Heptagonal Crash Box for Simultaneous RCAR Corner and Center Test Performance
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Solution Overview
Problem
Conventional crash boxes fail to simultaneously satisfy the RCAR corner test and center test due to their cross-sectional shapes, which are either advantageous for compress-deformation or load support but not both, leading to inefficiencies in impact energy absorption and structural rigidity.
Innovation Solution
A crash box with a heptagonal cross-sectional shape in the vehicle width direction, featuring parallel vertical and horizontal sides, inclined sides, and reinforcement ribs and pipe tubes, which connect in a cross shape to enhance both compress-deformation and load support capabilities, while being lightweight and formed from plastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cross-sectional shapes are used, then manufacturing simplicity is maintained, but performance in both RCAR corner test and center test cannot be satisfied simultaneously
Solution Approach 1:
The crash box cross-section is divided into multiple functional regions: compression-resistant regions (first and second compression-resistant regions) for absorbing impact energy during corner tests, and load-supporting regions (first and second load-supporting regions) for maintaining structural integrity during center tests. This segmentation allows each region to be optimized for its specific function, resolving the contradiction between compress-deformation performance and load support performance.
Solution Approach 2:
Different portions of the crash box cross-section are given different structural qualities tailored to their specific functions. The compression-resistant regions have geometries optimized for energy absorption during diagonal impacts, while the load-supporting regions have geometries optimized for axial load bearing. This local differentiation of structural properties allows the single crash box to satisfy both RCAR corner test and center test requirements simultaneously.
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 heptagonal cross-sectional shape and reinforcement structures enable high performance in RCAR corner tests and sufficient rigidity for center tests, maintaining impact absorption and structural integrity while reducing weight and improving fuel efficiency.
Implementation Method 1
The crash box is configured to absorb impact energy by being compress-deformed in an axial direction (front/rearward)
Implementation Method 2
a plurality of reinforcement ribs formed at an inner space of the intermediate connection portion
Data Source
AI summary
A crash box for a vehicle may include a front connection portion that is connected to both ends of a back beam of the vehicle, a rear connection portion that is connected to a side member of the vehicle, an intermediate connection portion for connecting the front connection portion and the rear connection portion, which is formed as a hollow box shape and through which a cut cross-section of a heptangular shape is formed in a vehicle width direction, and a plurality of reinforcement ribs formed at an inner space of the intermediate connection portion.