The paper describes the application of fibre reinforced polymer composites to the design of lightweight energy absorbing (EA) elements for use in vehicle front-ends. The elements are placed between front bumper and vehicle longitudinal beams and are designed for use within a progressive frontal collapse concept. At first the front bumper absorbs impact energy, than the absorber element is triggered for medium energy levels, with loads being transferred into the longitudinal beams at higher energies. Based on this concept a design envelope of required crush lengts, allowable lead levels and EA is defined for the front-end absorber structure. Metallic and composite material systems are first reviewed to define materials and devices with high specific EA per unit mass. Using data from impact tests at the DLR a comparison is than made between the EA properties of polymer and metallic foams and honeycombs, composite cellular structures, and metallic and composite tubes. It is shown that composite tubes have exceptionally good specific EA when loaded axially in compression with suitable trigger devices. These EA mechanism can be utilised in the vehicle element by designing a conical absorber, which can absorb crash energy in frontal and off-set impacts. Impact tests results on two types of conical composite absorber are presented. One type is based on glass fibre reinforced thermoplastic prepreg, with both mat and fabric reinforcement. The second type of cone absorber is based on an innovative use of high performance polyethylene in combination with 3D-glass fabrics. Both cone concepts were found to be suitable for a low weight, mass production absorber for road vehicles.
Composite energy absorging concepts for lightweight vehicles
Kombinierte Konzepte zur Energieaufnahme bei leichten Kraftfahrzeugen
1996
10 Seiten, 9 Bilder, 2 Tabellen, 4 Quellen
Conference paper
English
Composite Energy Absorbing Concepts for Lightweight Vehicles
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