One-Piece Cold Extruded Crash Element
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Solution Overview
Problem
Existing crash elements or crash boxes are designed as multi-part components, leading to increased production costs due to the need for reliable transmission of forces from the support plate to the deformable hollow chamber profile during a crash, and they often require labor-intensive and costly manufacturing connections.
Innovation Solution
A one-piece crash element with a carrier plate and hollow chamber profile, produced using cold extrusion technology, where the carrier plate has varying thicknesses and the hollow chamber profile has changing cross-sections, eliminating the need for separate manufacturing connections and allowing for efficient energy absorption during crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crash elements are designed as multi-part components, then the hollow chamber profile can be combined with the carrier plate, but the production cost increases due to the need for reliable force transmission connections
Solution Approach 1:
The patent merges the hollow chamber profile and the carrier plate into a single integrated component. This eliminates the need for separate connections between parts, thereby reducing production costs while ensuring reliable force transmission during crashes, as the integrated design inherently provides continuous structural integrity.
2Productivity
If the hollow chamber profile and carrier plate are connected as separate parts, then assembly is possible, but labor-intensive and costly manufacturing connections are required
Solution Approach 1:
By combining the hollow chamber profile and carrier plate into one piece, the patent eliminates the need for separate assembly operations and connection processes. This significantly improves manufacturing efficiency and reduces the complexity associated with creating and verifying connections between separate parts.
3Ease of manufacture
If the carrier plate has uniform thickness, then manufacturing is simpler, but areas with higher loads cannot be adequately reinforced
Solution Approach 1:
The patent implements variable thickness in the carrier plate, where the thickness is adapted to the local load requirements. Areas subjected to higher loads during crashes have greater thickness for enhanced strength, while areas with lower loads have reduced thickness to minimize material consumption. This localized differentiation optimizes both structural performance and manufacturing efficiency.
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 reduces production costs, ensures high stability, and minimizes material consumption while maintaining high surface quality and dimensional accuracy, enabling the production of lightweight and robust crash elements with reduced risk of separation between components during crashes.
Implementation Method 1
a hollow chamber profile (2) that can be deformed in an energy-absorbing manner in the event of a crash
Implementation Method 2
the hollow chamber profile and the carrier plate are produced as a one-piece component using extrusion technology, in particular cold extrusion technology
Implementation Method 3
A blank is placed in the corresponding forming device and plastically deformed in a predetermined manner by a press die
Data Source
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AI summary
The crash element (1) has a deformable hollow chamber profile (2) absorbing energy in crash fall and a carrier plate (3) for arranging the hollow chamber profile on a longitudinal- or bent carrier of the motor vehicle. The hollow chamber profile and the carrier plate are formed extrusion press technically, particularly cold extrusion press technically as integrated component. The component is formed of aluminum, an aluminum alloy or aluminum material. The component is reinforced by reinforcing elements, particularly bars (4) extending between the hollow chamber profile and the carrier plate. An independent claim is also included for a method for manufacturing a crash element, particularly crash box for a motor vehicle.