Dashboard Crossbeam Assembly with Interchangeable Fastening Interfaces

Solution Overview

Problem

Conventional dashboard crossbeam assemblies require separate and expensive molds for each configuration due to the need for distinct metal and composite material portions, which differ based on attached accessories, limiting production efficiency and increasing costs.

Innovation Solution

A dashboard crossbeam assembly featuring a plastic-containing first longitudinal portion with multiple fastening interfaces and a metal second longitudinal portion, allowing for various configurations without the need for multiple molds, as the plastic portion can accommodate a range of accessories through interchangeable lugs and recesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate molds are used for each dashboard crossbeam configuration, then manufacturing precision and customization are improved, but manufacturing cost and device complexity increase

Engineering Contradiction:

Improveconfiguration precisionVSAvoidmold complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single mold that can produce multiple different dashboard crossbeam configurations. The mold includes a movable cavity wall that can be positioned in different locations to form different recess patterns, allowing one mold to create multiple accessory configurations (e.g., different numbers and positions of recesses for airbags, speakers, or other accessories) without requiring separate molds for each configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies dynamics by making the mold cavity dynamic rather than static. The cavity wall can move between different positions during the molding process, allowing the mold to adapt its shape and create different recess configurations. This dynamic capability enables a single mold to replace multiple static molds, reducing device complexity while maintaining manufacturing precision.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If separate molds are used for each dashboard crossbeam configuration, then manufacturing precision is improved, but production cost increases

Engineering Contradiction:

Improveconfiguration precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a single mold that can produce multiple different dashboard crossbeam configurations. The mold includes a movable cavity wall that can be positioned in different locations to form different recess patterns, allowing one mold to create multiple accessory configurations (e.g., different numbers and positions of recesses for airbags, speakers, or other accessories) without requiring separate molds for each configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies merging by combining the functionality of multiple separate molds into a single integrated mold system. Instead of having distinct molds for each crossbeam configuration, the invention merges them into one mold with a movable cavity wall that can assume different positions, thereby consolidating multiple manufacturing tools into one and reducing overall production costs.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If a single plastic-containing longitudinal portion is used for different configurations, then device complexity and manufacturing cost are reduced, but adaptability must be maintained

Engineering Contradiction:

Improvecrossbeam complexityVSAvoidaccessory configuration versatility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent applies universality by designing a single mold that can produce multiple different dashboard crossbeam configurations. The mold includes a movable cavity wall that can be positioned in different locations to form different recess patterns, allowing one mold to create multiple accessory configurations (e.g., different numbers and positions of recesses for airbags, speakers, or other accessories) without requiring separate molds for each configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies parameter changes by modifying the position of the cavity wall within the mold to change the geometry of the recesses formed in the plastic-containing longitudinal portion. By varying the cavity wall position, the mold can create different configurations (e.g., different numbers, sizes, or positions of recesses) from the same basic mold structure, enabling adaptability without increasing device complexity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20240034413A1Dashboard crossbeam assembly for a vehicle

Publication Date: 2024.02.01 FAURECIA INTERIEUR IND

AI summary

A dashboard crossbeam assembly for a vehicle includes a dashboard crossbeam with a first longitudinal portion, preferably made of plastic-containing material, the first longitudinal portion forming a plurality of fastening interfaces. Each fastening interface has a recess for receiving a lug. The dashboard crossbeam assembly further includes at least one fastening tab having at least one lug received in one of the recesses forming a fastening interface.