Integrally Formed Dashboard Crossbar with Arc Support
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Solution Overview
Problem
Existing dashboard crossbars in motor vehicles are complex to assemble, lack structural integrity, and fail to effectively dissipate forces during a frontal impact, particularly when made from glass-fibre-reinforced polymers.
Innovation Solution
A dashboard crossbar formed integrally in one piece, comprising a crossmember extending between A-pillars and a support protruding forward in an arc, surrounding a panel, which is produced from metal and designed to dissipate forces by integrating functional elements like ventilation ducts and cable guides, enhancing rigidity and crash resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dashboard crossbars are made from glass-fibre-reinforced polymer and assembled with separate functional components, then manufacturing flexibility is improved, but structural integrity and force dissipation capability deteriorate
Solution Approach 1:
The patent merges the crossbar structure with functional components (ventilation ducts, cable guides, support elements) into a single integrally formed metal crossbar, eliminating separate assemblies and improving structural integrity while maintaining manufacturing capability through metal forming processes
Solution Approach 2:
The patent transitions from glass-fibre-reinforced polymer to metal material for the crossbar, leveraging metal's superior strength and force dissipation properties while integrating multiple functions within the same component
2Adaptability or versatility
If dashboard crossbars are assembled with multiple separate parts, then functional versatility is improved, but assembly complexity deteriorates
Solution Approach 1:
The patent designs the crossbar as a multi-functional component that simultaneously provides structural support, ventilation channels, cable routing, and mounting functions, reducing the need for separate functional parts while maintaining versatility
Solution Approach 2:
The patent combines multiple functional elements (crossbar, ventilation ducts, cable guides, supports) into a single integrally formed component, eliminating assembly steps and reducing complexity while preserving all required functions
3Area of stationary object
If dashboard crossbars extend only between A-pillars without longitudinal extent, then spatial efficiency is improved, but force dissipation capability deteriorates
Solution Approach 1:
The patent extends the crossbar structure in the longitudinal direction with arcuate supports protruding forward, creating a three-dimensional force distribution network that dissipates impact forces while maintaining spatial efficiency through optimized geometry
4Ease of manufacture
If dashboard crossbars lack integral formation with supports, then manufacturing simplicity is improved, but crash resistance deteriorates
Solution Approach 1:
The patent integrates the crossbar and supports into a single monolithic metal component formed in one manufacturing process, eliminating weak joints and ensuring consistent crash performance while maintaining manufacturing efficiency
Data Source
AI summary
A dashboard crossbar of a motor vehicle, including a crossmember which extends transversely to a longitudinal direction of the motor vehicle from one A-pillar to an opposite A-pillar, the crossmember including end portions at two opposite ends thereof, and a support. The support is integrally connected to the end portions of the crossmember and protrudes towards a front of the vehicle in an arc, the crossmember and the support surrounding at least some regions of an extending panel. The crossmember, the support and the surrounded panel are formed integrally or together in one piece.