Control Element Housing Structural Weakening for Crash Deformation
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Solution Overview
Problem
Existing control element housings in vehicles are rigid and poorly deformable, which limits their ability to absorb mechanical loads without damage, posing a risk in crash scenarios and restricting their functionality.
Innovation Solution
Incorporating structural weakenings, such as recesses or material thinning on the bottom and top faces, particularly in an L-shape configuration, to allow defined deformability and enhance force distribution, while also providing sealing to protect components from moisture and dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the control element housing is designed rigidly, then structural strength is improved, but deformability deteriorates
Solution Approach 1:
The housing features localized structural weakenings in the form of recesses or material thinnings at specific positions on the bottom and top faces. These localized modifications create defined deformation zones that allow controlled bending while the rest of the housing maintains its rigid structure for strength. The L-shaped configuration of these weakenings specifically targets areas where deformation is desired without compromising overall structural integrity.
2Adaptability or versatility
If structural weakenings are added to improve deformability, then deformability is improved, but structural strength deteriorates
Solution Approach 1:
The housing is pre-formed during manufacturing with structural weakenings in the form of recesses or material thinnings at predetermined locations. These preemptive modifications create planned weak zones that guide deformation in a controlled manner during crash scenarios, preventing uncontrolled failure while maintaining adequate strength in non-deformation areas.
3Reliability
If the housing is made deformable to absorb mechanical loads, then reliability under mechanical load is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process incorporates parameter changes by varying material removal depth and pattern to create recesses or material thinnings. This allows control over the degree of deformability through adjustable parameters such as recess depth, width, and distribution, enabling optimization of crash absorption characteristics without fundamentally changing the manufacturing process or requiring complex additional components.
Data Source
AI summary
A control element housing has a front face that receives at least one control element, a rear face lying opposite the front face, a first side face and a second side face lying opposite the first side face, the two side faces connecting the front face to the rear face, a base which interconnects the two side faces and the rear face, and an upper face lying opposite the base, the upper face connecting the front face, the first side face, the second side face and the rear face. The base and/or the upper face has or have at least one structural weakening that allows the control element housing to be deformed under mechanical stress. Also disclosed is a door interior trim having the control element housing.