Dash Panel Assembly Stiffness and Pedestrian Protection
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Solution Overview
Problem
In vehicles where the lower portion of the cowl and shock absorber housings cannot be connected, the dash panel's stiffness to withstand pressure is weakened, leading to noise, vibration, and harshness (NVH) issues, and pedestrian protection is compromised due to the trade-off between rigidity and safety.
Innovation Solution
A dash panel assembly with a cowl upper panel featuring an open section, coupled with a dash main panel, cowl inner upper and lower panels, and a dash cross upper member, forming a pi-shaped structure that enhances pedestrian protection and dash panel stiffness without connecting the lower cowl and shock absorber housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a closed section is arranged at the upper portion of the cowl to increase the rigidity of the dash panel, then the stiffness of the dash panel to withstand pressure is improved, but pedestrian protection capability deteriorates due to increased hardness
Solution Approach 1:
The cowl is divided into multiple sections: an upper portion with an open section for pedestrian protection and a lower portion with a closed section for structural rigidity. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
Different sections of the cowl are designed with different structural qualities - the upper section has an open structure to be softer for pedestrian safety, while the lower section has a closed structure to be stiffer for dash panel rigidity. This local differentiation resolves the contradiction between overall stiffness and localized pedestrian protection.
2Ease of operation
If the lower portion of the cowl and shock absorber housings are not connected to avoid interference with the brake booster, then ease of operation is improved, but the stiffness of the dash panel deteriorates
Solution Approach 1:
The cowl is segmented into upper and lower portions with different structural configurations. The lower portion maintains an open structure to accommodate the brake booster layout, while the upper portion provides the necessary rigidity through its design, allowing both connectivity flexibility and structural strength.
Solution Approach 2:
The structural reinforcement is achieved not by connecting the lower cowl to shock absorber housings (horizontal connection), but by creating a closed section structure in the lower portion of the cowl itself (vertical/structural dimension), thereby maintaining layout flexibility while achieving stiffness.
3Ease of manufacture
If the planar sections of the dash panel are increased to avoid connection between lower cowl and shock absorber housings, then ease of manufacture is improved, but the stiffness of the dash panel deteriorates
Solution Approach 1:
The dash panel structure is segmented into different functional zones with specific structural characteristics. The lower portion uses a closed section design that provides stiffness without requiring additional planar extensions, maintaining manufacturing simplicity while achieving the required structural strength.
Data Source
AI summary
A dash panel assembly includes: a cowl inner upper panel coupled to a first side of a dash main panel; a cowl inner lower panel coupled to the cowl inner upper panel and the dash main panel, and configured to form a closed section with the cowl inner upper panel; and a dash cross upper member coupled to a second side of the dash main panel and configured to overlap the closed section with the dash main panel disposed therebetween.