Vehicle Impact Absorber Fixing Insert Design
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Solution Overview
Problem
Existing shock absorbing systems for vehicles face challenges in reducing the risk of tilting and verticalization during impacts involving lateral forces, especially under new, more severe impact test protocols that include lateral and asymmetrical forces.
Innovation Solution
A shock absorbing structure with a hollow profile absorber inserted inside a spar, featuring a fixing insert with transverse cavities that cooperate with bolts and nuts to secure the absorber, reducing the risk of buckling and providing a stable assembly that minimizes tilting and verticalization during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the absorber is fixed to the side member using conventional fastening means, then the assembly is simple to manufacture, but the absorber is prone to tilting and verticalization during impacts with lateral forces
Solution Approach 1:
A fixing insert is introduced as an intermediary component between the absorber and the side member. This insert provides a stable mounting structure with transverse cavities that cooperate with fastening means to prevent tilting and verticalization of the absorber during impacts with lateral forces, while maintaining ease of assembly.
Solution Approach 2:
The fixing insert introduces a new dimensional aspect to the fastening system by providing transverse cavities that extend perpendicular to the longitudinal walls. This additional dimensional feature allows the fastening means to engage the absorber at multiple points, preventing rotation and tilting in directions that would otherwise be uncontrolled.
2Reliability
If the absorber is inserted deeply into the side member cavity, then the risk of buckling is reduced, but the available space for deformation is reduced
Solution Approach 1:
The fixing insert is designed with transverse cavities that are offset from each other in the longitudinal direction. This segmentation of the fastening points along the longitudinal axis allows the absorber to be securely anchored at multiple locations, providing anti-buckling support while still leaving sufficient length for the functional deformation zone.
3Ease of manufacture
If fastening means are oriented perpendicular to the longitudinal walls, then the assembly is easy to manufacture, but the fastening means may not adequately prevent tilting during lateral impacts
Solution Approach 1:
The transverse cavities in the fixing insert are offset from each other in the longitudinal direction, creating an asymmetric fastening arrangement. This asymmetry, combined with the transverse orientation of the cavities, provides rotational stability and prevents tilting during lateral impacts while maintaining the simple perpendicular orientation of the fastening means relative to the longitudinal walls.
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 solution effectively reduces the risks of absorber tilting and verticalization during impacts, enhancing the stability and performance of the shock absorbing system, particularly under conditions involving lateral forces.
Implementation Method 1
fastening means that secure the longitudinal walls opposite the crash box and the side member. These fastening means are typically bolts passing through said longitudinal walls opposite the crash box and the side member.
Implementation Method 2
During a collision at a speed above four kilometers per hour, the bumper and crash boxes undergo plastic deformation, which allows them to absorb at least part of the impact energy.
Implementation Method 3
During a frontal collision at a speed below four kilometers per hour, the bumper and crash boxes deform within their elastic range and return to their initial position without damage.
Data Source
Figure 1~2
Figure 3a~4
AI summary
The invention relates to an impact-absorbing structure (10) for a vehicle, the structure of which comprises at least one side rail (4) intended for supporting a bumper crossbeam (6), said side rail being a hollow profile member arranged according to the longitudinal axis of said vehicle, said impact-absorbing structure including said bumper crossbeam, at least one absorber (7) placed between said side rail and said bumper crossbeam, said absorber being a hollow profile member intended for deforming in the event of an impact, one end (72) of said profile member being intended to be inserted into the open end (5) of said side rail, said end of said profile member being attached to said side rail via transversely arranged attachment means (20a, 20b), and an attachment insert (30) provided with opposing surfaces (35.1 and 35.2). Each of the opposing surfaces of the insert is provided with two transverse recesses (31a and 31b) arranged perpendicular to said opposing surfaces (35.1 and 35.2), intended for engaging with said attachment means, and offset relative to one another both in the longitudinal direction (L) and in the transverse direction (Z) perpendicular to the direction (Y) of the axis of said transverse recesses.