Collapsible Map Pocket Using Thermoformed Fibrous Substrate
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Solution Overview
Problem
Current map pocket substrates made from injection-molded plastic resins have rigidity that exceeds desirable levels for deformability during side-impact collisions, and achieving tunable deformability requires multiple molds and can result in 'soft spots' on the trim panel.
Innovation Solution
A collapsible map pocket using a polyethylene/polypropylene fibrous, thermoformed substrate with a non-woven, thermoformed A-side material layer, eliminating the need for cut-outs and providing continuous surfaces for aesthetic and safety enhancements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If injection-molded plastic resin is used for map pocket substrate, then structural rigidity is improved, but deformability during side-impact collision deteriorates
Solution Approach 1:
The patent applies composite materials by combining polyethylene/polypropylene fibers with a binder resin to create a substrate that exhibits both rigidity for structural support and controlled deformability during side-impact collisions. The fibrous composite structure allows the material to maintain strength while enabling energy-absorbing deformation, resolving the contradiction between rigidity and deformability.
Solution Approach 2:
The patent utilizes parameter changes by controlling the fiber orientation, density, and binder content in the polyethylene/polypropylene composite to achieve tunable deformability. By adjusting these material parameters, the substrate can be designed to provide appropriate rigidity under normal conditions while allowing controlled deformation during collisions, eliminating the need for cut-outs.
2Adaptability or versatility
If cut-outs are added to injection-molded substrate to achieve deformability, then deformability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the deformability function from the geometric design (cut-outs) and transfers it to the material properties themselves. By using polyethylene/polypropylene fibrous composites with appropriate binder content, the substrate achieves controlled deformation through material behavior rather than geometric voids, eliminating the need for cut-outs and simplifying manufacturing to a single-mold injection process.
3Adaptability or versatility
If cut-outs are added to substrate to reduce rigidity, then deformability is improved, but aesthetic quality deteriorates due to soft spots
Solution Approach 1:
The patent uses composite materials with uniformly distributed polyethylene/polypropylene fibers and binder resin to achieve homogeneous deformability across the entire substrate surface. This eliminates localized soft spots that would compromise aesthetic quality, while still providing the necessary deformability for collision energy absorption. The continuous fibrous structure maintains surface integrity without requiring geometric cut-outs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for tunable deformability without additional molds, eliminating 'soft spots and enhancing safety while maintaining interior aesthetics by using thermoformed materials that are both rigid enough for structural support and deformable during collisions.
Implementation Method 1
an inward-facing, substrate material layer including a polyethylene/polypropylene fibrous, thermoformed material
Implementation Method 2
an outward-facing, A-side material layer including a non-woven, thermoformed material
Implementation Method 3
disposed abuttingly against the substrate material layer with adhesive
Data Source
AI summary
A map pocket usable as a trim component for a vehicle door assembly includes an inward-facing, substrate material layer including a polyethylene/polypropylene fibrous, thermoformed material and an outward-facing, A-side material layer including a non-woven, thermoformed material, disposed abuttingly against the substrate material layer.