Uniform Deceleration Unit for Small Overlap Crash Energy Absorption

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Solution Overview

Problem

Current safety systems for automobiles, such as frontal air bags and structural crumple zones, do not adequately address the energy absorption and dissipation in small overlap frontal crashes, leading to potential injury from intrusion into the passenger compartment, and there is a need for a cost-effective solution that does not increase vehicle mass or complexity.

Innovation Solution

A Uniform Deceleration Unit (UDU) comprising first and second crash pads and a connection beam, which absorbs and dissipates kinetic energy through strain energy, potentially retrofitted into existing vehicles, to minimize deformation and intrusion into the passenger compartment during frontal, side, and rear crashes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If current safety systems (frontal air bags, structural crumple zones) are used, then basic occupant protection is provided, but energy absorption and dissipation in small overlap frontal crashes is inadequate leading to potential intrusion into passenger compartment

Engineering Contradiction:

Improveoccupant protectionVSAvoidenergy absorption and dissipation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The safety system is divided into multiple functional components: front crash pad, rear crash pad, connection beam, and interaction with wheel assembly. Each component serves a specific energy absorption function, with the front crash pad absorbing initial impact energy and the rear crash pad absorbing residual energy after wheel assembly deformation, thereby improving overall energy dissipation effectiveness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The UDU acts as an intermediary energy absorption system positioned between the external impact and the passenger compartment. It includes intermediate components such as the connection beam linking front and rear crash pads, and interacts with the wheel assembly as an intermediary structure to progressively absorb and dissipate crash energy before it reaches occupants

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If additional safety structures are added to improve crash performance, then occupant safety is improved, but vehicle mass and manufacturing cost increase

Engineering Contradiction:

Improvecrash performanceVSAvoidvehicle mass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The crash pads utilize cellular materials where key parameters such as density, cell structure geometry, and material composition can be adjusted to optimize energy absorption per unit mass. By changing these parameters, the system achieves high crash performance while controlling weight, allowing customization for different vehicle types and crash risk profiles

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system employs composite material structures including cellular materials with skin layers, where different materials are combined to achieve optimal balance between strength, energy absorption, and weight. The composite structure of crash pads (cellular core with reinforcing skins) provides high specific energy absorption capability

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If cellular materials with skin layers are used in crash pads, then energy absorption capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy absorption capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The crash pad is segmented into distinct functional layers: cellular material core for energy absorption and skin layers for structural integrity. This segmentation allows each layer to be optimized and manufactured separately using appropriate processes, then assembled together, reducing overall manufacturing complexity while maintaining high energy absorption capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The use of cellular (porous) materials provides inherent energy absorption through cell collapse mechanisms. The porous structure naturally dissipates energy through controlled deformation, reducing the need for complex additional energy-absorbing mechanisms and simplifying the overall device design while maintaining effective crash energy absorption

Inventive Principle:

Principle #31Porous materials

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 UDU effectively absorbs and dissipates crash energy, reducing the risk of injury to occupants by minimizing deformation and intrusion into the passenger compartment, while maintaining fuel economy and reducing manufacturing costs.

Implementation Method 1

Strain energy may be in the form of both elastic and plastic deformation of the crash pads and connection beam

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

Strain energy may be in the form of both elastic and plastic deformation of the crash pads and connection beam

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11820307B2Uniform deceleration unit

Publication Date: 2023.11.21 TESSERACT STRUCTURAL INNOVATIONS

AI summary

An apparatus and method for improving the safety and performance of an automobile in crash events is disclosed. The apparatus includes a front crash pad, rear crash pad, and a connection beam. Both crash pads and the connection beam are coupled to an automobile in such fashion as to absorb and dissipate energy by converting kinetic energy into strain energy.