Method for configuring and making a modular energy absorber

[0001] This application is a divisional of U.S. application Ser. No. 10/760,760 filed Jan. 20, 2004 which is a continuation-in-part of U.S. application Ser. No. 10/004,739 filed Dec. 4, 2001 (now U.S. Pat. No. 6,752,450) which is a continuation-in-part of U.S. application Ser. No. 09/884,813 filed Jun. 19, 2001 (now U.S. Pat. No. 6,682,128) which is a continuation-in-part of U.S. application Ser. No. 09/499,205 filed Feb. 7, 2000 (now U.S. Pat. No. 6,247,745), which is a continuation of U.S. application Ser. No. 09/328,196 filed Jun. 8, 1999 (now U.S. Pat. No. 6,199,942), which is a continuation-in-part of U.S. application Ser. No. 09/018,666 filed Feb. 4, 1998 (now U.S. Pat. No, 6,017,084), the disclosures of which applications are being incorporated by reference herein. U.S. application Ser. No. 10/760,760 filed Jan. 20, 2004 is also a continuation-in-part of U.S. application Ser. No. 09/617,691 filed Jul. 17, 2000 (now U.S. Pat. No. 6,679,967) which is a continuation-in-part of U.S. application Ser. No. 09/328,196 filed Jun. 8, 1999 (now continuation-in-part of U.S. application Ser. No. 09/018,666 filed Feb. 4, 1998 (now U.S. Pat. No. 6,017,084), the disclosures of which applications are being incorporated by reference herein.

[0002] 1. Field of the Invention

[0003] This invention generally relates to occupant safety during a collision, and more specifically to an energy absorber that absorbs energy imparted by an incident object that impacts the absorber, and a method for configuring the absorber.

[0004] 2. Background Art

[0005] There have been proposed various ways to protect the occupant or rider of an automobile when the occupant impacts the A and B pillars, headliner, or any hard structure during an impact. Illustrative approaches are described in commonly owned U.S. Pat. Nos. 6,247,745 and 6,199,942; and U.S. Pat. No. 6,443,513, which issued on Sep. 3, 2002 to Glance.

[0006] It is known, for example, to deploy truncated plastic cones at rollover stiff points or on door panels for side impacts with the objective of providing better performance than energy absorbent foam. Also, such cones may be less expensive to manufacture. Manufacturing economics have been realized from the raw materials being melt recyclable. Such structures not only provide weight savings and a better performance, but also a cost advantage which may amount to $4-$5 per vehicle.

[0007] The required energy absorption characteristics are defined in Federal Motor Vehicle Standards 201. To meet the relevant standards, the industry continues its quest not only for the physical structures that conform to federally mandated standards, but also to develop computer modeling protocols that predict head injury sustained from impacting forces and comparing the results with head injury criteria. It would be desirable in such developments to measure actual head impact (of, for example, a dummy occupant) during in-vehicle testing at selected locations in the vehicle. Ideally, the actual measurements will approximate the values predicted by computer dynamic finite element analysis.

[0008] Additionally, the desire to reduce costs while complying with End of Life Vehicle (ELV) legislation in Europe stimulates the use of mono-materials in automotive interior soft trim applications. Related considerations emphasize recyclability of automotive plastics. The impact or influence of the ELV directive on automotive interiors will be felt in various ways: e.g., cost effective use of recycling techniques with environmentally benign consequences. Most interior modules today are made from a combination of skin/foam/substrate. Thus, the materials currently used may present challenges to the recycling task. Such challenges may be met by more use of energy absorbing modules that are made from mono-materials. Such materials might, for example, include polyolefins and melt recyclable polymers, since they show promise as being versatile alternatives to skin/foam/substrate.

[0009] It is expected that Europe will adopt the U.S. HIC(d) requirements. This will affect the choice and quantity of materials used for energy absorbers in headliners. Similar door trim panel requirements apply to the pelvis and torso (side impact applications). It is therefore anticipated that there will be an increase in the usage of energy absorbers that will be incorporated into the structure of modules such as door trim panel, instrument panel uppers, and headliners.

[0010] To meet cost reduction goals, there is an increasing desire to manufacture interior modules using a reduced number of manufacturing steps.

[0011] In light of these and related approaches, there remains the desire to absorb as much impact energy in as little crush distance as possible, with as little weight as possible, yet be capable of being designed and manufactured under favorable economic conditions.

