Vehicle Front Dash Structure for Rib Gap Noise Suppression

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Solution Overview

Problem

Existing vehicle front portion structures with integrally molded dash panel lowers and reinforcing ribs fail to adequately suppress noise from entering the vehicle interior due to insufficient compliance with pad members, leading to gaps that allow noise ingress.

Innovation Solution

A vehicle front portion structure with a dash panel lower integrally molded with a skeleton portion, featuring ribs, a soundproofing member along the ribs, a dash silencer adjacent to the soundproofing member, a floor silencer adjacent to the rear side, and a pad member at the interior side, which collectively suppress noise entry through overlapping and multilayered soundproofing configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a dash panel lower is integrally molded with a skeleton portion by casting and includes ribs, then structural strength and rigidity are improved, but compliance with pad members deteriorates, resulting in gaps that allow noise entry

Engineering Contradiction:

Improvestructural strengthVSAvoidnoise entry

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A soundproofing member is introduced as an intermediary element between the rigid dash panel lower with ribs and the pad member. This soundproofing member has both soundproofing functionality and compliant properties that allow it to adapt to the rib structures, filling gaps and preventing noise entry while maintaining the structural integrity of the integral molding with ribs.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a pad member is disposed at a vehicle interior side of a dash panel lower, then a toe board face is formed, but compliance with ribs is insufficient, resulting in gaps between members that enable noise entry

Engineering Contradiction:

Improvetoe board face formationVSAvoidnoise entry

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The soundproofing member serves as a mediator between the pad member and the ribbed dash panel lower. It maintains the toe board face formation function while adding soundproofing capability and compliance to bridge the gap between the rigid structure and the pad member, preventing noise from entering through the gaps.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If reinforcing ribs are formed at the dash panel lower, then the integrally molded skeleton portion is reinforced, but unnecessary gaps appear between members due to insufficient pad member compliance

Engineering Contradiction:

Improvestructural stabilityVSAvoidgap control

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The soundproofing member changes the physical parameters of the assembly by introducing a material with different compliance characteristics. This allows the system to maintain structural stability provided by the ribs while achieving better gap control through the compliant nature of the soundproofing material that can deform to fit the rib geometry.

Inventive Principle:

Principle #35Parameter changes

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

Effectively suppresses noise entry into the vehicle interior by utilizing overlapping and multilayered soundproofing elements, enhancing compliance with ribs and absorbing noise before it enters, even with assembly variations.

Implementation Method 1

a soundproofing member that is disposed along the ribs... noise entering through the ribs is effectively suppressed by the soundproofing member

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 2

utilizing overlapping and multilayered soundproofing configurations... enhances compliance with ribs and absorbing noise before it enters

Methodology Applied

Scientific EffectAcoustic attenuation through extended path: Acoustic Absorption

Data Source

PatentUS20260021778A1Vehicle front portion structure

Publication Date: 2026.01.22 TOYOTA JIDOSHA KK

AI summary

A vehicle front portion structure includes a dash panel lower, a soundproofing member, a dash silencer, a floor silencer, and a pad member. The dash panel lower is integrally molded with a skeleton portion of a vehicle front portion by casting, and includes ribs at a vehicle interior side. The soundproofing member is disposed along the ribs. The dash silencer is disposed adjacent to a vehicle upper side of the soundproofing member. The floor silencer is disposed adjacent to a vehicle rear side of the soundproofing member. The pad member is disposed adjacent to a vehicle interior side of the soundproofing member.