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Content archived on 2024-05-07

Energy absorbing materials for low impact forces

Objective



Safety of transportation vehicles, especially passenger cars, has to meet permanently increasing demands. Developments in active and passive security systems in vehicles have already led to high standards. Nevertheless weak points are still passenger as well as the pedestrian protection in various crash situations.
Besides passenger protection also the safety of "weaker" traffic participants like bikers and children possibly being involved in accidents with cars has to be improved. So there is a vital necessity for the development of energy absorbing structures and materials not only to meet legal regulations on e.g. side impact, head impact or pedestrian protection (by so called "soft noses"). For this reason the energy absorption potential of cellular structures made from various materials have to be investigated and evaluated. The materials properties will be analysed with respect to the transferability of their behaviour in a component respectively a completed car.
Additionally to the analysis of existing structures materials modelling and simulation procedures for energy absorption behaviour will be developed enabling the tailoring of cellular structures with applicationally optimised properties profiles.
At the end of the project duration it will be possible to react quickly on new safety demands. New basic properties data and improved modelling and simulation tools as well as adequate testing methods will enable a quick development of components with optimised energy absorption properties.
All possible applications mentioned in this project have to work under low impact torces. This means in comparison to structural energy absorption in a car (deformation of frame elements) the energy level is in the range of 0.1 to 1 kJ related to a 100 x 100 x 100 mm3 test specimen.
The working programme can be devided in five major working packages: 1 Screening of available materials and methods
2 Materials production and optimisation
3 Functional relation of material properties and energy absorption data
4 Mathematical numerical description of the material behaviour, modelling and simulation
5 Verification on typical components
Innovative aspects:
A decisive degree of innovation will be the development of foams respectivelycellular materials structures with ideal force
displacement characteristics. Those materials will have a steep force gain, a regulated deformation force level (crush strength) respecting the safety requirements e.g. for head impact, hip, thorax, legs, shoulders and others. Additionally they will have a maximised deformation length (> 80 %) before the required strength level is exceeded.
The development will end up in an optimised cellular material with adequate production processes concerning also minimised masses (lightweight) and environmental aspects.
Test methods are standardised and the procedures will be comparable.Modelling of foams and other cellular materials is enabling
behaviour simulation under dynamic load (crash) without a reference of an existing material.
Decisive impact on "safety design".
Social aspects:
* Improved safety design will reduce the heaviness of injuries and thus reduce the subsequent medical and social expenditures.

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Coordinator

VOLKSWAGEN AG
EU contribution
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Address
Berliner Ring 2
38436 WOLFSBURG
Germany

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