ANISOTROPIC MULTI-SECTIONAL MODULAR ENERGY ABSORBER AND METHOD FOR CONFIGURING SAME

Abstract

A multi-sectional, modular energy absorber 10 comprising one or more modules, which have one or more energy absorbing units 12. Some have a first section 14 and a second section 16 in some embodiments that are united like a clamshell to form the energy absorbing unit 12. There is a means for locating the sections 18 in relation to each other. First and second flange sections 20,22 extend from at least some of the first and second sections. There are means for coordinating energy absorbing units 24 in one of the one or more modules, the means for coordinating 24 having a topography including a number (n) of apertures 26 defined therein, where n is an integer ≧0. At least some of the sections include an upper perimeter 28, a lower perimeter 30 and an intermediate wall 32 extending therebetween with a number (m) of breaches defined in the intermediate wall before impact, where m is an integer ≧0. When positioned over an underlying elongate support member, the energy absorption characteristics at the distal ends of the absorber differ from those at its central region.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a bumper system including one embodiment of the anisotropic modular energy absorber of the present invention;

FIG. 2 is a front elevational view of one module of a bi-sectional form of energy absorber;

FIG. 3 is a perspective view of a bi-sectional form of energy absorbing module depicting a number of breaches within the walls of a section in some energy absorbing units;

FIG. 4 is a rear perspective view of the embodiment of FIG. 3;

FIG. 5 is an end view thereof;

FIG. 6 is a top plan view of an energy absorber with five energy absorbing modules, similar to that depicted in FIG. 1;

FIG. 7 illustrates one embodiment of a means for locating the sections of an energy absorbing unit in relation to each other;

FIG. 8 depicts an embodiment of a multi-sectional energy absorber in which energy absorbing units are placed in a staggered or alternating sequence and in which various dome sizes of energy absorbers are alternately positioned forwardly and rearwardly;

FIG. 9 is a perspective view of a bi-sectional embodiment of an energy absorbing module in which two sections of the module appear as they might emerge from a forming tool;

FIG. 10 depicts along the line X-X of FIG. 6 one form of a hinge region that unites two sections of a bi-sectional energy absorbing unit;

FIG. 11 depicts a sectional view along the line XI-XI of FIG. 6 of an attachment area between adjacent energy absorbing units shown in FIG. 10;

FIG. 12 depicts a sectional view along the line XII-XII of FIG. 6 illustrating a location and attachment area;

FIG. 13 is a horizontal sectional view of a multi-sectional modular energy absorber with a bumper beam that lies inboard of the multi-sectional energy absorber;

FIG. 14 is a graph of force versus deflection for a conventional thermoformed energy absorber (lower line) and one constructed according to the present invention (upper line);

FIG. 15 is a force versus deflection curve comparing the invention (lower line) to a foam energy absorber (upper line);

FIG. 16 is a top plan view of an alternate embodiment of the present invention;

FIG. 17 is a cross-sectional view taken along the line XVII-XVII (FIG. 16) of one energy absorbing unit of the embodiment of FIG. 16;

FIG. 18 is a front view of a central portion of an alternate embodiment of an energy absorber;

FIG. 19 is a front view of an end portion of a box-shaped energy absorber;

FIG. 20 is a front view of an alternate embodiment of an energy absorber that has an augmented wall volume on a lower face thereof;

FIG. 21 is a front view of an embodiment of an energy absorber wherein a hinge region is relocated so that it is lower on a front face thereof;

FIG. 22 is a quartering perspective view of an energy absorber that includes a means for supporting the fascia;

FIG. 23 is a quartering perspective view of an end of a bumper beam that is at least partially protected by an anisotropic multi-sectional energy absorber according to the present invention;

FIG. 24 is a sectional view of a fascia-energy absorber-bumper beam system that illustrates one way to attach the energy absorber to the bumper beam and fascia;

FIG. 25 depicts a sectional view of an energy absorbing system that supports knee loads that are downwardly applied from an upper region thereof;

FIG. 26 is a sectional view of an embodiment of an energy absorbing system that depicts one way in which part of an energy absorber may be attached to a bumper beam;

