Description:
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.
TECHNICAL FIELD

Present disclosure in general relates to a field of automobiles. Particularly, but not exclusively, the present disclosure relates to a crash box. Further, embodiments of the present disclosure relate to an improved crash box for a vehicle.

BACKGROUND OF THE DISCLOSURE

Generally, vehicles are equipped with impact energy absorbing members that are configured to buckle by absorbing impact load during collision, for protecting components of the vehicles from impact. One such impact absorbing members employed in the vehicles is crash box. Usually, the impact energy absorbing members are disposed in a front and a rear side of the vehicle.

Crash box plays a vital role in minimizing main cabin damage and save occupant during collision at low and high-speed collisions. During collision, the crash box may absorb majority of the impact load before other components of the vehicle such as front rails absorb deformation energy. For effective crash absorbing feature i.e., to absorb maximum axial kinetic energy by plastic deformation, the crash box should possess minimum peak force to avoid shock to the occupants. Conventional crash boxes are made of two C-section structures formed by stamping process and then joined using spot-welding, forming a rectangular cross-section. However, such crash boxes possess higher peak force, which leads to minimizing energy absorption capacity, which is undesired.

With advancement, crash boxes with multi-chamber profile have been developed. Such crash boxes are usually manufactured by extrusion process using aluminium material. Though multi-chamber crash boxes possess high impact absorbing capacity, the extrusion process and the aluminium material escalates cost of manufacturing the crash boxes.

The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the prior arts.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by system and a method as disclosed and additional advantages are provided through the crash box and method of manufacturing the crash box, as described in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment, a crash box for a vehicle is disclosed. The crash box includes a plurality of cellular sections, each formed by continuously shaping a sheet metal to define a predetermined profile. Further, adjacent cellular sections of the plurality of cellular sections are separated by a wall defining a continuous profile between the adjacent cellular sections.

In an embodiment, continuous shaping of the sheet metal is a bending process.
In an embodiment, corners of each of the plurality of cellular sections is defined with a fillet having radius ranging from 1.8 mm to 2.2 mm and angles at corners of each of the plurality of cellular sections ranges from about 80 degrees to 100 degrees.
In an embodiment, an end of diagonal walls of the adjacent cellular sections of the plurality of cellular sections are joined to corresponding adjacent wall through one of a mechanical and a thermal joining process.
In an embodiment, the crash box is a unitary structure.
In an embodiment, the sheet metal is manufactured by steel.
In another non-limiting embodiment, a method for forming a crash box for a vehicle is disclosed. The method includes forming a plurality of surface patterns on the sheet metal by a stamping process. Further, the method includes shaping the sheet metal in a predetermined pattern to form a plurality of cellular sections such that, adjacent cellular sections of the plurality of cellular sections are separated by a wall defining a continuous profile between the adjacent cellular sections.

In an embodiment, the method includes joining an end of diagonal walls of the adjacent cellular sections of the plurality of cellular sections. Joining is done by one of a mechanical joining process and a thermal joining process.

In an embodiment, the method includes defining fillets at corners of each of the plurality of cellular sections.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figure. 1 illustrates a perspective view of a crash box, in accordance with an exemplary embodiment of the present disclosure;

Figure. 2 illustrates a front view of the crash box of Figure. 1;
Figure. 3 illustrates top view of the crash box of Figure. 1; and

Figure. 4 illustrates a flow chart depicting a method of forming the crash box, in accordance with an exemplary embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the apparatus and system illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent apparatus and systems depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to operation of the apparatus and system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.
Embodiments of the present disclosure disclose a crash box for a vehicle. Conventionally, crash boxes with multi-chamber profile have been developed. Such crash boxes are usually manufactured by extrusion process using aluminium material. Though multi-chamber crash boxes possess high impact absorbing capacity, the extrusion process and the aluminium material escalates cost of manufacturing the crash boxes, which is undesired. Accordingly, the present disclosure discloses a crash box manufactured in a simpler way and yet possessing high impact absorbing capacity.

