BACKGROUND OF THE INVENTION The invention relates to an elastomeric energy absorbing device comprised of cup shaped absorbers, which is particularly desirable for vehicle bumper applications but also can be used for other energy absorbing applications.

Resilient, natural and synthetic resins are used for a number of energy management purposes. Such devices are used in automobile bumper assemblies, for example, and in various other applications requiring energy absorption. An object of the present invention is to provide an improved, lightweight, inexpensive energy absorber with a low ratio of weight to crush force output.

BRIEF SUMMARY OF THE INVENTION The present invention comprises an energy absorbing device formed of natural or synthetic resin material or composite material, wherein energy absorption is provided by a plurality of cup-shaped cells having a thin-walled construction with a circular cross section. The absorber is useful for automotive bumper impact and also for other applications, including automotive padding and general cushion applications.

These and other features, objects, and benefits of the invention will be recognized by one having ordinary skill in the art and by those who practice the invention, from the specification, the claims, and the drawing figures.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING FIG. 1 is a perspective view of a cup absorber of the present invention.

FIG. 2 is a similar view of the same cup absorber formed of an injection molded high density, polyethylene alloy.

FIG. 3 is a front view of the cup absorber of FIG. 2.

FIG. 4 is a cross-sectional view taken along lines 4-4 of FIG. 3.

FIG. 5 is a cross-sectional view taken along lines 5-5 of FIG. 3.

FIG. 6 is a side elevation view of the cup absorber of FIG. 3.

FIG. 7 is an end view of the cup absorber of FIG. 3.

FIG. 8 is a perspective view of a bumper absorber module having eight cells formed by vacuum forming or thermoforming.

FIGS. 9-14 show the bumper absorber of FIG. 8 with view corresponding to FIGS. 2-7 which show an injection molded bumper absorber module of eight cells.

FIG. 15 is a line drawing perspective view of an eight absorber module molded on a common flat sheet base.

FIG. 16 is a perspective view showing a buckling analysis of a single, inverted cell.

FIG. 17 is a top view of the cup of FIG. 16.

FIG. 18 is a perspective view of an absorber comprising a series of cup- shaped cells positioned side by side.

FIG. 19 is a front view of the absorber of FIG. 18.

FIG. 20 is an end view of the absorber of FIG. 19.

FIG. 21 is a perspective view of a single cell in the absorber of FIGS.

18-20.

FIG. 22 is a chart showing a comparison of force-deflection curves of an EPP foam absorber and a proposed molded inverted cup absorber.

FIG. 23 is a chart showing an actual impact test of a cup absorber formed in accordance with the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT Referring to the drawings and more particularly to Fig. 1, an absorber 10 comprises a series of individual cup-shaped cells 10 mounted on a flat sheet 14 and interconnected by ribs 16. The cups have side walls 18 formed with a circular cross section, a top end 20, and an open bottom end 22. Thus, each cell forms an inverted cup.

One method of forming a cup absorber of the present invention is by injection molding, as shown in FIGS. 1-7. Preferably the molded product is formed from a composite material which is a plastic elastomer, further preferably from the polyolefin family of resin materials. Injection molded high density polyethylene (HDPE) with a rubber modifier is the preferred material used in the process. However, other materials and manufacturing processes are feasible and are within the scope of the present invention.

The shape of the individual cells or cups provides an extremely efficient construction in comparison with prior energy absorbing structures. In the preferred practice of the present invention, the aspect ratio of the cup (the relationship between the height, width and wall thickness) permits efficient energy management, high force output and large compression in comparison to other devices and other designs. One exemplary cup cell size that appears to function well for a 5 mph bumper impact is 58 mm high, 32 mm in diameter and has a 1 mm wall thickness. A molded HDPE cell of the described size will weigh only 0.01 Ibs., yet will produce approximately 200 Ibs. resistance to axial compression. This is a ratio of 1/2000 in weight to crush force output.

The 1 mm wall thickness allows fast molding cycle, low piece cost, and high percentage of cell collapse. A 58 mm cell folds approximately four times on itself to allow a total of 50 mm of collapse with 90-100% return after impact, depending on resin material selected. FIG. 22 is a chart showing a force- deflection curve of a cell of the present invention compared with a typical EPP foam force-deflection curve. It can be seen that the present invention absorbs approximately the same energy as a foam absorber but the cup absorber has a higher efficiency and a lower deflection.

The cup absorber of the present invention typically produces 70% of a square wave energy curve, which is commercially advantageous in reducing bumper stroke and therefore reducing vehicle overhand length.

