Perturbed Honeycomb Crush Structure for Controlled Buckling
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Solution Overview
Problem
Standard honeycomb structures exhibit non-linear compressive stiffness with an initial stiffness peak that decreases after cell buckling, making it difficult to control crumpling location and leading to unpredictable energy absorption in impact applications.
Innovation Solution
Incorporating geometric perturbations on cell sidewalls not parallel to the longitudinal axis, such as creases, folds, or thinned regions, to reduce stiffness and crush strength in a controlled manner, allowing for modifiable compressive and shear stiffness and improved formability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard honeycomb structures are used, then the structure provides basic energy absorption through cell buckling, but the initial stiffness peak makes it difficult to control crumpling location and predict energy absorption
Solution Approach 1:
The patent applies preliminary action by pre-forming geometric perturbations (creases, folds, thinned regions) on the cell sidewalls before impact occurs. These pre-formed features create predetermined weak points that initiate buckling at specific locations and phases, eliminating the random initial stiffness peak and making crumpling location predictable and controllable.
2Stability of the object's composition
If pre-crushing is applied to eliminate initial stiffness peak, then the stiffness peak is reduced, but the crumpling location cannot be precisely controlled
Solution Approach 1:
The patent applies local quality by creating non-uniform geometric perturbations at specific locations on cell sidewalls. These localized features (creases, folds, thinned regions) have different properties than the surrounding material, creating predetermined sites for controlled buckling initiation. This allows precise control of where crumpling occurs while simultaneously reducing the initial stiffness peak.
3Manufacturing precision
If geometric perturbations are added to control buckling, then crumpling location control improves, but the structure complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the cell sidewall into distinct regions with different geometric properties. Instead of uniformly modifying the entire sidewall, specific segments are perturbed with creases, folds, or thinned regions. This segmented approach provides precise control over buckling location while keeping the overall structure relatively simple and manufacturable.
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 eliminates the initial stiffness peak, enables controlled buckling, and provides multi-phasic compressive stiffness, reducing the load required for plastic deformation and enhancing impact mitigation properties in energy-absorbing structures like helmet liners.
Implementation Method 1
plastic deformation in response to an applied load
Implementation Method 2
controlled buckling of interconnected cells by plastic deformation
Data Source
AI summary
An impact-absorbing structure that includes a plurality of interconnected cells forming a sheet, each cell having a sidewall and a longitudinal axis. Each cell may be configured to absorb energy through plastic deformation in response to an applied load, and a sidewall of at least one cell may include a geometric perturbation that is oriented in a direction that is not parallel to the longitudinal axis of the cell. The geometric perturbation may reduce the load required to cause plastic deformation of the cell.