Progressive Energy Absorber With Segmented Reinforcing Webs
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Solution Overview
Problem
Existing energy absorbers in the automobile industry are not cost-effective and lightweight, and they fail to achieve a desired level of energy absorption efficiently, as they do not provide a uniform force over time and distance during collapse.
Innovation Solution
A tubular energy absorber with tapered ends and reinforcing webs that progressively collapse, allowing controlled deformation to absorb energy, with the webs initiating collapse only after the tubular structure has begun to collapse, ensuring a more efficient energy absorption by maintaining a nearly constant force over time and distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional energy absorber constructions are used, then energy absorption is achieved, but the design is not lightweight and cost-effective
Solution Approach 1:
The energy absorber is segmented into a tubular outer shell assembly and multiple reinforcing webs positioned at different locations. The webs are shorter than the tubular structure, creating distinct collapse zones. This segmentation allows progressive collapse from the smaller end toward the larger end, enabling lightweight design while maintaining effective energy absorption through controlled sequential deformation of different segments.
2Loss of energy
If traditional energy absorber constructions are used, then energy absorption is achieved, but manufacturing cost is high
Solution Approach 1:
The energy absorber is divided into a tubular outer shell and multiple reinforcing webs that can be manufactured separately and assembled. This segmentation enables independent optimization of each component for manufacturing efficiency, allowing the use of cost-effective processes like sheet metal stamping for the webs and tubular forming for the shell, thereby reducing overall manufacturing cost while achieving progressive collapse energy absorption.
Solution Approach 2:
The design employs parameter changes in the geometry of the reinforcing webs (length, position, spacing) to optimize the collapse progression. By adjusting these parameters, the force-time history can be tuned to achieve desired energy absorption characteristics, allowing cost-effective manufacturing with standardized components while maintaining performance.
3Loss of energy
If traditional energy absorber constructions are used, then energy absorption occurs, but the force is not uniform over time and distance
Solution Approach 1:
The energy absorber structure segments the collapse process into distinct phases corresponding to the sequential engagement of reinforcing webs. Each web is positioned to engage at a specific point during collapse, creating multiple force plateaus that collectively produce a more uniform force-time history. This segmented approach stabilizes the force composition throughout the energy absorption process.
Solution Approach 2:
By changing geometric parameters of the reinforcing webs (lengths, positions, spacing intervals), the collapse progression can be controlled to maintain more uniform force over time and distance. The parameter optimization ensures that each web engages at the appropriate moment, creating a stepped force response that approximates uniform energy absorption characteristics.
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 achieves efficient energy absorption by maintaining a nearly constant force over time and distance, improving upon the inefficiencies of existing designs by using a tubular structure with strategically placed reinforcing webs to manage the collapse progression.
Implementation Method 1
the tubular outer shell will collapse progressively from the smaller end toward the larger end... the web is subjected to progressive energy absorbing collapse
Data Source
AI summary
An energy absorbing device includes a longitudinal extending tubular outer shell assembly tapered from a smaller end to a larger end so that upon the imposition of a longitudinal applied force on the ends thereof the tubular outer shell will collapse progressively from the smaller end toward the larger end. At least one reinforcing web is located within the tubular structure and is shorter in length than the tubular structure and has an end spaced from the one smaller end of the tubular structure that first collapses so that the web is subjected to progressive energy absorbing collapse only after the tubular outer shell assembly has begun to collapse. One or more such webs can be employed to sequentially and progressively collapse and deform to absorb the longitudinal applied force in a preferred manner.