Dash Panel Reinforcement for Vehicle Crash Rigidity

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Solution Overview

Problem

The existing dash panel structure in vehicles, as described in JP 2013-159156 A, lacks sufficient rigidity along the length of the vehicle, which may not meet the increased demand for crash safety performance.

Innovation Solution

A vehicle front structure with a dash panel and reinforcing members, where a center reinforcing member and outer reinforcing members are superposed and joined around and between through holes to enhance the rigidity of the dash panel, reducing deformation during crashes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single reinforcing member is mounted on the dash panel, then the structure is simple and easy to manufacture, but the rigidity along the length of the vehicle is insufficient

Engineering Contradiction:
Improverigidity of dash panelVSAvoidstructure of reinforcing member
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The reinforcing member is divided into multiple segments: a first reinforcing member extending from the left edge to a first position, and a second reinforcing member extending from the right edge to a second position. These segments are disconnected, allowing independent installation and optimization of each segment's position and dimensions to maximize rigidity enhancement without requiring a complex continuous structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The reinforcing members are positioned specifically at locations where the dash panel rigidity is most compromised - namely, extending from the edges toward the center but stopping before reaching the through holes. This local placement strategy concentrates reinforcement where it is most needed while avoiding the areas with pre-existing structural weaknesses at the hole locations.

Inventive Principle:
Principle #3Local quality

2Reliability

If reinforcing members are added to increase rigidity, then crash safety performance improves, but the manufacturing complexity and cost increase

Engineering Contradiction:
Improvecrash safety performanceVSAvoidmanufacturing process
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

By segmenting the reinforcing structure into separate first and second reinforcing members that can be manufactured independently, the manufacturing process is simplified. Each member can be produced, inspected, and installed separately, reducing the complexity compared to manufacturing and assembling a single continuous reinforcing structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The reinforcing members extend from the edges toward the center through holes but stop before actually reaching them, providing partial reinforcement that is sufficient for crash safety without requiring complete coverage. This partial action approach achieves adequate safety performance while minimizing material usage and manufacturing complexity.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS11097786B2Vehicle front structure
Publication Date: 2021.08.24 TOYOTA JIDOSHA KK
  • US11097786B2 patent drawing
  • US11097786B2 patent drawing
  • US11097786B2 patent drawing

AI summary

A vehicle front structure includes a dash panel and a reinforcing member. The dash panel includes a steering column hole. The reinforcing member includes a center reinforcing member mounted in a center portion along a width of a vehicle and an outer reinforcing member attached outward along the width of the vehicle. The center reinforcing member and the outer reinforcing member are superposed and joined together on the dash panel around the steering column hole.