Porous Cellular Part Structure for Lightweight Shock Absorption
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Solution Overview
Problem
Existing methods for manufacturing shock absorbing devices with cellular structures struggle to produce pores smaller than 14 mm, are energy-intensive, and fail to achieve lightweight designs required for reducing vehicle energy consumption.
Innovation Solution
A porous structure is created through additive manufacturing, utilizing a periodic repetition of a basic pattern with parietal porosity greater than 5% and parietal pores smaller than the cellular pores, achieved by controlling the energy density and movement speed of a laser beam during the additive process to form lightweight metal or polymer parts with high porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If founding is used to manufacture shock absorbing devices, then cellular structure can be formed, but it is energy intensive and cannot produce pores smaller than 14 mm
Solution Approach 1:
The patent changes the manufacturing parameters by transitioning from founding to additive manufacturing, which enables precise control of pore sizes below 14 mm while reducing energy consumption. The additive manufacturing process allows for digital control of geometric parameters including pore size, distribution, and wall thickness.
Solution Approach 2:
The patent replaces the mechanical founding process with additive manufacturing technology, substituting a high-energy mechanical deformation process with a layer-by-layer material deposition process that offers better energy efficiency and precision control for creating cellular structures with small pores.
2Strength
If dense walls are used in cellular structure, then mechanical strength is improved, but weight increases
Solution Approach 1:
The patent applies local quality by introducing porosity specifically in the walls (parietal porosity greater than 5%) rather than making the entire structure dense. This allows the walls to provide sufficient mechanical strength while containing air pockets that reduce material weight, creating a lightweight structure with optimized local properties.
Solution Approach 2:
The patent utilizes porous materials by incorporating parietal pores within the walls of the cellular structure. This creates a hierarchical porous system where the walls themselves contain pores, reducing material density and weight while maintaining structural integrity through the cellular architecture.
3Weight of moving object
If high porosity is achieved to reduce weight, then material weight decreases, but manufacturing complexity increases
Solution Approach 1:
The patent employs periodic action through the periodic repetition of a basic pattern to generate the cellular structure. This systematic approach allows complex high-porosity structures to be created by repeating a simple unit cell, reducing manufacturing complexity compared to designing each pore individually while achieving high weight reduction.
Solution Approach 2:
The patent applies segmentation by dividing the structure into repeating basic patterns or unit cells. This modular approach simplifies the manufacturing of complex porous structures by breaking them down into manageable, repeatable elements, making the production of high- porosity lightweight parts more feasible.
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 method enables the production of lightweight shock absorbing devices with high porosity, reducing material weight and energy consumption, while maintaining mechanical performance.
Implementation Method 1
controlling the energy density and movement speed of a laser beam during the additive process
Implementation Method 2
utilizing a periodic repetition of a basic pattern with parietal porosity greater than 5% and parietal pores smaller than the cellular pores, achieved by controlling the energy density and movement speed of a laser beam during the additive process
Data Source
AI summary
A part including a porous structure including cellular pores and formed at least in part by the periodic repetition of a basic pattern, each cellular pore being delimited by a wall, made of a metal or a polymer, having a parietal porosity greater than 5% and including parietal pores with a mean size less than the mean size of the cellular pores.