Energy absorbing composite structure for frontal pedestrian protection in electric light vehicles

Abstract

This article collects the development of a frontal composite structure for electric light vehicles (concretely within L7e European category), which has been required to fulfil energy absorption capabilities for pedestrian protection. An initial design made of a composite sandwich structure (glass fibre skins with polyvinyl chloride foam core) was proposed and a prototype was manufactured and tested against impact. Then, a numerical model was created and the impact test was simulated by the finite element method. After adjusting the numerical model to the real performance of the component, the initial material configuration of the sandwich composite was optimized according to design objectives involving safety, current regulations and repairability.