Arkansas Patent of the Month – December 2023
Tesseract Structural Innovations, Inc. is bringing a new era of safety to the automotive industry, with a unique lightweight technology, known as Uniform Deceleration Unit (UDU).
The recently patented aluminum composite foam technology was designed to meet the need for improved passive structural safety in vehicles, while at the same time creating a new playbook for lightweighting in many structural areas of the vehicle, such as electric vehicle (EV) battery packs.
Using the material in crash pads provides a method for converting kinetic energy into strain energy, offering a multifaceted approach to safety. The design strategically structures a cellular layer between two skin layers. This innovative design isn’t just about durability; it’s a strategic move to absorb and dissipate energy during a crash by inducing both elastic and plastic deformation in the crash pads and the connection beam.
Tesseract’s safety system isn’t limited to a one-size-fits-all approach. The forward crash pad, rear crash pad, and the connecting beam collectively create a protective network that efficiently absorbs crash energy upon deflection. Versatility is key, as the assembly finds its place in crucial areas like wheel wells and side doors, ensuring a comprehensive safety net for occupants.
The system’s inverted “U” shape underscores its adaptability, demonstrating a thoughtful integration into various automobile architectures. What’s truly innovative is the utilization of metallic foam with a mass per unit volume less than 1,000 kg/m3 in constructing the crash pads, ensuring a lightweight yet formidable defense against impact forces.
But Tesseract’s ingenuity doesn’t stop there. Hollow, thin-walled tubular sections, intricately arranged in a matrix of ribs and webs, elevate the crash pad’s structural integrity. In a crash, these elements work in harmony, initially deforming elastically and then transitioning into plastic deformation, offering a controlled and effective energy absorption mechanism.
This inventive safety system is not just a concept on paper; it’s a testament to Tesseract Structural Innovations’ commitment to advancing automotive safety. As vehicles continue to be an integral part of our lives, innovations like these pave the way for a safer and more secure future on the roads.
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