FIG. 27 is a sectional view of an embodiment of an energy absorbing system that illustrates how a dome of an energy absorber may be attached to a face of a bumper beam;

FIG. 28 is a sectional view of an embodiment of an energy absorbing system that illustrates how a dome of an energy absorber may be attached to fascia;

FIG. 29 is a front view of an embodiment of an energy absorber illustrating an absorber that is anisotropic in that it has multiple densities of energy absorbing structures wherein the number of energy absorbing units per unit length at a central portion is less than the number of energy absorbers per unit length toward the end of the energy absorber;

FIG. 30 is a top view that illustrates an embodiment of an energy absorber wherein different mating surfaces are joined together between adjacent energy absorbing units;

FIG. 31 is a graph of displacement against dynamic force comparing the performance of a multi-sectional energy absorber with an expanded polypropylene bumper foam;

FIG. 32 is a graph of displacement against dynamic force for different beginning sheet thicknesses; and

FIG. 33 depicts an embodiment of an energy absorbing system wherein an attachment point is placed in an intermediate wall of an energy absorbing unit.

Claims

1. A multi-sectional, modular energy absorber comprising: one or more modules, each of the modules having an average energy absorbing characteristic so that when positioned in relation to an underlying support elongate member, a module positioned adjacent an end of the support member has an end module energy absorbing characteristic that differs from that of a module positioned in a central region of the support member, one or more of the modules having:one or more energy absorbing units associated with at least some modules, at least some of the units having a first section and a second section that are juxtaposed to form an energy absorbing unit;a first and second flange section extending from at least some of the first and second sections;means for locating the first and second sections in relation to each other, the locating means being provided in the first and second flange sections;means for coordinating energy absorbing units in at least one of the one or more modules, the means for coordinating having a topography including a number (n) of apertures defined therein, where n is an integer ≧0, the means for coordinating positioning the energy absorbing units in relation to each other before and during relative motion between an incident object and the modular energy absorber, so that impact forces resulting therefrom are at least partially absorbed by at least some of the energy absorbing units,at least some of the first and second sections in the one or more energy absorbing units including an upper perimeter, a lower perimeter and an intermediate wall extending therebetween and a number (m) of breaches defined in the intermediate wall before impact, where m is an integer ≧0, the wall at least partially collapsing during energy absorption wherein at least some of the energy absorbing units are oriented such that their intermediate walls resist a major incident component of the impacting force, and wherein some of the energy absorbing units cooperate with the means for coordinating to afford mutual support in decelerating an object that imparts the impacting force.

2. The modular energy absorber of claim 1, wherein the end modular energy absorbing characteristic is such that it is stiffer than that of the module positioned in a central region of the support member.

3. The modular energy absorber of claim 1, further including: a hinge region with leaves positioned between the first and second sections,at least some of the first and second sections being provided with a dome,each leaf extending from one of the domes.

4. The modular energy absorber of claim 3, wherein the hinge region lies below an imaginary center line that extends longitudinally along the elongate underlying support member.

5. The modular energy absorber of claim 3, wherein there are multiple second sections of energy absorbers that are separated by the hinge region from a single first section of an energy absorber that lies on an opposing side of the hinge region in relation to the second sections, thereby enabling the energy absorber to have an average energy absorbing characteristic on one side of the hinge region that differs from an average energy absorbing characteristic on the opposing side of the hinge region.

6. The modular energy absorber of claim 1, further including: means for locating the energy absorber in relation to the underlying support elongate member.

7. The modular energy absorber of claim 1, further including: means for attaching a fascia to the modular energy absorber.

8. An energy absorbing system comprising: an underlying support elongate member;an energy absorbing module positioned adjacent the underlying support elongate member, the module including one or more energy absorbing units, at least some of which having a first section and a second section that are juxtaposed to form an energy absorbing unit; anda fascia that may be positioned adjacent the energy absorbing module.

9. The energy absorbing system of claim 8, further including means for attaching the fascia to the energy absorber at a lower portion thereof.

10. The energy absorber of claim 8, further including: a knee support means in the energy absorbing module that lies below a generally horizontally extending portion of the fascia.

