Cowl Cross Assembly Composite Bar and Plastic Panel

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Solution Overview

Problem

The existing cowl cross assemblies for vehicles are heavy and costly due to their steel composition, leading to reduced gas mileage and compromised coupling strength between the cowl cross member and air conditioning equipment.

Innovation Solution

A cowl cross assembly featuring a steel cowl cross bar with a cut part and a plastic cowl cross half-panel, where the engaging flange and bar mechanism enhance coupling strength and reduce weight, with the air conditioning equipment mounted outside for improved support and workability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the cowl cross bar is made of steel material, then the strength and rigidity are improved, but the weight and cost increase

Engineering Contradiction:

Improvestrength of cowl cross barVSAvoidweight of cowl cross bar

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The cowl cross assembly uses a composite structure combining steel cowl cross bar with plastic cowl cross half-panel. The steel bar provides necessary strength and rigidity for structural support, while the plastic half-panel reduces overall weight and cost. This composite material approach resolves the contradiction by strategically using different materials in the same assembly to balance strength requirements with weight reduction goals.

Inventive Principle:

Principle #40Composite materials

2Strength

If the cowl cross bar is made of steel material, then the strength and rigidity are improved, but the cost increases

Engineering Contradiction:

Improvestrength of cowl cross barVSAvoidcost of cowl cross bar

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The assembly combines expensive steel cowl cross bar with cheaper plastic cowl cross half-panel. This composite construction maintains the necessary strength through the steel component while reducing overall manufacturing cost through the plastic component, directly addressing the cost-strength contradiction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The cowl cross assembly is divided into separate components: steel cowl cross bar, plastic cowl cross half-panel, and fastening mechanisms. This segmentation allows each part to be manufactured using optimal processes for its material properties, reducing overall manufacturing cost while maintaining assembly strength.

Inventive Principle:

Principle #1Segmentation

3Strength

If the cowl cross bar is made of steel material, then the structural strength is improved, but the coupling strength with air conditioning equipment deteriorates

Engineering Contradiction:

Improvestructural strength of cowl cross barVSAvoidcoupling strength with air conditioning equipment

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The plastic cowl cross half-panel serves as an intermediate coupling component between the steel cowl cross bar and the air conditioning equipment. The plastic material provides better surface characteristics for bonding or fastening, improving coupling strength and reliability while the steel bar maintains overall structural strength.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8801087B2Cowl cross assembly

Publication Date: 2014.08.12 HYUNDAI MOTOR CO LTD

AI summary

A cowl cross assembly includes a cowl cross bar positioned in the front region of a vehicle body, and a cowl cross half-panel joined to one end of the cowl cross bar. A part of the cowl cross bar made of a steel material is cut, and the cowl cross half-panel made of a plastic material is mounted to the cowl cross bar, thereby reducing the weight and the cost and reinforcing the strength to support the air conditioning equipment. In addition, the cowl cross bar can be easily joined to the cowl cross half-panel to improve the workability.