Defrost Duct With Integral Speaker Bowl for Simpler Dashboard Mounting

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Solution Overview

Problem

Existing mounting systems for loudspeakers and automatic emergency call systems in vehicles are inefficient due to the need for universal fixing mechanisms, which are not necessary on all vehicles, leading to unnecessary bulk and increased production costs.

Innovation Solution

A defrost duct with integral speaker bowls that are welded to the dashboard, eliminating the need for universal fixing mechanisms by only adding the loudspeaker support when necessary, and using thermoplastic or composite materials for enhanced robustness and ultrasonic or vibration welding for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If universal fixing mechanisms are installed in all vehicles, then mounting capability is ensured, but device complexity and production costs increase

Engineering Contradiction:

Improvemounting capabilityVSAvoidfixing mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The speaker bowl is integrated directly into the defrosting duct at the specific location where mounting is needed, rather than using a universal fixing mechanism throughout. The ribs are locally formed on the speaker bowl perimeter to provide attachment points only where required, eliminating unnecessary components in vehicles without speakers.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The speaker bowl is merged with the defrosting duct body as an integral component, forming a unified structure. This combination eliminates the need for separate mounting brackets or universal fixing mechanisms, as the speaker bowl itself becomes part of the duct assembly that can be directly attached to the dashboard panel.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If integral speaker bowls with welding ribs are used, then mounting robustness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvemounting robustnessVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The speaker bowl and defrosting duct are merged into a single integral component formed by injection molding. The ribs are simultaneously formed as part of the speaker bowl during the molding process, eliminating separate manufacturing steps for creating attachment features and reducing assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical assembly process is replaced by direct injection molding of the integral speaker bowl with integrated ribs. Instead of manually assembling separate components with fasteners, the entire structure is formed in one molding operation, and attachment to the dashboard panel is achieved through ultrasonic or vibration welding of the pre-formed ribs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If speaker mounting components are pre-mounted on the defrosting duct, then assembly is simplified, but unnecessary components are added to vehicles without speakers

Engineering Contradiction:

Improveassembly efficiencyVSAvoidunnecessary components

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The speaker bowl is merged with the defrosting duct as an integral component, eliminating the need for separate mounting brackets or pre-assembled speaker kits. The ribs are formed as part of the speaker bowl itself, so no additional mounting components are required. Vehicles without speakers simply have the speaker bowl position filled or the opening closed, without carrying unnecessary mounting hardware.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution simplifies and economizes the mounting process, reduces unnecessary components, and enhances the robustness of the dashboard assembly by ensuring fixings are only present when required, thereby improving manufacturing efficiency and reducing costs.

Implementation Method 1

This rim has a series of ribs for attaching the speaker bowl to a dashboard panel by ultrasonic welding or vibration

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

This rim has a series of ribs for attaching the speaker bowl to a dashboard panel by ultrasonic welding or vibration

Methodology Applied

Scientific EffectVibration welding: Vibration

Data Source

PatentEP4157677B1Installation of a loudspeaker and/or an automatic emergency call system in the dashboard of a motor vehicle

Publication Date: 2024.07.17 STELLANTIS AUTO SAS

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AI summary

The invention relates to a defrosting duct (17) for a motor vehicle, the defrosting duct (17) comprising a body which has a trough (23) and is intended to be attached to a dashboard panel, the defrosting duct (17) being characterised in that it comprises at least one loudspeaker bowl (25) and in that at least one loudspeaker bowl (25) is made in one piece with the body. A loudspeaker seat (29) can be attached if necessary to the loudspeaker bowl (25) before the defrosting duct (17) is attached to the dashboard panel, preferably by a step of ultrasonic or vibration welding.