity increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidnumber of components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Multiple functional components (outer section, inner section, reinforcement elements) are merged into a single integrated deformation element. This reduces the total number of components from multiple separate parts to one unified structure, simplifying assembly while maintaining all necessary functions.

Inventive Principle:

Principle #5Merging (Combining)

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 stiffens the bumper beam, enhances energy absorption, and reduces intrusion into the vehicle, thereby improving passenger safety and compliance with regulatory requirements without significant weight increase.

Implementation Method 1

The deformation element of an automobile is designed to improve damageability and repair-ability of the car body, which allows the absorption of impact forces through bending deformation. During crushing, these structures will exhibit plastic deformation by collapse and sequential folding process.

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

Methodology Applied

Scientific EffectStress distribution:

Data Source

PatentEP4187121A1Deformation element in an impact absorbing structure

Publication Date: 2023.05.31 CONSTELLIUM SINGEN GMBH

Figure 1a~1b
Figure 2a~2b
Figure 3a~3b

AI summary

Deformation element (3) for a motor vehicle made from an extruded hollow profile having at least one internal web (35), said deformation element (3) having a crash length (L), an outer section (31), an inner section (32), a superior lateral wall (331), an inferior lateral wall (332), side lateral walls (333) and at least one lateral section (34, 34a, 34b), said deformation element (3) being intended to connect a bumper beam (2) to a side rail (4), the outer section (31) intended to be in relation to a bumper beam connecting wall (22, 23) having an outer surface area (A1) and the inner section (32) intended to be in relation to the side rail (6) having an inner surface area (A2), wherein said outer surface area (A1) is larger than said inner surface area (A2).