Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
  • F16F7/00—Vibration-dampers; Shock-absorbers
  • F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
  • F16F7/123—Deformation involving a bending action, e.g. strap moving through multiple rollers, folding of members
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
  • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
  • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
  • B60R19/04—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects formed from more than one section in a side-by-side arrangement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
  • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
  • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
  • B60R19/24—Arrangements for mounting bumpers on vehicles
  • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
  • B60R19/34—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means destroyed upon impact, e.g. one-shot type

Definitions

• the invention relates to an energy absorber element and a bumper system for vehicles based on the energy absorber element, which serves for the transmission and absorption of kinetic energy, e.g. in the event of motor vehicle accidents.
• the energy absorber element is particularly suitable in bumper systems of vehicles, but can also serve as part of another vehicle structure and other safety elements with a comparable requirement profile.
• Energy-transmitting and converting systems are known and are used successfully. There are widespread bumper systems that survive minor accidents (with an impact speed of up to about 8 km h) without damage due to energy-absorbing elements. In order to achieve favorable risk ratings for vehicle insurers, many vehicle manufacturers are striving for shock-absorbing systems that can withstand loads well above a crash speed of 10 km / h (bumper systems with a damage-free crash speed of up to 8 km / h are generally used in the USA). Is the energy introduced into the system even greater, e.g. With the AZT crash at a speed of 15 km / h, the energy is absorbed by special energy absorber elements.
• the available installation space for the known systems mentioned is generally small.
• the high kinetic energy of a damage event to be implemented requires a high efficiency of the system, ie an energy absorber with ideal force-deformation characteristics.
• This ideal characteristic is characterized by the fact that after an initially steep increase in force with progressive energy absorption, a horizontal plateau with the same force occurs.
• the work absorbed is defined as the area under the force-displacement curve and should have the greatest possible content.
• Reversible systems include, for example, those with hydraulic dampers (gas pressure springs). These systems are very powerful and convert the energy efficiently.
• a disadvantage of the hydraulic damping systems is the complex and very expensive production, which prevents the widespread use of this system.
• Non-reversible systems are e.g. Support systems made of steel or aluminum with plastically deformable steel or aluminum elements for energy absorption. With lower energies to be converted, quasi-reversible systems can be used (foam blocks made of energy absorption (EA) foam or aluminum foam). If the energy to be absorbed is large, deformable sheet metal profiles are mostly used.
• EA energy absorption
• the invention is based on the object of developing an energy transmission and absorption system which converts the kinetic energy of moving vehicle masses into the smallest possible space by plastic deformation of a material (mostly into heat).
• This system should be easy to use and allow positioning (tolerance compensation) in all three spatial directions, especially when it is attached to a vehicle. Furthermore, it should show absolutely reproducible behavior over the entire period of use, be inexpensive to produce and be light.
• the system should be able to transfer the forces acting on the outside from a damage event to the adjacent ones Distribute structures and stabilize the body or frame structure of vehicles.
• An energy absorption element was found which fulfills the above-mentioned requirements with regard to ease of manufacture, lightness and energy absorption behavior.
• a bumper system has been found which, due to the specific arrangement of a cross member and energy absorption elements and their special shape, is able to absorb the energy offered on a given deformation path with very high efficiency.
• this system offers a much larger route for energy conversion than conventional systems with rear energy absorbers arranged behind a cross member have.
• the subject matter of the invention is an energy absorber element consisting of at least two metal sheets arranged opposite one another, which have a large number of predetermined bends, which enable the sheets to be folded together in the longitudinal direction (x direction), and connecting ribs, in particular made of thermoplastic or thermosetting plastic, which connect the metal sheets opposite one another connect.
• the ribs are preferably made of thermoplastic, in particular polyamide, polypropylene, polyester, which, e.g. attached by means of injection molding, which connects the preformed metal sheets with each other.
• a special embodiment of the energy absorber element is particularly preferred, in which the ribs are connected to the sheets at discrete anchoring points, in particular at knobs, openings or at the edges of the metal sheets by overmolding. This increases the mechanical stability of the energy absorber element transversely to the direction of energy absorption.
• the kinks of the metal sheets are particularly preferably formed by corrugated, trapezoidal or sawtooth profiling of the metal sheets.
• the transverse stability of the energy absorber element can be increased in a preferred form in that the ribs connect opposing kinks of the metal sheets to one another.
• An energy absorber element is particularly preferred, in which the ribs connect mutually opposite depressions or elevations in the metal sheets.
• the metal sheets are placed so that the depressions on one sheet face the depressions on the other sheet.
• Another preferred variant of the energy absorber element is characterized in that the ribs have additional foot bridges at the connection points to the metal sheets.
• the energy absorber element is connected to a base plate at one end of the energy absorber element.
• the base plate is e.g. arranged transversely to the x-direction and has holes for mounting on vehicle parts.
• Another object of the invention is a bumper system for vehicles, which has at least one energy absorber element according to the invention.
• a bumper system for vehicles is preferred in which the bumper system consists of at least one cross member and at least one energy absorber element attached to the two ends of the cross member.
• the cross member is releasably attached to the side of the energy absorber elements.
