Vehicle Center Console Merging Attachments via Foam Injection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing center console manufacturing methods are costly and time-consuming due to the need for numerous separate components and a multi-panel design, which increases weight and installation complexity.
Innovation Solution
A center console is designed with two thermoplastic foam injection-molded halves that integrate attachments directly onto the sides, eliminating the need for additional components and using a thermoplastic foam injection molding process to increase wall thickness ratios, allowing for a more integrated and lightweight structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform material center console is manufactured as one piece in an injection-molding process, then manufacturing simplicity is maintained, but numerous attachments must be added separately which increases manufacturing time and cost
Solution Approach 1:
The patent merges multiple separate components (console support, air duct, reinforcements, trim covers) into a single integrated center console manufactured as one piece. This eliminates the need for separate manufacturing and assembly of attachments, thereby reducing manufacturing time and cost while maintaining ease of production through a single injection-molding process.
Solution Approach 2:
The single-piece center console design makes the main body serve multiple functions by integrating attachments directly into its structure. The console support simultaneously provides structural support, housing for air ducts, mounting points for reinforcements, and integration surfaces for trim covers, eliminating the need for separate specialized components.
2Adaptability or versatility
If numerous attachments are added to the console support, then functional requirements are met, but the joining process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple functional attachments (air duct, reinforcements, trim covers) directly into the console support structure during a single injection-molding process. This integration eliminates complex joining processes such as bolting, clipping, welding, or gluing, while still meeting all functional requirements through the unified design.
3Reliability
If distance is kept between individual components to compensate for tolerances, then noise is prevented, but installation space increases
Solution Approach 1:
The patent merges all components into a single monolithic structure manufactured by injection-molding. This eliminates gaps and distances between components, preventing noise while optimizing installation space. The unified design inherently compensates for tolerances without requiring additional spacing.
4Adaptability or versatility
If multiple components are used in the center console, then functional requirements are met, but the weight increases due to double-panel design
Solution Approach 1:
The patent combines multiple separate components into a single integrated center console manufactured as one piece. This eliminates the double-panel design and associated weight, while still meeting all functional requirements through the unified structure that incorporates air ducts, reinforcements, and trim covers as integral parts.
5Device complexity
If the console support is divided into two halves, then manufacturing complexity is reduced, but multiple attachments still need to be added separately
Solution Approach 1:
The patent merges the two halves into a single unified center console that is manufactured as one piece in a single injection-molding cycle. This eliminates the need to separately add attachments to each half, thereby reducing manufacturing complexity and production time simultaneously.
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
This approach reduces manufacturing time and cost, decreases weight by eliminating multiple panels, and enhances system integration, resulting in a more efficient and cost-effective center console production.
Implementation Method 1
using a thermoplastic foam injection molding process in order to manufacture the two halves as thermoplastic foam injection molding parts, whereby the wall thickness ratio may be increased considerably and the attachments constructed with sufficient wall thickness and stability
Data Source
AI summary
A center console for vehicles including a first half formed of a first material and a second half formed of a second material. The first and second halves joined directly with each other. The first half includes a first side panel extending in a longitudinal direction and a first element connecting to the first side panel. The second half includes a second side panel extending in the longitudinal direction and a second element connected to the second side panel. The first element projects from the first side panel toward the second side panel. The second element projects from the second side panel toward the first side panel. The first and second elements complement one another to form a functional element.