[0012] One object of the present invention is to provide a more cost effective, efficient energy absorber that can be “tuned” to produce predefined energy absorption characteristics within spatial constraints that may be imposed by a particular application.

[0013] The invention includes a modular energy absorber with one or more energy absorbing modules that are provided with means for coordinating energy absorbing units therewithin. The coordinating means has a topography with a variable number (n) of apertures. The means for coordinating alternatively include a web, a tether, a hinge, a planar surface, and wings or combinations thereof that serve to position and support the energy absorbing units in relation to each other before, during and after relative motion between an incident object and the energy absorber. The relative motion causes impact between the energy absorbing units and the incident object so that forces resulting from the impact are at least partially absorbed.

[0014] The absorber also has energy absorbing units that have a crushable member with an upper extremity that defines an upper perimeter, a lower extremity that defines a lower perimeter, and an intermediate section extending therebetween. Either the upper or lower extremities can be presented to the impacting force.

[0015] The crushable member at least partially collapses during energy absorption to a crushed configuration which in part is determined by the provision of a number (m) of breaches that are defined in the crushable member before impact. The breaches may be defined by slits (no material moved) or slots (material removed to form an opening).

[0016] To configure the modular energy absorber, the following steps are taken:

• • [0017] selecting one or more energy absorbing modules according to given spatial constraints and desired energy absorbing criteria;
  • [0018] providing a means for coordinating energy absorbing units with a pre-defined contoured topography;
  • [0019] locating one or more energy absorbing units in association with the means for coordinating energy absorbing units so that the one or more energy absorbing units are positioned in relation to each other before, during and after relative motion between an incident object and the energy absorber;
  • [0020] providing a wall within some of the one or more energy absorbing units so that the wall provides an upper perimeter, a lower perimeter, and an intermediate section extending therebetween;
  • [0021] defining a number (m) of breaches within the wall, (m) being an integer selected from the group consisting of (0, 1, 2, 3, . . . , 100); and
  • [0022] providing a number (n) of apertures defined within the means for coordinating energy absorbing units, (n) being an integer selected from the group consisting of (0, 1, 2, 3, . . . , 100).

[0034] Turning first to FIGS. 1-2 of the drawings, there is depicted a modular energy absorber 10 that has one or more energy absorbing modules 12. Those modules include means 14 for coordinating energy absorbing units 16 of the energy absorbing modules. The means for coordinating 14 have a topography that includes a number (n) of apertures 18 defined therein.

[0035] The energy absorbing units coordinate with each other through the provision of coordinating means 14 that position and support the units in relation to each other before, during and after relative motion between an incident object (not shown) and the energy absorber 10. That relative motion causes impact between the energy absorbing units 16 and the incident object so that forces resulting therefrom are at least partially absorbed. In this way, the impact forces that are transmitted to an occupant of a vehicle within which, for example, the modular energy absorber 10 is situated are reduced, together with injuries sustained.

[0036] At least some of the energy absorbing unit 16 include a crushable member 20 that has an upper extremity or perimeter 22, a lower extremity or perimeter 24, and an intermediate section 26 extending therebetween.

[0037] Additionally, a number (m) of breaches 28 are defined within the crushable member 20 before impact. Preferably, the number of breaches is three where the breach is provided in the form of slots. As used in this disclosure, the term “slots” implies an aperture with facing edges which lacks material or where material has been removed. As used herein, the term “slits” implies a cut or gash that is formed without the removal of material. In the preferred embodiment, the three slots are inclined to an axis of symmetry of a given crushable member 20, but lie parallel to the draft angle, in the case where the crushable member is presented in the form of a cone.

[0038] As depicted in FIG. 1(b), the modular energy absorber includes, in the embodiment depicted, a hinge section 30 having leaves 32. Each leaf 32 extends from one of the one or more energy absorbing modules 12 so that they may be configured within the spatial constraints that are imposed by an environment within which the modular energy absorber 10 is positioned. The environment (not depicted) is selected from a group consisting of a headliner in a vehicle, a bumper assembly, a knee bolster, and a side impact location including a vehicle pillar and a door, a head rest or seat back.