• the energy absorber elements are attached in particular by means of a flange connection, the flanges on the cross member having elongated holes which have their main orientation in the x direction, i.e. have in the direction of the force absorption of the energy absorber.
• the energy absorption element consists of two metal sheets arranged opposite one another, which have a large number of predetermined bending points, which enable the sheets to be folded in the longitudinal direction (x-direction).
• the metal sheets can be designed in a wave, trapezoidal or sawtooth shape.
• Connecting ribs in particular made of thermoplastic or thermosetting plastic, establish the connection between the opposing metal sheets.
• the connection of the plastic ribs to the metal sheet is e.g. realized as a positive connection.
• the ribs are connected to the sheets at discrete anchoring points, in particular by knobs, breakthroughs (injections) or by extrusion coating on the edges of the metal sheets.
• each rib connects opposing depressions or elevations in the metal sheets.
• the plastic ribs can have additional footbridges. These webs create a non-positive connection between metal sheets and plastic ribs.
• the opposite sheets of the energy absorption element can be attached to a base plate (welding).
• the base plate serves that Connection of the energy absorption element to a structure behind it (in the vehicle, for example, this is the side member).
• the two main parts of the bumper system, energy absorber and cross member are preferably non-positively and / or positively connected to one another in such a way that the connection can be loosened and restored several times.
• This special form of connection is realized by means of screws and elongated holes in a flange on the cross member in order to allow dimensional adjustment of the cross member in the x direction.
• the adjustability in the y and z direction is e.g. through oversized holes in the base plate of the energy absorption element.
• the system can be positioned on the vehicle in all three spatial directions without additional elements and is therefore a very cost-effective system.
• the energy absorption efficiency is very high due to the targeted influence on the wrinkle bulging process.
• the structure of the energy absorption element according to the invention defines the exact number of folds. For this reason, the energy consumption or the force-deformation characteristic is very reproducible.
• the force-deformation characteristic curve can also be designed progressively and / or degressively by different division of the 'wave structure', which was not possible with conventional elements.
• the plastic dictates how the metal is deformed due to its connection to the metal sheets.
• the production of the energy absorption elements and thus the connection between sheet metal and plastic is realized inexpensively and simply by the plastic injection molding process. An additional assembly of the individual parts is not necessary. in the As part of the injection molding process, other components can also be integrated into the bumper system. Add-on parts in the immediate vicinity are positioned or fastened with dimensional accuracy.
• the plastic-metal connections are e.g. realized in such a way that the metal structure is inserted into a plastic injection molding tool and the plastic melt is injected into the closed tool.
• the sheet metal element can be protected against corrosion by painting, phosphating, galvanizing, etc.
• Thermoplastics such as PA 6, PA 66, PBT or PA 6 GF, PA 66 GF, PBT GF etc. or other plastics such as thermosets are particularly suitable as plastics.
• connection of the energy absorption element and the cross member allows the system to be adjustable in the x direction and, due to the base plate of the energy absorption element, also allows a y, z adjustability. In conventional systems, variable adjustment in all three spatial directions is only possible using additional elements.
• Fig. 1 The perspective view of a bumper system
• Fig. 2 shows a cross section through an energy absorber element according to the invention
• the perspective view of the bumper system can be seen. It consists of a cross member 1 and two energy absorption elements 2, 2 'attached to the ends of the cross member 1.
• Each energy absorption element 2, 2 ' consists of two metal sheets 7, 8 arranged opposite one another, which have a plurality of predetermined bending points 11.
• the metal sheets 7, 8 are formed in a sawtooth shape.
• the bending points 11 described enable the structure of the energy absorption elements 2, 2 'to be folded in a very defined manner in the longitudinal direction (x direction) after a certain critical load has been exceeded.
• At the two ends of the cross member 1 there are shaped flanges 3 which have elongated holes 4.
• the two energy absorber elements 2, 2 ' are screwed in such a way that the cross member 1 can be ideally positioned in the x direction. Dimensional tolerances in the vehicle's longitudinal directions can thus be compensated for without additional spacers.
• the connecting ribs 9 consist of thermoplastic (glass fiber reinforced polyamide 6) and establish the connection to the opposing metal sheets 7, 8.
• the connection of the plastic ribs 9 to the metal sheet 7 or 8 is realized as a positive connection.
• the ribs 9 are particularly connected to the sheets 7, 8 at discrete anchoring points 10 in the metal sheets 7, 8.
• the metal sheets have 10 holes 16 at the desired anchoring points. Since the entire energy absorber 2 or 2 'is produced in one work step in the plastic injection molding process, the plastic melt can penetrate through the holes 16 of the metal sheet 7 or 8 and there a button or rivet-like connection between the plastic ribs 9 and the metal create sheets 7 and 8.
• the opposing sheets 7 and 8 of the energy absorption element 2 are attached to a base plate 6 by welding.
• the base plate 6 has fastening bores 4 and is used to connect the energy absorption element 2 to a structure located behind it (in the vehicle, for example, this is the side member).
• FIG. 3a Various possibilities for connecting plastic ribs 9 to the metal sheet 7 or 8 can be seen in FIG. 3a.
• This injection 10 can be compared to a riveted joint.
• the lower picture in FIG. 3b shows a possible support of the plastic ribs 9 on the metal sheet 7, 8 by so-called foot bridges 15.
• FIGS. 4a and 4b show the basic behavior of an energy absorber 2 which is subjected to high longitudinal forces.
• the energy absorber 2 folds in the manner predetermined by the wave structure and absorbs the energy introduced almost ideally even with a very simple geometry.
• the associated force-displacement curve is shown in FIG. 5. The force increases to the maximum level within a very short period of time. If the energy absorber is deformed further, the force curve remains approximately constant on average. This force-deformation characteristic comes very close to that of an ideal energy absorber.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Vibration Dampers (AREA)
• Body Structure For Vehicles (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=7661600

