Scalable crush can for vehicle

Abstract

In one aspect, the invention is directed to a crush can for a vehicle frame including a crush can body having a longitudinal axis and a cross-sectional shape that is at least approximately a 10-sided polygon. In another aspect, the invention is directed to a crush can for a vehicle frame including a crush can body having a longitudinal axis and a cross-sectional shape that includes a plurality of outwardly pointing apexes and a plurality of inwardly pointing apexes.

1 . A crush can for a vehicle frame, comprising:
 a crush can body having a longitudinal axis and a cross-sectional shape that is a 10-sided polygon.   
     
     
         2 . A crush can as claimed in  claim 1 , wherein the 10-sided polygon is a regular polygon. 
     
     
         3 . A crush can as claimed in  claim 1 , wherein the 10-sided polygon is a decagon. 
     
     
         4 . A crush can as claimed in  claim 1 , wherein the crush can body has a length and is tapered along the length. 
     
     
         5 . A crush can as claimed in  claim 4 , wherein the crush can body has a large end and a small end, wherein, in use, the large end is rearward of the small end. 
     
     
         6 . A crush can as claimed in  claim 1 , wherein the crush can body includes a first clamshell portion and a second clamshell portion wherein the first and second clamshell portions are welded together. 
     
     
         7 . A crush can as claimed in  claim 1 , wherein the crush can body has a front end and a rear end, and wherein the crush can further includes a front plate mounted to the front end and a rear plate mounted to the rear end. 
     
     
         8 . A crush can as claimed in  claim 1 , further comprising at least one buckling feature positioned at a selected position along the crush can body to initiate buckling at the selected position in the event of a sufficiently large axial compressive force on the crush can body. 
     
     
         9 . A crush can as claimed in  claim 8 , wherein the crush can body is made up of 10 planar forms that meet at 10 apexes, wherein the at least one buckling feature includes a lateral deformation of at least one apex. 
     
     
         10 . A crush can as claimed in  claim 1 , wherein the crush can body is made up of 10 generally planar forms that meet at 10 apexes. 
     
     
         11 . A crush can as claimed in  claim 10 , wherein the crush can body has a wall thickness and wherein each apex has a radius that is between 2 and 10 times the wall thickness. 
     
     
         12 . A crush can as claimed in  claim 4 , wherein the crush can body has a wall thickness that is substantially constant along the length of the crush can body. 
     
     
         13 . A crush can for a vehicle frame, comprising:
 a crush can body having a longitudinal axis and a cross-sectional shape formed by a wall and that includes a plurality of apexes, wherein at least two portions of the wall are in abutment with each other.   
     
     
         14 . A crush can as claimed in  claim 13 , wherein the at least two wall portions are joined together. 
     
     
         15 . A crush can as claimed in  claim 13 , wherein the at least two wall portions together form an arm that separates a central hollow shape and a distal hollow shape. 
     
     
         16 . A crush can as claimed in  claim 15 , wherein the central hollow shape has a plurality of apexes. 
     
     
         17 . A crush can as claimed in  claim 15 , wherein the distal hollow shape has at least one apex. 
     
     
         18 . A crush can for a vehicle frame, comprising:
 a crush can body having a longitudinal axis and a non-hollow cross-sectional shape including a central spine and a plurality of arms extending from the spine.   
     
     
         19 . A crush can as claimed in  claim 18 , wherein each of the arms includes an apex therein. 
     
     
         20 . A method for making a crush can, comprising:
 extruding a non-hollow cross-sectional shape including a central spine and a plurality of arms extending from the spine.