Composite Instrument Panel Cross-Beam for Vehicle Weight Reduction
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Solution Overview
Problem
Existing instrument panel beams in vehicles are predominantly metallic, which are heavy, costly, and do not efficiently meet the requirements for reduced carbon emissions, stiffness, and strength needed for modern vehicle designs, particularly in new energy vehicles.
Innovation Solution
A cross-beam structure for vehicle interiors comprising a beam body with a combination of plastic and metal components, including tubular brackets made of plastic material with reinforcing ribs, formed through advanced injection molding techniques, providing a lightweight and cost-effective solution with enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic instrument panel beams are used, then strength and rigidity are ensured, but weight and manufacturing cost increase
Solution Approach 1:
The patent employs composite materials by integrating a plastic beam member with an embedded metal beam member. The plastic material (such as polypropylene or polyamide) provides corrosion resistance and weight reduction, while the metal beam member (such as steel or aluminum alloy) provides structural strength and rigidity. This composite structure resolves the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent applies local quality by strategically placing metal beam members only in critical load-bearing regions within the plastic beam member. The metal reinforcement is positioned where strength is most needed (such as connection points and high-stress areas) while leaving other regions as lightweight plastic, thus optimizing the strength-to-weight ratio.
2Strength
If metallic instrument panel beams are used, then structural integrity is maintained, but manufacturing cost increases
Solution Approach 1:
The patent merges the plastic beam member and metal beam member into a single integrated component through embedding technology. The metal beam member is placed within the plastic material during the injection molding process, creating a unified structure that functions as one piece. This combining approach reduces manufacturing complexity and cost compared to assembling separate metal components.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (such as bolting or welding separate metal beams) with injection molding technology. The plastic beam member is molded around the embedded metal beam member in a single manufacturing step, eliminating the need for secondary assembly operations and reducing manufacturing cost.
3Strength
If traditional solid structure beams are used, then strength is ensured, but carbon emissions increase due to weight
Solution Approach 1:
The use of composite materials with plastic and metal components achieves weight reduction while maintaining strength. The lighter weight of the composite beam compared to traditional solid metal beams reduces vehicle mass, which directly lowers energy consumption and carbon emissions during vehicle operation while preserving the required structural strength.
Solution Approach 2:
The patent changes the material composition parameters by transitioning from solid metal to a composite of plastic and metal. This parameter change in material density and structure reduces the overall beam weight, thereby reducing the vehicle's energy consumption and carbon footprint while maintaining the necessary strength through strategic metal reinforcement.
4Weight of moving object
If plastic brackets with tubular structure are used, then weight is reduced, but structural rigidity may compromise
Solution Approach 1:
The plastic brackets with tubular structure incorporate metal reinforcement elements within the plastic material. The tubular plastic structure provides weight reduction and corrosion resistance, while the embedded metal elements provide the necessary rigidity and structural stability, resolving the contradiction between weight and rigidity.
Solution Approach 2:
The patent employs tubular (curved) structures for the plastic brackets instead of flat or straight designs. The curved tubular geometry inherently provides higher structural rigidity and resistance to deformation while maintaining lightweight characteristics, as the circular cross-section distributes stresses more effectively than flat structures.
Data Source
AI summary
A component for a vehicle interior comprising a cross-beam structure such as for an instrument panel beam may comprise a beam body comprising driver side section (SCS) and center section (CS) and co-pilot section (PBS); set of brackets for the beam body may comprise a steering column section bracket (SCB) and center section bracket (CSB) for floor area and passenger section bracket (PBB); a bracket may comprise plastic material and/or a tubular structure; center section bracket may be connected to vehicle floor; passenger section bracket (PBB) may be configured to mount an airbag; cross-section of the tubular structure may comprise a circle, ellipse, rectangle, triangle, polygon or irregular shape and/or with reinforcing ribs. The beam body may comprise a metal beam member within a plastic beam member; the beam body may comprise a U-shape, a C-shape, a W-shape, a V-shape, Ω-shape, etc.