U-Shaped Deformation Element With Accordion Folds

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing deformation elements for motor vehicles lack the ability to efficiently absorb energy through deformation, particularly in varying load conditions, and require complex production processes.

Innovation Solution

A multi-stage deformation element with a U-shaped profile and accordion-like side legs featuring z-shaped deformation folds, allowing for uniform folding under force and adjustable energy absorption through varying rhomboidal openings, produced via cutting, bending, and molding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If multi-stage z-shaped deformation folds are implemented in accordion-like side legs, then energy absorption capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidstructural complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The side legs are divided into multiple vertical sections with z-shaped deformation folds, creating a segmented accordion-like structure. Each section contains bending edges that form rhomboidal openings, allowing progressive deformation stages that enhance energy absorption while maintaining manageable structural complexity through modular segmentation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deformation folds are designed to dynamically collapse in a controlled sequence during impact. The z-shaped folds with alternating 180-degree rotations create a dynamic folding mechanism where rhomboidal openings progressively close, enabling the structure to adapt its stiffness and energy absorption characteristics based on the deformation stage.

Inventive Principle:

Principle #15Dynamics

2Stability of the object's composition

If z-shaped deformation folds with alternating rotations are used, then uniform folding behavior is improved, but production complexity increases

Engineering Contradiction:

Improveuniform folding behaviorVSAvoidproduction complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Adjacent vertical sections feature z-shaped folds rotated 180 degrees relative to each other, creating an asymmetric alternating pattern. This asymmetry ensures that inwardly directed bending edges of one section face outwardly directed bending edges of the adjacent section, promoting uniform folding behavior and preventing localized stress concentrations during deformation.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The design incorporates variable rhomboidal opening sizes that continuously increase or decrease from the web to the supports. This parameter variation along the longitudinal direction allows optimization of energy absorption characteristics while maintaining manufacturability through systematic geometric progression rather than arbitrary complex shapes.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If rhomboidal openings of different sizes are implemented, then energy absorption adaptability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveenergy absorption adaptabilityVSAvoidopening size precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Different rhomboidal openings along the longitudinal direction have different sizes, with upper openings near the transverse web being larger than lower openings near the supports. This local variation in opening quality allows the structure to exhibit stepped characteristic curves for energy absorption, adapting to different load conditions with larger openings providing initial compliance and smaller openings providing later-stage resistance.

Inventive Principle:

Principle #3Local quality

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 deformation element effectively absorbs energy through uniform folding, adapting to different load conditions and enabling efficient energy absorption, with the ability to be produced in a simple and cost-effective manner.

Implementation Method 1

The vertical sections of the side legs of the element are formed at least with two-stage or three-stage z-shaped deformation folds... the side walls to be folded together in the manner of an accordion in the event of a deformation. Thus, the side legs can fold together uniformly under the action of a force.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9150179B2Deformation element

Publication Date: 2015.10.06 DR ING H C F PORSCHE AG

AI summary

The deformation element has a profile part and may be of U-shaped profile with legs in cross section or may be of single-shear configuration. The deformation element has at least one side wall formed in the manner of an accordion with z-shaped deformation folds. The predefined deformation folds are provided in a direction transverse to an acting force and are arranged opposed to one another.