[0039] In one embodiment, the modular energy absorber 10 has means for coordinating 14 the energy absorbing units 16 that may take the form of a web, a tether, a hinge, a planar surface (as depicted), and rings, or a combination thereof. In some cases, no apertures are provided in the energy absorbing coordinating means.

[0040] FIG. 6 depicts a floor 40 that extends at least partially between opposing faces of a wall 38. In one embodiment the floor is annular. Alternatively, the floor may extend from an intermediate section 26 of the wall 38. It should be appreciated, that in some embodiments, the floor may have a configuration that is non-planar. For example, where the floor 40 is provided proximate an upper extremity or perimeter 22 of an energy absorbing unit 16, the floor 40 may undulate or be otherwise configured in order to conform the modular energy absorber 10 to the spatial constraints imposed by the environment in which the absorber 10 is installed.

[0041] In FIG. 7, the floor is configured with a topography that is akin to a wedding cake with one or more layers. Alternatively, the floor 40 can be configured in a more rounded form as a volcano type of structure, including one or more craters defined therewithin. Continuing with reference to FIG. 7, some of the one or more energy absorbing units 16 have an imaginary axis of symmetry A-A to which the floor 40 may be inclined at an angle between zero and 180 degrees.

[0042] It will be appreciated that as a result of tuning the energy absorber (e.g. dimensional control of wall height, provision of slits or slots, wall thickness, and material selection), the configuration following impact is located in substantially the same position as the pre-impact configuration.

[0043] Continuing with primary reference to FIGS. 6-7, it will be appreciated that the wall 38 be characterized by a thickness (t) which may or may not be uniform between a top edge 22 and a lower edge 24 of the wall 38. In some configurations, where particular energy absorbing characteristics are desired or mandated, the wall 38 of a given energy absorbing unit 16 may have an average thickness (t₁) that differs from an average thickness (t₂) of a wall associated with another energy absorbing unit.

[0044] In some embodiments (FIG. 6 for example), means of coordinating 36 may be in the form of a rib or a channel 46,48. While the means may be located at an intermediate section of a wall, it will be appreciated that it may also lie proximate its top or bottom edges.

[0045] Returning now to FIGS. 1-2, the designer may choose how best to locate energy absorbing units 16 within a given module. To facilitate an understanding of positional considerations, it is helpful to imagine that each energy absorbing unit 16 has an axis of symmetry which when projected may intersect an imaginary plane at a loci. An imaginary line can be drawn connecting adjacent loci in that plane. The energy absorbing unit 16 may be configured so that the line joining adjacent loci describes a geometrical figure. The figure may be a segmented line, a circle, an oval, an ellipse, a square, a diamond, a quadrilateral, and a polygon.

[0046] With reference to FIGS. 4(a-c), the lower perimeter 24 of a given energy absorbing unit 16 may describe a circle, an oval, or an ellipse. Similarly for the upper perimeter and intermediate section.

[0047] In FIG. 5, cooperating means 44 are provided in order to coordinate the deformation and energy absorbing characteristics of adjacent energy absorbing modules 12. It will be appreciated that the cooperating means may take the form of an adhesive, a clip, a vibration weld, a sonic weld, a heat stake, a “tongue in groove” arrangement, and the like. It will be appreciated that the stacked configuration depicted in FIG. 5 may be reoriented such that the energy units 12 may be nested in such a way that the peak of a given energy unit may lie in a valley (or floor) of the adjacent energy unit.

[0048] A method for configuring a modular energy absorber comprises the steps of:

[0049] selecting one or more energy absorbing modules according to given spatial constraints and desired energy absorbing criteria;

[0050] providing a means for coordinating energy absorbing units with a pre-defined contoured topography;

[0051] locating one or more energy absorbing units in association with the means for coordinating energy absorbing units so that the one or more energy absorbing units are positioned in relation to each other before, during and after relative motion between an incident object and the energy absorber;

[0052] providing a wall within some of the one or more energy absorbing units so that the wall provides an upper perimeter, a lower perimeter, and an intermediate section extending therebetween;

[0053] defining a number (m) of breaches within the wall, (m) being an integer selected from the group consisting of (0, 1, 2, 3, . . . , 100);

[0054] providing a number (n) of apertures defined within the means for coordinating energy absorbing units, (n) being an integer selected from the group consisting of (0, 1,2,3, . . . 100);

[0055] quantifying the resulting modular energy absorbing characteristics of the absorbing structure;

[0056] comparing the characteristics with those desired; and

[0057] reiterating as necessary.

