Thermoplastic CFRP Energy Absorption with Microstructured Impact Element
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Solution Overview
Problem
Current energy absorption structures in vehicles, particularly those made of carbon-fiber-reinforced plastic (CFRP), fail catastrophically under transverse forces and exhibit reduced energy absorption at high temperatures, lacking controlled failure modes and efficient energy dissipation mechanisms.
Innovation Solution
An energy absorption structure featuring a fiber composite component with a microstructured impact transmission element that countersinks into the side wall of the absorption element, allowing the element to be guided along the side wall during impact, thereby achieving superficial destruction and maintaining structural integrity through positive locking, independent of force angle and temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If CFRP carrier structures are used for energy absorption through crushing, then energy absorption is achieved through fiber fracturing and friction, but the structure fails catastrophically under transverse forces and shows unfavorable temperature dependence
Solution Approach 1:
The invention divides the energy absorption process into two distinct stages: a controlled first failure mode (deflection at the crash front) and a second failure mode (crushing). This segmentation allows the structure to exhibit predictable behavior under different loading conditions, particularly under transverse forces where the first failure mode provides controlled energy absorption without catastrophic failure.
Solution Approach 2:
The invention changes the material parameter by using thermoplastic polymer materials instead of traditional CFRP composites. This parameter change enables the material to be processed into complex three-dimensional structures while maintaining controlled failure modes and reducing temperature dependence, as thermoplastics have more favorable thermal properties compared to thermosetting CFRP materials.
2Use of energy by moving object
If CFRP material is used for impact structures, then energy absorption occurs through defined deflection and fiber fracturing, but absorbed energy decreases at relatively high temperatures
Solution Approach 1:
The invention changes the material parameter from thermosetting CFRP composites to thermoplastic polymers. This parameter change fundamentally alters the temperature dependence of energy absorption, as thermoplastics maintain their mechanical properties and energy absorption capabilities at higher temperatures where thermosetting CFRP materials exhibit degradation and reduced performance.
3Reliability
If additional structural measures are provided to absorb transverse forces, then controlled failure under transverse loading is achieved, but device complexity and cost increase
Solution Approach 1:
The invention creates a universal energy absorption mechanism that handles both longitudinal and transverse forces through the same structural design. The thermoplastic polymer structure with its specific geometry and material properties provides controlled energy absorption in all directions, eliminating the need for additional specialized structural measures for transverse force absorption.
Solution Approach 2:
The invention uses thermoplastic polymer materials that combine the benefits of high strength, controlled failure modes, and favorable temperature dependence. These composite material properties enable the structure to absorb transverse forces effectively without requiring complex additional structural elements, thus reducing overall device complexity.
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 solution enables high energy absorption without complete destruction of the absorption element, maintaining residual load-bearing capacity and allowing for scalable energy absorption across various vehicle variants, with the microstructure's design influencing the degree of surface destruction and force levels, while compensating for temperature-related energy absorption reductions.
Implementation Method 1
the fiber fracturing mechanism in conjunction with friction comes into effect in order to dissipate the kinetic energy
Implementation Method 2
in the event of an impact, the impact transmission element can be guided along the side wall
Data Source
AI summary
An energy absorption structure for a vehicle has an energy absorption element, in particular an engine longitudinal carrier, and at least one impact transmission element, which impact transmission element is pressed against a side wall of the engine longitudinal carrier and, in the event of an impact, is guidable along the side wall, wherein the engine longitudinal carrier is a fiber composite component and the impact transmission element has a microstructure which can be countersunk into the engine longitudinal carrier.