Integral Additive Crumple Element for Steering Column
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Solution Overview
Problem
Modern safety steering columns are complex and costly due to a high number of interacting components, making them expensive to construct and repair, while maintaining the need for reliable energy absorption and torque transmission during frontal impacts.
Innovation Solution
A crumple element with first and second connecting portions and an interrupted crumple portion is designed to be made integrally from metal using additive production methods, such as selective laser melting, allowing for a structurally simple and efficient energy absorption mechanism that can be easily replaced after deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crumple element with multiple interacting components is used to achieve reliable energy absorption and torque transmission, then safety performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the crumple portion and connecting portions into a single integral component made from metal using additive production. This merging eliminates the need for multiple separate parts and their associated connections, thereby reducing device complexity and manufacturing cost while maintaining the structural integrity needed for reliable energy absorption and torque transmission during frontal impacts
2Strength
If traditional manufacturing methods are used for crumple elements, then structural integrity is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (such as machining, assembling multiple parts, or welding) with additive production technology. This substitution enables the creation of complex integral structures with optimized geometries for both strength and energy absorption, while significantly reducing manufacturing steps, time, and cost
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 crumple element effectively shortens the steering column and absorbs energy during impacts, preventing penetration into the driver's compartment while maintaining torsional stiffness for torque transmission, and can be easily integrated and replaced, reducing the overall complexity and cost of the safety steering column.
Implementation Method 1
the crumple portion is deformable by an axially acting threshold force
Implementation Method 2
made integrally from metal by additive production, such as selective laser melting
Data Source
AI summary
The disclosure concerns a crumple element for a steering column. In order to provide a reliable, structurally simple steering column, according to the disclosure, it is provided that the crumple element has first and second connecting portions arranged axially at an end to connect adjacent steering column parts, and an interrupted crumple portion arranged in between the first and second connecting portions, and is able to deform by a threshold force acting axially, while the connecting portions are deformation-resistant to the threshold force. The crumple element is made integrally by additive production from metal. An end region of the first connecting portion facing the crumple portion has a first portion that protrudes axially relative to a second portion lying opposite the first portion transversely to the axial direction.