The crash box of the present disclosure may include a plurality of cellular sections, each formed by continuously shaping a sheet metal to define a predetermined profile. Adjacent cellular sections of the plurality of cellular sections are separated by a wall defining a continuous profile between the adjacent cellular sections. The predetermined profile may be any geometrical profile such as but not limiting to a rectangular profile and the sheet metal may be made of metal such as but not limiting to steel. Further, corners of each of the plurality of cellular sections may define an angle ranging from about 80 degrees to 100 degrees and corners of each of the plurality of cellular sections may be defined with a fillet having radius ranging from 1.8 mm to 2.2 mm. The fillet may aid in stress distribution over broader area, thus improving impact absorption capacity of the crash box.

Further, the crash box may include a plurality of surface patterns defined on a surface of each of the plurality of cellular sections. The plurality of surface patterns may be defined by a stamping process. The plurality of surface patterns may facilitate in lowering the peak force during impact initiation. The crash box of the present disclosure is simpler to manufacture and exhibits about 60% higher impact energy absorbing capacity, when compared to conventional crash boxes.

In the following detailed description, embodiments of the disclosure are explained with reference to accompanying figures that form a part hereof, and in which are shown by way of illustration of specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
Figure. 1 is a perspective view of a crash box (100) for a vehicle. The crash box (100) may be disposed in a front end and a rear end of the vehicle. As an example, the crash box (100) may be disposed beneath a bumper positioned at the front end and the rear end. The crash box (100) may be configured to convert kinetic energy into controlled deformation, thus facilitating dissipation of the kinetic energy. Therefore, the crash box (100) may protect components of the vehicle and occupants inside the vehicles, during crash. As seen in Figure. 1, the crash box (100) may include a plurality of cellular sections (101), which may be formed by continuously shaping a sheet metal to define a predetermined profile. As an example, the predetermined profile may be any geometrical profile such as but not limiting to a rectangular or square profile and the sheet metal may be made through suitable manufacturing process by using metal such as but not limiting to steel. Further, as apparent from Figure. 1, adjacent cellular sections of the plurality of cellular sections (101) may be separated by a wall (102), defining a continuous profile between the adjacent cellular sections. That is, adjacent cellular sections are divided by the wall (102) which extends continuously between the adjacent cellular sections. In an embodiment, continuous profile infers that the wall (102) is an integral part of the cellular sections, which separates the adjacent cellular sections.
In an embodiment, continuous shaping of the sheet metal may be performed by bending process such that, as best seen in Figures. 2 and 3, an end of diagonal walls (105) of adjacent cellular sections of the plurality of cellular sections (101) may overlap a portion of the corresponding adjacent wall, thus forming a unitary structure. The overlapped ends of the diagonal walls of the adjacent cellular sections (101) may be joined to the corresponding adjacent wall (102) through one of a mechanical joining such as by using fasteners, rivets and the like, and a thermal joining process such as welding, brazing and the like. In an embodiment, the overlapped ends of the diagonal walls of the adjacent cellular sections (101) may be joined to the corresponding adjacent wall (102) by spot welding process. A plurality of weld points (106) having radius of but not limiting to 5mm may be formed at equidistant to each other. Further, the topmost weld point and the bottom weld point may be at a distance of but not limiting to 5mm from a top end and a bottom end, respectively.
Further referring to Figure. 3, corners (104) of each of the plurality of cellular sections (101) may be defined with a fillet. In an embodiment, radius of the fillet may range from about 1.8 mm to 2.2 mm. Further, angles at corners (104) of each of the plurality of cellular sections (101) may range from about 80 degrees to 100 degrees. The fillet may facilitate in distributing the stress over a broader area and thus making the crash box (100) durable and capable of absorbing larger impact loads.
Referring again to Figure. 1, the crash box (100) may include a plurality of surface patterns (103) defined on a surface of each of the plurality of cellular sections (101). In an embodiment, the plurality of surface patterns (103) may be defined by a stamping process. Stamping process may involve placing a flat sheet metal, into a stamping press. In the stamping press, a tool and die surface form the metal into the desired shape. As an example, the plurality of surface patterns (103) may be in the form of embossing, defining a substantially elliptical shape. The plurality of surface patterns (103) may facilitate in lowering the peak force during impact initiation. The lower peak force allows a controlled progressive axial crash, thus increasing impact energy absorbing capacity. In an embodiment, the plurality of cellular sections (101) may act as hinges and may facilitate controlled deformation during crash.
In an embodiment, the crash box (100) of the present disclosure exhibits upto-60% higher energy absorption capacity, with respect to the conventional crash boxes formed by two C-section structures.
Figure. 4 illustrates a flow chart of a method for forming a crash box (100) for a vehicle. At block 201, a plurality of surface patterns (103) may be formed on a sheet metal. In an embodiment, the plurality of surface patterns (103) may be formed by a stamping process and the surface patterns (103) may be in the form of embossing. Further, at block 202, the sheet metal may be shaped in a predetermined pattern to form a plurality of cellular sections (101), such that adjacent cellular sections (101) of the plurality of cellular sections (101) may be separated by a wall (102) defining a continuous profile between the adjacent cellular sections (101). In an embodiment, shaping may be a bending process. Upon shaping the sheet metal, ends of diagonal walls (105) of the adjacent cellular sections (101) of the plurality of cellular sections (101) may be joined by one of a mechanical process such as but not limiting to fasteners, rivets, and a thermal joining process such as welding and brazing [as seen in block 203]. Additionally, at block 204, the method may include defining fillets at corners (104) of each of the plurality of cellular sections (101).
In an embodiment, the crash box (100) is easy to manufacture as it includes shaping (thus, bending) the sheet metal in predetermined pattern, unlike conventional extrusion process for manufacturing crash boxes, which is tedious and involving high costs.
EQUIVALENTS