Other cell sizes can be used to vary the stiffness characteristics of the cell. The cells can be one-half or double the cell height of the exemplary cell that is 58 mm high. The other dimensions of the cell (width and wall thickness) are changed accordingly so as to maintain substantially the same aspect ratio between height, width and wall thickness.

In the present invention, the multiple cells are positioned strategically, as desired, in order to absorb and manage the energy of an automotive bumper impact. In the exemplary embodiment, the base sheet 22 is used to secure the absorber 10 to a component of a motor vehicle. Such securement is most typically carried out with adhesive or plastic push pin mechanical fasteners. Because each cell acts somewhat independently, the cell can be placed as desired for specific absorber applications. This makes it possible to use the absorber for many energy managing applications, including interior automotive padding and general cushion applications as well as bumper applications.

Because of the thin walled construction of the present invention, an effective absorber requires only a minimum amount of material. This translates into a low cost and a low mass absorber.

As stated above, the cup absorber can be molded from a composite material by injection molding. A second good manufacturing process is high speed vacuum forming or thermoforming, which permits the use of an extrusion grade of HDPE sheet, which will have better material properties than injection molding polyethylene. Molding from a sheet, on the other hand, has the disadvantage of limiting thickness in design control and connecting the cells.

The construction of an eight cell module of a bumper absorber 30 using a vacuum forming or thermoforming process is shown in FIGS. 8-15.

Individual cells 32 are substantially similar to injection molding cells, in that the cells constitute inverted cups having side walls 34, a top 36, and an open

bottom 38, with the cups being mounted on a flat sheet 40. One difference between the vacuum or thermoformed module and an injection molded module is that the thermoformed cups do not have ribs 16 interconnecting the cups.

In addition, the corners 42 of the cups between sidewalls 34 and top 36 have an increased radius in comparison with the construction of the injection molded product.

In both the injection molded and vacuum formed or thermoformed modules, however, the impact is absorbed by a series of inverted cups.

While a cup configuration having one closed end and one open end is preferred, the cups also could be formed by blow molding, in which case cups can be formed with both ends closed. Also, cups can be formed with both ends open with at least some of the molding techniques.

Various cell configurations are shown in the drawings. An exemplary absorber configuration 50 that can be employed in an automobile bumper is shown in FIGS. 18-20. Figure 21 is a perspective view of a single cell 52 of the absorber configuration 50 of FIG. 18-20. In this exemplary application, the absorber configuration 50 has a length L of approximately 1280 mm. Each cell 52 has a height H of approximately 57.5 mm, an upper diameter d of approximately 32 mm and a lower diameter D of approximately 33 mm.

A buckling analysis of single inverted cup shaped cells is shown in FIGS. 16 and 17. The illustrations are color-coded with shading, and the scale adjacent the illustrations a stress map plotted on the compressed shape of the cell as generated from a computerized structural analysis.

Among the important features and advantages of the present invention are: 1. The aspect ratio of cell-designed parameters (ratio of wall thickness to cell height and width) provides advantageous characteristics. Other cup sizes and shapes are possible, including square, oval, rectangular and the like and are within the scope of the invention.

2. A high percentage of cell collapse by virtue of the design aspect ratio of wall thickness in comparison to cell size.

3. A high energy efficiency, approximately 70% of a square wave by virtue of its aspect ratio of design parameters.

4. Cell placement can be varied as desired. A discreet number of cells produce a known force output and can be tailored and positioned for different vehicle masses, thereby minimizing material usage.

5. Cell placement can be made to direct the majority of the bumper resistance forces at pre-designed locations, such as over the vehicle rails or on center to resist pole intrusion. This is an important design feature for lowering vehicle structural mass.

6. The interconnection of individual cells by vertical ribs in the injection molded product permits horizontal multi- sweep usage. Both vertical and horizontal rib connection is possible and within the scope of the present invention.

Interconnecting the cells provides lateral stability. Vertical ribs are shown in addition to horizontal ribs in phantom in FIG. 3.

7. The horizontal connection of the individual cells by a common molded base sheet makes it possible to position an absorber module over a structural bumper reinforcement beam to take any sweep. This allows molding in a flat, straight shape and then attaching the module to a vehicle to form a"plan view"sweep which minimizes tooling costs.

The foregoing is representative of the preferred practice of the present invention. However, various changes in the arrangements and details of construction of the present invention may be made without departing from the spirit and scope of the present invention. It is anticipated that the teachings of the present invention may be alternatively incorporated into energy absorbing components including but not limited to trim panels, knee bolsters, and head liners.