Shaped contoured crushable structural members and methods for making the same

Abstract

Shaped, contoured crushable structural members and methods for making the same are described. The contoured structural members comprise composite or metal materials sandwiching a support or stabilizing structure. The structural members are made crushable by incorporating an initiator into the structural members. The structural member crushes at the location of the initiator by absorbing the energy of an exerting load. The shaped structure is provided by bending the generally straight shape of the structural member. With a shaped, contoured, crushable, and generally non-flat structure, applications and uses for the structural members of the present invention are nearly limitless.

1 . A shaped contoured structural member, comprising: 
 an inner section containing a continuous plurality of contoured layers comprising both a layer of a composite material and a layer of a metal-containing material;    an outer section containing a continuous plurality of contoured layers comprising both a layer of a composite material and a layer of a metal-containing material; and    at least one intermediate layer having a honeycomb core structure connecting the inner section and the outer section.    
     
     
         2 . The structural member of  claim 1 , wherein the structural member has a substantially non-straight configuration.  
     
     
         3 . (canceled)  
     
     
         4 . (canceled)  
     
     
         5 . The structural member of  claim 1 , wherein the layers of metal-containing material are layers of metal alloy.  
     
     
         6 . The structural member of  claim 1 , further comprising at least one initiator.