Multi-layer Energy Absorber for Uniform Impact Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle bumpers lack uniform energy absorption structures, leading to inconsistent performance during low-speed impacts, particularly with pedestrians, as separate longitudinal lobes do not efficiently distribute loads and provide uneven protection.
Innovation Solution
A multi-layer energy absorber design featuring a central portion with interconnected layers forming meshed patterns, including a unitary front member and multiple layers with alternating open and closed sections, which absorbs and disperses energy uniformly across its width, enhancing impact performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If separate longitudinal lobes are used in the bumper structure, then the bumper can absorb energy during impact, but the energy absorption is inconsistent and peak loading conditions occur
Solution Approach 1:
The energy absorber is divided into multiple layers (first layer, second layer, third layer) with each layer containing segmented structures such as cells, compartments, and alternating open/closed sections. This segmentation allows energy to be distributed and absorbed uniformly across multiple zones, preventing peak loading conditions while maintaining consistent energy absorption throughout the impact event.
Solution Approach 2:
Different regions of the energy absorber are designed with different structural qualities - the first layer has a specific cell structure, the second layer has a different cell structure, and the third layer has alternating open and closed sections. Each layer's local structure is optimized to contribute differently to energy absorption, creating a uniform overall performance that prevents inconsistent energy absorption and peak loading.
2Reliability
If a multi-layer structure with interconnected members is used, then energy absorption consistency is improved, but the structural complexity increases
Solution Approach 1:
The first layer, second layer, and third layer are interconnected and merged into a single integrated energy absorber structure. The interconnection means that the layers work together as a unified system, distributing loads uniformly across the entire structure. This merging approach achieves uniform energy absorption while managing complexity through integrated design rather than separate components.
Solution Approach 2:
The energy absorber transitions from a single-layer two-dimensional structure to a multi-layer three-dimensional structure. By adding the vertical dimension with multiple interconnected layers, the design achieves uniform energy absorption across the impact area while the systematic arrangement of layers provides a method to manage and organize the structural complexity.
3Loss of energy
If alternating open and closed sections are used in the third layer, then energy dispersion is improved, but the manufacturing complexity increases
Solution Approach 1:
The third layer is segmented into alternating open sections and closed sections, creating a pattern that optimizes energy dispersion. This segmentation allows the structure to manage energy absorption in a controlled manner, dispersing energy uniformly while the repetitive alternating pattern provides a systematic approach that can simplify manufacturing through standardized production techniques.
Solution Approach 2:
The third layer alternates between open and closed sections, changing the structural parameter of openness along the length of the energy absorber. This parameter change optimizes energy dispersion by creating zones of different stiffness and energy absorption characteristics, while the systematic alternation provides a manufacturable pattern that can be produced using consistent manufacturing processes.
Data Source
AI summary
An energy absorber for a vehicle bumper assembly having a central portion that is a multi-layer structure having a unitary front member extending between two end portions, a first layer, a second layer, and a third layer disposed between and interconnecting the first and second layers. The first layer has a first plurality of members forming a first latticework structure having a first network of open sections between the first plurality of members. The first layer extends between the two end portions and between a rear member of the first layer and the unitary front member. The second layer has a second plurality of members forming a second latticework structure having a second network of open sections between the second plurality of members. The second layer extends between the two end portions and between a rear member of the second layer and the unitary front member.