Plastic Energy Absorber with Collapsible Channels
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Solution Overview
Problem
Existing energy absorbers in vehicles are costly due to metal construction, add excessive weight, and fail to effectively cushion occupants of varying sizes and weights during impacts, as they are designed for specific weight and height ranges.
Innovation Solution
A single-piece, injection molded plastic energy absorber with channels and engagement features that collapse upon impact, allowing for customizable resistance by varying channel height, length, and material distribution, and incorporating straps and transverse walls for enhanced deformation and impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal is used in the construction of the energy absorber, then the strength and energy absorption capability are improved, but the cost increases and the weight increases
Solution Approach 1:
The patent changes the material parameter from metal to plastic, and modifies the structural parameters by creating channels with varying heights, thicknesses, and configurations within the plastic energy absorber. This allows the plastic component to achieve energy absorption capabilities comparable to metal while significantly reducing weight and cost.
Solution Approach 2:
The patent employs plastic as a composite or alternative material to traditional metal construction. By using plastic with specifically engineered channel structures, the design achieves the desired mechanical performance for energy absorption without the weight and cost penalties of metal materials.
2Strength
If separate metal pieces are assembled to form the energy absorber, then the energy absorption effectiveness is improved, but the device complexity and manufacturing labor increase
Solution Approach 1:
The patent merges multiple separate metal pieces into a single integrated plastic component. The energy absorber is formed as one piece with channels of varying heights and configurations that provide the necessary energy absorption characteristics, eliminating the need for complex assembly of multiple components.
Solution Approach 2:
By changing from metal construction to plastic injection molding, the patent enables the creation of complex three-dimensional channel structures in a single manufacturing step. The varying channel parameters (height, thickness, configuration) are directly formed during molding, achieving energy absorption effectiveness without assembly complexity.
3Strength
If the energy absorber is designed for a specific weight and height range, then the cushioning effectiveness for that range is improved, but the adaptability to occupants of different sizes decreases
Solution Approach 1:
The patent applies local quality by creating channels with varying heights, thicknesses, and configurations at different locations within the energy absorber. This non-uniform structure allows different regions to provide appropriate resistance for occupants of varying sizes and weights, with the engagement feature enabling selective engagement of specific channel configurations.
Solution Approach 2:
The energy absorber incorporates dynamic characteristics through its channel structure that allows progressive deformation. The varying channel parameters create a progressive resistance profile that adapts to different impact forces and occupant characteristics, providing effective cushioning across a range of occupant sizes and weights.
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 provides a lightweight, cost-effective energy absorber that can effectively cushion occupants of different sizes and weights by tuning resistance levels through design modifications, ensuring optimal impact force distribution and absorption.
Implementation Method 1
The at least one channel having the first engagement feature may be configured to at least partially collapse when an impact force causes the at least one channel to engage the stationary member
Implementation Method 2
Energy absorbers may aid in preventing injury and saving lives by providing cushioning, by extending the period of time over which the force of an impact may act on the body of a person
Data Source
AI summary
An energy absorber for a vehicle includes an elongate member having lateral and longitudinal axes. The elongate member may include one or more channels which are oriented to have walls which extend in the general direction of the lateral axis. An upper surface of at least one of the channels may have an engagement feature that may be configured to engage a stationary member of a vehicle when an impact force brings the engagement feature into contact with the stationary member. The channels may be configured to deform and collapse to absorb at least some of the impact force.