Crush box for vehicle impact

Patent metadata

Field	Value
Publication number	US-9751480-B1
Application number	US-201615137728-A
Country	US
Kind code	B1
Filing date	Apr 25, 2016
Priority date	Apr 25, 2016
Publication date	Sep 5, 2017
Grant date	Sep 5, 2017

Abstract

Embodiments of a crush box are described. One embodiment of the crush box includes a first sidewall that is coupled to a vehicle and a second sidewall that is coupled to the vehicle, where the first sidewall and the second sidewall include similarly pre-bent portions that cause the first sidewall and the second sidewall to bend outward upon receipt of a force. In some embodiments, the first sidewall and the second sidewall include a plurality of tabs that couple the first sidewall and the second sidewall to a top wall that bends inward upon receipt of the force.

First claim

What is claimed is:

1. A crush box, comprising:
a first sidewall that is coupled to a vehicle;
a second sidewall that is coupled to the vehicle,
wherein the first sidewall and the second sidewall are similarly pre-bent portions that cause the first sidewall and the second sidewall to bend outward upon receipt of a force, and
wherein the first sidewall and the second sidewall include a plurality of tabs that couple the first sidewall and the second sidewall to a top wall that bends towards a center of the crush box upon receipt of the force.

2. The crush box of claim 1 , wherein the top wall comprises a first side portion and a second side portion that couples to the plurality of tabs to create a substantially rectangular outer surface.

3. The crush box of claim 1 , wherein the force is applied asymmetrically to the crush box and wherein the crush box buckles substantially symmetrically in a predetermined buckle configuration.

4. The crush box of claim 1 , wherein an inlet is disposed on the top wall between the plurality of tabs to define a location that the top wall buckles upon receipt of the force.

5. The crush box of claim 1 , wherein the top wall comprises a pre-bent configuration that defines a location that the top wall buckles upon receipt of the force.

6. The crush box of claim 1 , wherein the first sidewall and the second sidewall are individual pieces coupled to the top wall.

7. The crush box of claim 1 , wherein the first sidewall and the second sidewall are parts of a single structure that is connected by another surface that wraps under the top wall.

8. A system, comprising:
a vehicle; and
a crush box that is coupled to the vehicle, the crush box comprising:
a first sidewall that is coupled to the vehicle, wherein the first sidewall includes a first sidewall securing surface to secure the first sidewall to the vehicle and a first lateral surface that is substantially perpendicular to the first sidewall securing surface, and wherein the first sidewall further includes a first plurality of tabs;
a second sidewall that is coupled to the vehicle, wherein the second sidewall includes a second sidewall securing surface to secure the second sidewall to the vehicle and a second lateral surface that is substantially perpendicular to the second sidewall securing surface, and wherein the second sidewall further includes a second plurality of tabs; and
a top wall that is coupled to the first plurality of tabs and the second plurality of tabs to create a substantially rectangular outer surface,

wherein the first sidewall and the second sidewall include similarly pre-bent portions that cause the first sidewall and the second sidewall to bend outward upon receipt of a force.

9. The system of claim 8 , wherein the first plurality of tabs and the second plurality of tabs define a location on a side portion of the top wall that buckles in response to receipt of the force.

10. The system of claim 8 , wherein the force is applied asymmetrically to the crush box and wherein the crush box buckles substantially symmetrically in a predetermined buckle configuration.

11. The system of claim 8 , wherein an inlet is disposed on the top wall between the first plurality of tabs to define a location that the top wall buckles, upon receipt of the force.

12. The system of claim 8 , wherein the top wall comprises a pre-bent configuration that defines a location that the top wall buckles, upon receipt of the force.

13. The system of claim 8 , further comprising:
a bumper reinforcement that is coupled to the crush box; and
an energy absorbing foam that is coupled to the bumper reinforcement.

14. The system of claim 13 , further comprising a bumper cover that covers the crush box, the bumper reinforcement, and the energy absorbing foam.

15. A vehicle with a crush box, the crush box comprising:
a first sidewall that is coupled to the vehicle, wherein the first sidewall includes a first lateral surface, wherein the first sidewall further includes a first plurality of tabs;
a second sidewall that is coupled to the vehicle, wherein the second sidewall includes a second lateral surface, wherein the second sidewall further includes a second plurality of tabs; and
a top wall that is coupled to the first plurality of tabs and the second plurality of tabs,
wherein the first sidewall and the second sidewall include similarly pre-bent portions that cause the first sidewall and the second sidewall to bend according to a predetermined buckle configuration upon receipt of a force, and the top wall bends towards a center of the crush box.

16. The vehicle of claim 15 , wherein the first plurality of tabs and the second plurality of tabs define a location on a side portion of the top wall that buckles in response to receipt of the force.

17. The vehicle of claim 15 , wherein the force is applied asymmetrically to the crush box and wherein the crush box buckles substantially symmetrically in the predetermined buckle configuration.

18. The vehicle of claim 15 , wherein the top wall comprises a pre-bent configuration that defines a location that the top wall buckles upon receipt of the force.

19. The vehicle of claim 15 , wherein an inlet is disposed on the top wall between the first plurality of tabs to define a location that the top wall buckles, upon receipt of the force.

20. The vehicle of claim 15 , wherein at least one of the first lateral surface and the second lateral surface include a ridgeline that determines an amount of force required for buckling the crush box.

Assignees

• Toyota Motor Eng & Mfg North America Inc

Inventors

• Graves William F
• Mikolaizik Ryan A
• Schnug Tyler E
• Clauser Mark D

Classifications

• B60R19/34 Primary

  destroyed upon impact, e.g. one-shot type · CPC title

• B60R19/26

  comprising yieldable mounting means ({B60R19/38 takes precedence;} springs, shock absorbers, or means for damping vibrations per se F16F) · CPC title