# US 9,751,480 B1 · Crush box for vehicle impact

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- Number: US 9,751,480 B1
- Document ID: US9751480B1
- Status: Granted
- Kind: B1
- Application number: 15/137,728
- Filed: 2016-04-25
- Granted: 2017-09-05
- Earliest claimed: 2016-04-25
- Assignees: Toyota Motor Engineering & Manufacturing North America, Inc.
- Applicants: Toyota Motor Engineering & Manufacturing North America, Inc.
- Inventors: William F. Graves; Ryan A. Mikolaizik; Tyler E. Schnug; Mark D. Clauser
- Web page: https://patentgrep.com/patent/US9751480B1

## CPC

- B60R 19/34: destroyed upon impact, e.g. one-shot type
- B60R 19/26: comprising yieldable mounting means ({B60R19/38 takes precedence;} springs, shock absorbers, or means for damping vibrations per se F16F)
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR

## 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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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.

### Claim 4 (depends on 1)

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.

### Claim 5 (depends on 1)

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.

### Claim 6 (depends on 1)

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

### Claim 7 (depends on 1)

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.

### Claim 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.

### Claim 9 (depends on 8)

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.

### Claim 10 (depends on 8)

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.

### Claim 11 (depends on 8)

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.

### Claim 12 (depends on 8)

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.

### Claim 13 (depends on 8)

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.

### Claim 14 (depends on 13)

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

### Claim 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.

### Claim 16 (depends on 15)

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.

### Claim 17 (depends on 15)

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.

### Claim 18 (depends on 15)

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.

### Claim 19 (depends on 15)

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.

### Claim 20 (depends on 15)

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.