[0058] The disclosed energy absorber can be manufactured at relatively low cost by thermoforming and impact performance can be optimized without expensive tooling modification at heights below about 50 millimeters. However, above this height, the base material thickness required to produce an energy absorber for the appropriate crush resistance is such that it cannot easily and inexpensively be produced using in-line thermoforming equipment. In such circumstances, injection molded absorbers can be produced perhaps at a lower cost.

[0059] Historically, optimizing crush resistance or the amount of energy absorbed by injection molded energy absorbers that are formed from rows of free standing or a lattice of ribs have been difficult and expensive to modify once the mold has been produced. Modifying rib thickness is usually accomplished by adding material to or removing material from the mold by burning, cutting, inserting and the like.

[0060] It is especially difficult to produce injection molded wall sections having a thickness less than about 1.25 millimeters. In such circumstances, multi-drop hot runner systems have been used to prevent the material from “freezing off” in the thin sections. Cuts or areas devoid of material have been used to weaken such ribs, but prove to be less efficient because they may create additional manufacturing issues. When ribs are integrated into the back side of class A surfaces (whose appearance is critical), changes in the ribs can “read through” and result in a product whose appearance is unacceptable.

[0061] It is therefore essential that an absorber's crush resistance be “tuned” or “dialed up or down” to provide the greatest measure of energy management or the highest level of occupant protection for a given set of impact conditions. Foam energy absorbers can be tuned by a change in density but have proven to be less efficient than those composed of metal, thermoplastic, or composite materials. Metal and composite absorbers are proven to be more expensive than their plastic counterparts, such as injection molded and thermoformed energy absorbers.

[0062] Preferably, the disclosed energy absorbers that include a structure with recesses in a base sheet produced by injection or compression molding. The recesses, for example, may have a minimum wall thickness of about 1.25 millimeters. Small tapered or drafted areas may have a thickness which is below this thickness.

[0063] The walls of the recesses may be thicker than 1.25 millimeters, but may have areas as thin as 1.25 millimeters to promote buckling of the recess at a given point.

[0064] Slits, or slots (areas devoid of material) may be provided which run mostly parallel to the walls of a given energy absorbing unit. Such breaches may or may not be present, but when present, the slots may or may not be of varying width. Ribs that protrude from the interior or exterior of a wall of an energy absorbing unit may or may not be present.

[0065] When present, the ribs 50 (FIG. 6) run mostly parallel to a wall of a recess, and may have convolutions which promotes the buckling of a recess at a given point. It will be appreciated that to produce given energy management characteristics, the ribs may vary in both height and width.

[0066] Turning now to FIGS. 3(a-d), there now follows a disclosure of a series of experiments that were conducted which involve finite element analysis modeling.

[0067] In order to tune the impact performance, a DOE was performed via FEA modeling. The results of that DOE are summarized in FIGS. 3(a-d).

[0068] The minimum wall thickness of 1.25 mm is such that it promotes material flow within the mold for injection molded designs with a minimal number of injection ports. Below this thickness, formed articles have more shear stress caused by forcing the polymer into a thin section. Thin sections are also difficult to fill. This involves higher injection molding pressures, larger equipment, higher utility costs and higher scrap rates. Areas thicker than 1.25 mm are less prone to these issues. By maintaining a minimum wall thickness of 1.25 mm, the cost to tool an absorber is minimized. Also, by increasing or decreasing the wall thickness, the crush resistance of the absorber can be tuned to optimize the impact performance.

[0069] The presence of breaches, such as slits, or slots (areas devoid of material) reduces the crush resistance of the recess. The number of slits (FIG. 1(c)) can also be changed to optimize impact performance to a lesser degree. Preferably, but not necessarily, the slits should run the entire length of the recess wall. By doing so, knit lines (areas where two melt fronts of plastic come together which have proven to be weak points in the formed article) are forced toward areas which are less involved in the energy management—such as the base or the roof of the recess.

[0070] The presence of ribs, which protrude from either side of the recess wall (FIG. 6), can be added or reduced in size to either increase or decrease the crush resistance of the structure. When present, ribs may also provide a channel that promotes material flow to areas adjacent to the rib. The rib height and width can be varied to increase or decrease crush resistance. In the preferred embodiment, the ribs are present on the interior of the recess.