11. The energy absorbing system of claim 8, further including: means for affixing the energy absorbing module to the underlying support elongate member, the attachment means being associated with a flange section of an energy absorbing unit.

12. The energy absorbing system of claim 8, further including: means for affixing the energy absorbing module to the underlying support elongate member, the attachment means being associated with a dome of an energy absorbing unit.

13. The energy absorbing system of claim 8, wherein a dome of an energy absorbing unit includes means for attaching the energy absorbing unit to the fascia.

14. The modular energy absorber of claim 3, wherein at least a portion of some of the leaves extending from a dome in a section are joined with a corresponding portion of a leaf associated with a facing section of an energy absorbing unit.

15. The modular energy absorber of claim 1, wherein the number (n) of apertures equals zero.

16. The modular energy absorber of claim 1, wherein the means for coordinating comprises a form selected from the group consisting of a web, a tether, a hinge, a planar surface, a rib, a channel, a non-planar surface, and combinations thereof.

17. The modular energy absorber of claim 3, wherein the dome has a configuration that is non-planar.

18. The modular energy absorber of claim 1, wherein some of the one or more energy absorbing units have an imaginary axis of symmetry and at least a segment of the dome is inclined to the axis of symmetry.

19. The modular energy absorber of claim 1, wherein a released configuration following rebound is located in substantially the same position as a pre-impact undeflected configuration.

20. The modular energy absorber of claim 1, wherein the intermediate wall has a thickness, the thickness being non-uniform between the upper and lower perimeters.

21. The modular energy absorber of claim 1, wherein the intermediate wall of a given energy absorbing unit has an average thickness (t1) that differs from an average thickness (t2) of a wall associated with another energy absorbing unit.

22. The modular energy absorber of claim 1, wherein a lower perimeter of an energy absorbing unit defines a geometric figure that is selected from the group consisting of a portion of a circle, an oval, an oblong, an oblate oblong, an ellipse, a quadrilateral, and a polygon.

23. The modular energy absorber of claim 1, wherein an upper perimeter of an energy absorbing unit defines a geometric figure that is selected from the group consisting of a circle, an oval, an oblong, an oblate oblong, an ellipse, a quadrilateral, and a polygon.

24. The modular energy absorber of claim 1, wherein the size of the first section differs from that of the second section.

25. The modular energy absorber of claim 1, further including one or more stiffening ribs that are associated with one or more of the sections.

26. The modular energy absorber of claim 1, where the breaches include slots, the slots having edges.

27. The modular energy absorber of claim 1, wherein the number (m) of breaches equals zero.

28. The modular energy absorber of claim 26, wherein the slots have edges that are not parallel.

29. The modular energy absorber of claim 1, further including means for attaching one or more modules of the multi-sectional modular energy absorber to a bumper beam, the means for attaching being selected from the group consisting of adhesives, push pins, formed snaps, dovetails, rivets, and combinations thereof.

30. The modular energy absorber of claim 1, wherein the intermediate wall extending between the upper and lower perimeter of one or more energy absorbing units includes one or more stepped portions that are linked by interconnecting sections.

31. The modular energy absorber of claim 30, wherein the stepped portions have a thickness that is greater than the thickness of those in proximity to the upper perimeter.

32. The modular energy absorber of claim 30, wherein the interconnecting portions have a taper such that the thickness of the interconnecting portions rises with distance from an axis of symmetry of a unit.

33. The modular energy absorber of claim 1, further including: means for locating the sections in relation to each other, the locating means being provided in the first and second flange sections.

34. An energy absorbing system comprising: an underlying support member; andan energy absorbing module positioned adjacent the underlying support member, the module including one or more energy absorbing units, at least some of which have a first section and a second section that are juxtaposed to form an energy absorbing unit.

35. The energy absorbing system of claim 34, wherein the underlying support member is selected from a group consisting of a bumper beam, a door panel, a highway barrier, and combinations thereof.

36. The energy absorbing system of claim 8, further including means for attaching the fascia to the energy absorber using one or more intermediate wall of the one or more energy absorbing units.