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

Referral Numerals Description
100 Crash box
101 Cellular sections
102 Wall
103 Surface patterns
104 Corners
105 Diagonal walls
106 Weld points
201-204 Process steps

Claims:We Claim:
1. A crash box (100) for a vehicle, the crash box (100) comprising:
a plurality of cellular sections (101), each formed by continuously shaping a sheet metal to define a predetermined profile;
wherein, adjacent cellular sections (101) of the plurality of cellular sections (101) are separated by a wall (102) defining a continuous profile between the adjacent cellular sections (101).

2. The crash box (100) as claimed in claim 1, wherein continuous shaping of the sheet metal is a bending process.
3. The crash box (100) as claimed in claim 1, wherein corners (104) of each of the plurality of cellular sections (101) is defined with a fillet having radius ranging from 1.8 mm to 2.2 mm.
4. The crash box (100) as claimed in claim 1, wherein angles at corners (104) of each of the plurality of cellular sections (101) ranges from about 80 degrees to 100 degrees.
5. The crash box (100) as claimed in claim 1, comprises a plurality of surface patterns (103) defined on a surface of each of the plurality of cellular sections (101).
6. The crash box (100) as claimed in claim 5, wherein the plurality of surface patterns (103) are defined by a stamping process.
7. The crash box (100) as claimed in claim 1, wherein an end of diagonal walls (105) of the adjacent cellular sections (101) of the plurality of cellular sections (101) are joined to corresponding adjacent wall (102) through one of a mechanical and a thermal joining process.
8. The crash box (100) as claimed in claim, wherein the crash box (100) is a unitary structure.
9. The crash box (100) as claimed in claim 1, wherein the sheet metal is manufactured by steel.
10. A vehicle comprising a crash box (100) as claimed in claim 1.
11. A method for forming a crash box (100) for a vehicle, the method comprising:
forming, a plurality of surface patterns (103) on a sheet metal by a stamping process; and
shaping, the sheet metal in a predetermined pattern to form a plurality of cellular sections (101) such that, adjacent cellular sections (101) of the plurality of cellular sections (101) are separated by a wall (102) defining a continuous profile between the adjacent cellular sections (101).

12. The method as claimed in claim 11, wherein shaping is a bending process.
13. The method as claimed in claim 11, comprises joining an end of diagonal walls (105) of the adjacent cellular sections (101) of the plurality of cellular sections (101).
14. The method as claimed in claim 13, wherein the joining is one of a mechanical joining process and a thermal joining process.
15. The method as claimed in claim 11, comprises defining fillets at corners (104) of each of the plurality of cellular sections (101).

Dated this 11th day of March 2021