Advanced thin-walled structures for enhanced crash performance

Abstract

A crash can for a vehicle includes a multi-cell structure that includes at least four hollow cuboids, each defined by four walls that meet at 90 degree angles and at least two of the cuboids share a wall. In another example, a crash can includes a multi-cell structure that includes a hollow cuboid having four walls, and four hollow isosceles trapezoidal prisms having a long base, a short base, and two legs. The multi-cell structures provided herein may increase energy absorption by the crash can if involved in a collision, reducing energy transfer to a vehicle frame and occupants therein.

What is claimed is: 
     
         1 . A thin-walled structure for crash zones of a vehicle, the thin-walled structure comprising:
 a multi-cell structure comprising:
 at least four hollow cuboids, each defined by four walls; 
 wherein the four walls of each hollow cuboid meet at 90 degree angles and at least two of the cuboids share a wall. 
   
     
     
         2 . The thin-walled structure of  claim 1 , wherein the multi-cell structure comprises nine hollow cuboids. 
     
     
         3 . The thin-walled structure of  claim 1 , wherein the multi-cell structure is comprised of aluminum alloy. 
     
     
         4 . The thin-walled structure of  claim 3 , wherein the multi-cell structure is comprised of an extruded piece of aluminum alloy. 
     
     
         5 . The thin-walled structure of  claim 4 , wherein the extruded piece of aluminum alloy includes silicon manganese. 
     
     
         6 . The thin-walled structure of  claim 4 , wherein the material of the extruded piece of aluminum alloy is thermally conductive. 
     
     
         7 . The thin-walled structure of  claim 4 , wherein the material of the extruded piece of aluminum alloy has anisotropic characteristics. 
     
     
         8 . The thin-walled structure of  claim 4 , wherein the extruded piece of aluminum alloy is formed at a prescribed range of die exit temperatures, the prescribed range predetermined so as to achieve a prescribed level of mechanical properties. 
     
     
         9 . The thin-walled structure of  claim 1 , wherein each of the walls is between 1 mm and 3.5 mm thick. 
     
     
         10 . The thin-walled structure of  claim 1 , wherein the length of each wall of each hollow cuboid is between 26 mm and 38 mm. 
     
     
         11 . The thin-walled structure of  claim 1 , wherein the multi-cell structure further comprises four outside walls. 
     
     
         12 . The thin-walled structure of  claim 11 , wherein the four outside walls meet at 90 degree angles to form four corners. 
     
     
         13 . The thin-walled structure of  claim 12 , wherein the four corners are rounded. 
     
     
         14 . The thin-walled structure of  claim 13 , wherein the radius of each of the four rounded corners is between 0.1 mm and 5 mm. 
     
     
         15 . The thin-walled structure of  claim 1 , wherein the length of the thin-walled structure is between 150 mm and 450 mm. 
     
     
         16 . The thin-walled structure of  claim 1 , wherein the thin-walled structure is comprised of a single piece of material formed by an additive process, molding, carving, or etching. 
     
     
         17 . The thin-walled structure of  claim 16 , wherein the single piece of material is formed by the additive process, molding, carving, or etching that is controlled by a computer. 
     
     
         18 . The thin-walled structure of  claim 16 , wherein the single piece of material is formed by the additive process, molding, carving, or etching that is performed by use of lasers or chemicals. 
     
     
         19 . The thin-walled structure of  claim 1 , wherein the thin-walled structure is comprised of a plurality of interconnected pieces of a single component, the plurality of interconnected pieces formed by welding. 
     
     
         20 . The thin-walled structure of  claim 1 , wherein the multi-cell structure comprises more than nine hollow cuboids. 
     
     
         21 . A thin-walled structure for crash zones of a vehicle, the thin-walled structure comprising:
 a multi-cell structure comprising:
 a plurality of rows of cells, each of the rows comprising a plurality of hollow cuboids, each of the hollow cuboids defined by four walls; 
 wherein the four walls of each hollow cuboid meet at 90 degree angles and at least two of the cuboids share a wall. 
   
     
     
         22 . The thin-walled structure of  claim 21 , wherein the multi-cell structure comprises three rows of three hollow cuboids.