Box-Shaped Tank Crash Structure for Vehicle Side Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solutions for protecting hydrogen tanks in vehicles from crash-related damage are inadequate, particularly due to the lack of reliable data and material parameters for fiber-reinforced composite materials, leading to complex and uncertain crash simulations, and insufficient protection against side impacts.
Innovation Solution
A box-shaped metal crash structure with a cavity for receiving the tank, which absorbs crash energy and minimizes damage by dissipating impact forces, combined with a mounting device for secure attachment to the vehicle frame, and optional deformation devices to further distribute and absorb energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen tanks are attached to the vehicle frame using L- or C-shaped supports and tension straps with only side underride guards, then the tank mounting is simple and device complexity is low, but the tank protection against crash damage is insufficient
Solution Approach 1:
The protection device is divided into multiple functional segments: a box-shaped crash structure for energy absorption, a mounting device for secure attachment to the vehicle frame, and a holding device for retaining the tank. This segmentation allows each component to be optimized for its specific function while maintaining overall system reliability.
Solution Approach 2:
The box-shaped crash structure is designed to absorb and dissipate impact forces before they reach the hydrogen tank. This beforehand cushioning mechanism protects the tank from crash damage by pre-absorbing the energy of potential impacts through controlled deformation of the metal structure.
2Reliability
If a 200 mm lateral clearance is maintained from the outer edge of the vehicle, then compliance with UN/ECE R 134 regulation is achieved, but the tank volume is significantly restricted and protection against side impact is insufficient
Solution Approach 1:
The hydrogen tank is nested within the box-shaped crash structure, which itself is mounted to the vehicle frame. This nested arrangement allows the tank to be positioned closer to the vehicle edge while still receiving protection from the crash structure, effectively increasing usable tank volume without compromising safety.
Solution Approach 2:
The box-shaped crash structure serves as an intermediary between the hydrogen tank and the external environment. It provides side impact protection and force distribution while allowing the tank to be positioned optimally for volume, eliminating the need for excessive lateral clearance.
3Strength
If fiber-reinforced composite materials with high carbon proportion are used for tank construction, then tank strength and weight properties are improved, but crash simulation becomes more complex and reliable data is insufficient
Solution Approach 1:
The metal crash structure acts as an intermediary that absorbs and dissipates crash forces through well-understood metallic deformation mechanisms. This mediates the complex interaction between the composite tank and crash forces, allowing simulation to focus on the simpler metal structure behavior while the composite tank receives protected forces.
Solution Approach 2:
By introducing the metal crash structure as an additional layer, the system changes the parameters of force transmission to the tank. The crash structure modifies the magnitude, duration, and distribution of forces reaching the composite tank, making the overall crash behavior more predictable and simulatable.
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 metal crash structure effectively protects the tank from crash damage, simplifies crash safety simulations, and ensures reliable protection against side impacts, reducing the need for complex simulations of composite tank properties.
Implementation Method 1
The box-shaped crash structure serves to protect the held hydrogen tank and/or to dissipate energy in the event of a crash-related energy impact on the impact protection device
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an impact protection device (10) for a tank (100a) for storing gas and/or liquefied petroleum gas (LPG) as fuel for a vehicle. The invention further relates to a vehicle (1), preferably a truck, with such an impact protection device (10). The impact protection device (10) comprises a box-shaped crash structure or crash box (11), preferably for energy dissipation in the event of a crash-related impact on the impact protection device. The box-shaped crash structure (11) has a cavity (12) for receiving and supporting the tank (100a; 100b) and is designed as a metal construction. Overall, this advantageously enables the safe storage of a tank for gas and/or LPG. Furthermore, verification of crash safety within the framework of a (strength) simulation is made significantly simpler and/or more accurate.