Undulated Fiber Composite Crash Structure for Vehicle Impact
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Solution Overview
Problem
Existing motor vehicle crash structures, particularly those made of carbon fiber reinforced plastics, face challenges in efficiently absorbing impact energy while being cost-effective and securely attached to the vehicle's load-bearing structure, especially in oblique impacts.
Innovation Solution
A crash structure featuring an undulated component with waves in the vehicle longitudinal direction, supported by a support unit that conforms to the wave geometry and includes mounting flanges for secure attachment to the load-bearing structure, allowing for effective absorption and distribution of impact energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a crash structure made of fiber composite material is used, then weight is reduced and energy absorption is improved, but secure attachment to the load-bearing structure becomes difficult due to inability to weld
Solution Approach 1:
The crash structure is divided into separate components: the undulated crash element made of fiber composite and a support unit with mounting elements. This segmentation allows the fiber composite crash element to be attached to the load-bearing structure via the support unit using mechanical connection techniques (screws, rivets, clips) rather than welding, thereby maintaining both weight advantages and attachment reliability.
Solution Approach 2:
The support unit acts as an intermediary between the fiber composite crash element and the load-bearing structure. It provides mounting elements that enable secure mechanical attachment while allowing the crash element itself to remain as a lightweight fiber composite component, thus resolving the contradiction between weight reduction and reliable attachment.
2Loss of energy
If the crash structure is designed to absorb impact energy through deformation, then energy absorption is improved, but structural rigidity may be compromised
Solution Approach 1:
The crash element features local undulations (waves) in specific regions while maintaining overall structural integrity. The undulated sections are designed to deform and absorb energy during impact, while other portions of the structure maintain sufficient rigidity to provide structural support and transmit forces to the load-bearing structure.
Solution Approach 2:
The crash element incorporates undulated (curved/wavy) geometry instead of straight rigid sections. These curved undulations are specifically designed to deform in a controlled manner during impact, converting kinetic energy into deformation energy, thereby improving energy absorption while maintaining adequate structural rigidity through the overall design and support units.
3Reliability
If the crash structure uses complex support elements to ensure rigid attachment, then attachment reliability is improved, but manufacturing cost and construction simplicity are reduced
Solution Approach 1:
The support unit is designed as a multi-functional component that combines several functions: providing mechanical attachment to the load-bearing structure, supporting the crash element, and potentially facilitating energy transmission. This universal design reduces the need for multiple separate components, simplifying manufacturing and assembly while ensuring reliable attachment.
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 undulated crash structure enhances the vehicle's stiffness and energy absorption capabilities, particularly in oblique impacts, while reducing material and manufacturing costs, and ensuring stable attachment to withstand various forces and torques.
Implementation Method 1
the impact energy, caused by the accident, is converted into deformation energy. This is achieved by providing the crash structure with a certain structural space, deforming the crash structure at least in parts in a crash situation to thereby absorb the impact energy
Data Source
AI summary
The invention relates to a crash structure (10a, 10b, 10c, 10d, 10e, 10f) for a motor vehicle, having a crash element (12a, 12b, 12c, 12d, 12e, 12f), which is made at least partially of a fiber composite material, and a support unit (16a, 16b, 16c, 16d, 16e, 16f) having at least one support element (14a, 14.1b, 14.2b, 14c, 14d, 14e, 14f) and being connectable to a load-bearing structure (18) of the motor vehicle. According to the invention, the crash element (12a, 12b, 12c, 12d, 12e, 12f) is made of an undulated component with waves (22) in the vehicle longitudinal direction (20) and an end region (24) which is supported on the load-bearing structure (18) of the motor vehicle at least via the at least one support element (14a, 14.1b, 14.2b, 14c, 14d, 14e, 14f) of the support unit (16a, 16b, 16c, 16d, 16e, 16f) in the vehicle transverse direction (26).