Folding Fiber Composite Deformation Element for Off-Axis Impact
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Solution Overview
Problem
Existing deformation elements for vehicles face challenges in efficiently absorbing kinetic energy during collisions, especially when the collision angle is off-axis, leading to potential buckling and failure in energy absorption, and require complex and costly manufacturing processes like deep-drawing and draping.
Innovation Solution
A three-dimensional deformation element is created by folding, bending, or deflecting flat starting material to form bulges, which increases deformation resistance and energy absorption capacity, while maintaining the original mechanical properties of the material, thus simplifying production and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deep-drawing or draping methods are used to create three-dimensional deformation elements, then the energy absorption capacity and structural integrity are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The deformation element is divided into multiple pre-formed three-dimensional modules, each with specific energy absorption characteristics. These modules can be independently manufactured and then assembled, simplifying the overall manufacturing process while maintaining structural integrity and energy absorption capacity.
Solution Approach 2:
The three-dimensional shape and bulges are pre-formed in the deformation elements during manufacturing, rather than being created through complex deep-drawing or draping processes during final assembly. This preliminary shaping allows for simpler production methods while ensuring the required structural integrity for energy absorption.
2Use of energy by moving object
If complex three-dimensional shapes with uniform wave heights are created, then the energy absorption capacity is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The deformation elements feature variable wave heights rather than uniform waves, with different sections having different absorption characteristics optimized for their specific function. This local variation in geometry allows for improved energy absorption while simplifying manufacturing compared to creating perfectly uniform complex three-dimensional shapes.
Solution Approach 2:
The invention transitions from two-dimensional flat material to three-dimensional deformed structures with varying wave heights. This dimensional transformation creates enhanced energy absorption capacity through out-of-plane deformations while allowing for simpler manufacturing processes compared to traditional deep-drawing methods.
3Strength
If fiber composite materials are used for deformation elements, then the strength and energy absorption are improved, but the susceptibility to buckling under off-axis loads increases
Solution Approach 1:
The deformation elements incorporate curved surfaces and bulges that distribute off-axis loads more effectively, reducing stress concentrations that lead to buckling. The three-dimensional curved geometry helps maintain structural stability under varying load directions while preserving the high strength characteristics of fiber composite materials.
Solution Approach 2:
The invention uses fiber composite materials with specific fiber orientations and stacking sequences that enhance resistance to buckling under off-axis loads. The composite structure is designed to accommodate multi-directional stress states while maintaining high strength and energy absorption capacity.
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 solution enables effective energy absorption and structural integrity during collisions, including off-axis impacts, with increased deformation resistance and simplified, cost-effective manufacturing, ensuring maximum energy conversion and prolonged structural integrity.
Implementation Method 1
convert the kinetic energy of the collision partner into deformation energy in a targeted manner
Implementation Method 2
A significant part of the kinetic energy is absorbed with the inversion process
Implementation Method 3
a fiber-reinforced plastic composite, in particular a unidirectional fiber-reinforced plastic composite, whose polymer matrix can be formed from duroplastics, thermoplastics or elastomers
Data Source
Figure 1a~1d
Figure 2a~2c
Figure 3a~3b
AI summary
The deformation element (1.3) has a breaking portion (1.4) that is made of a fiber plastic composite and is extended from the first edge (1.1) at a lateral distance from the second edge (1.2). The first edge and the second edge are connected by a lateral surface (1.5), which is formed by connecting the first edge and the second edge surface lines. The first edge has a greater length than the second edge. The first edge of a curve with the first protrusions is adjacent to the second recesses. An independent claim is included for a method for producing a deformation element.