Family Applications (1)

Country Status (11)

Families Citing this family (55)

Family Cites Families (20)

• 2000
  • 2000-10-30 DE DE10053840A patent/DE10053840A1/de not_active Withdrawn
• 2001
  • 2001-10-18 CA CA002426972A patent/CA2426972A1/en not_active Abandoned
  • 2001-10-18 CN CNA018182844A patent/CN1473122A/zh active Pending
  • 2001-10-18 MX MXPA03003802A patent/MXPA03003802A/es unknown
  • 2001-10-18 WO PCT/EP2001/012066 patent/WO2002036392A1/de not_active Application Discontinuation
  • 2001-10-18 JP JP2002539174A patent/JP2004513008A/ja active Pending
  • 2001-10-18 KR KR10-2003-7005923A patent/KR20030048091A/ko not_active Application Discontinuation
  • 2001-10-18 EP EP01992488A patent/EP1332070A1/de not_active Withdrawn
  • 2001-10-18 AU AU2002221700A patent/AU2002221700A1/en not_active Abandoned
  • 2001-10-18 BR BR0115010-3A patent/BR0115010A/pt not_active IP Right Cessation
  • 2001-10-25 US US10/032,529 patent/US6595502B2/en not_active Expired - Fee Related

Non-Patent Citations (2)

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