[0071] Injection molds can be manufactured from a solid block of material or can be composed of a number of inserts. The preferred embodiment of each recess is a frusto-conical in shape. The advantage of this design is that it lends itself to both a simple and inexpensive means of optimizing impact performance through the use of inserts for the cone interior. These inserts are typically produced inexpensively on a numerically controlled lathe, rather than by more expensive methods such as NC machining and EDM techniques. The wall thickness of the recess can be easily changed by either modifying or simply replacing the original insert with one whose profile is different. By changing the wall thickness, the crush resistance can also be changed as detailed in FIGS. 3(a-d).

[0072] In summary, the crush resistance of each recess can be varied in order to optimize the impact performance with a minimal impact on tooling cost. It also lends itself to high manufacturing rates and low costs versus current competitive products, while still providing excellent impact performance.

[0073] The purpose of the experiments (see, the data depicted in FIGS. 3(a-d)) was to predict the resistance performance of a given absorber design, (e.g. made from polypropylene: Basell Pro-fax SV 152) and efficiently tune or optimize its geometry to match known benchmarks (up to 80 psi) of given countermeasures for automotive side impact.

[0074] Among the conclusions were these observations:

• • [0075] Performance is most sensitive to number of slits and wall thickness
  • [0076] Cone spacing could have been a factor in study as pressure on one cone depends on this
  • [0077] Once a design is tuned to perform as desired—it may be advantageous (material usage, uniformity) to determine an equivalent design by re-spacing cones within reasonable limits and eliminate slits
  • [0078] Can recalculate pressures for different cone spacing with raw data if desired
  • [0079] Design approach ultimately depends on whether countermeasure interacts with occupant and thus necessity for load transfer or energy management
  • [0080] Because impact velocity is constant, mean pressure directly correlates with energy absorbed.
    Here is a summary of the results:

[0081]

	Impact	Wall		Peak	Mean	Std. Dev.
	Angle	Thickness	Rib Height	Pressure	Pressure	Pressure	Cone Mass
# of Slits	(degrees)	(mm)	(mm)	(PSI)	(PSI)	(PSI)	(tonnes)
0	0	1.25	0	141.57	86.79	29.53	0.0081
2	27	1.65	1.25	115.42	61.08	16.63	0.0118
2	0	1.25	0	54.01	20.74	12.20	0.0081

Method:

• • [0082] Transient finite element simulation of rigid plane (oriented normal to cone axis) impacting a single cone at constant velocity
  • [0083] Cone Materials modeled: Pro-fax SV152 PP; Cycolac EX75 ABS, Cycolac MC8800, Cycoloy IP1000 No strain rate dependency modeled, to reflect quasi-static performance
  • [0084] Cone supported by contact with rigid plane
  • [0085] Cone geometry—10 degrees draft, 15 mm top diameter; no ribs
  • [0086] Impact speed=33 mph (FMVSS214 resultant speed) to reduce simulation run time
  • [0087] Area for pressure calculation=maximum area that can be impacted and only affect one cone.—Assumed area at base of model (64 mm diameter)
  • [0088] Raw data filtered with SAE1000 (as other filters smoothed too much)
    Variables:
  • [0089] Impact Angle (0°, 14°, 27°)
  • [0090] Part Thickness (1.25 mm, 1.6 mm, 2.0 mm)
  • [0091] Number of 75 mm long Slits in Cone Wall (0, 1, 2, 4)
  • [0092] Height of Ribs inside Cone (0, 1.25 mm, 2.5 mm)
    Rows:
  • [0093] 108 (Full Factorial)
    Measurements:
  • [0094] Peak Pressure exerted on impactor
  • [0095] Mean Pressure exerted on impactor during entire event
  • [0096] Standard Deviation of Pressure during entire event
  • [0097] Cone Mass
    Temperature:
  • [0098] Room temperature (no temp effects considered)
    Analysis of results:
  • [0099] DOE pre and post processing using Altair Hyperworks® software suite
  • [0100] Simulation performed by LS-DYNA3D® nonlinear finite element solver
  • [0101] Analysis of results using JMP statistical software
    • [0102] Effects screening for main effects and interactions
    • [0103] Stepwise Backward Regression for transfer functions

[0104] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.