Honeycomb Energy Absorber with Predetermined Failure Points
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Solution Overview
Problem
Existing collision energy-absorbing devices are ineffective in absorbing kinetic energy from vehicle collisions, particularly due to mediocre energy absorption capabilities and potential for non-uniform deformation.
Innovation Solution
The device incorporates honeycomb-shaped absorbing elements with outward-deforming wall plates and pop rivets that fail at a predetermined load, along with stiffening ribs and air passages, to achieve controlled and efficient plastic deformation of the connection body and attachments, enhancing energy absorption and deformation uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cell assemblies are used between diaphragms, then the device provides structural support, but the energy absorption effectiveness is mediocre
Solution Approach 1:
The patent employs honeycomb blocks with numerous through-holes extending from front to rear sides. These porous absorbing elements allow kinetic energy to be converted into plastic deformation energy through the deformation of honeycomb walls and connection elements, significantly enhancing energy absorption effectiveness compared to solid cell assemblies.
Solution Approach 2:
The device combines plate-shaped bodies made of one material with honeycomb blocks made of potentially different materials, creating a composite structure. This allows optimization of each component for its specific function: plate-shaped bodies provide structural framework while honeycomb blocks provide energy absorption through their porous structure.
2Ease of manufacture
If the device structure is simplified, then manufacturing cost decreases, but deformation control during collision becomes non-uniform
Solution Approach 1:
The device is divided into multiple identical plate-shaped bodies and honeycomb blocks arranged in sequence. This segmentation allows standardized mass production of individual components at low cost, while the repeated modular pattern ensures uniform deformation distribution during collision as each segment deforms in a controlled manner.
Solution Approach 2:
Connection elements are strategically positioned at specific locations between plate-shaped bodies and honeycomb blocks. These localized connection points are designed to fail at predetermined loads, creating controlled deformation zones that guide the overall deformation pattern and ensure uniformity across the entire device structure.
3Ease of manufacture
If pop rivets are inserted into openings with uninterrupted edges, then assembly is simpler, but the load failure point is not predictable
Solution Approach 1:
Radial slits are pre-formed in the openings of plate-shaped bodies before assembly. These slits create predetermined stress concentration points that ensure pop rivets fail at specific, predictable loads during collision. The slits are created in advance during manufacturing, maintaining assembly simplicity while ensuring predictable failure characteristics.
4Strength
If the absorbing elements are made thicker, then energy absorption increases, but the device weight increases
Solution Approach 1:
Honeycomb blocks with high porosity are used as absorbing elements. The porous structure provides large surface area and numerous deformation pathways for energy absorption while maintaining low material density. This allows thick absorbing elements to be created with high energy absorption capacity without proportionally increasing device weight.
Solution Approach 2:
The honeycomb structure uses hexagonal cells with curved walls instead of straight edges. This curvature distributes stress more evenly during deformation and allows the material to deform in a controlled manner, maximizing energy absorption per unit mass and reducing the need for excessive thickness.
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 significantly improves collision energy absorption by converting kinetic energy into plastic deformation energy, ensuring effective and controlled deformation, resulting in enhanced energy absorption and a lightweight, cost-effective solution.
Implementation Method 1
kinetic energy is absorbed by plastic deformation of the connection body and/or the attachments between the plate-shaped bodies and the connection body
Data Source
Figure 1~2
Figure 3~4
AI summary
A collision energy-absorbing device (1), comprising - a substantially flat front side (3), - a rear side (4) situated at a distance from said front side (3), - a number of plate-shaped bodies (5) arranged at mutual distances in a row between said front side (3) and said rear side (4), and - a number of absorbing elements (6) arranged in the respective interspaces between adjoining plate-shaped bodies (5), - at least one connection body (7a, 7b, 7c, 7d) provided at the circumferential edge of said plate-shaped bodies (5) so as to interconnect said bodies (5), wherein the absorbing device (1) is constructed such that in case of a collision, kinetic energy is absorbed by plastic deformation of the connection body (7a, 7b, 7c, 7d) and/or the attachments between the plate-shaped bodies (5) and the connection body (7a, 7b, 7c, 7d). The absorbing elements (6) may comprise blocks provided with a plurality of honeycomb-shaped openings (6a), which blocks are provided in the interspaces between the plate-shaped bodies (5). The device (1) may comprise a wall plate (7a, 7b) which is provided along the circumferential edges of the plate-shaped bodies (5) and which is preformed slightly outwards.