Door Trim Coupling Structure for Crash-Resistant Armrest and Pull-Cup Assembly
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Solution Overview
Problem
Two-part door trim assemblies with armrest and pull-cup units tend to separate during crashes due to deformation, posing safety risks and failing to meet regulatory standards for maintaining a flush interior during and after impacts.
Innovation Solution
A coupling structure featuring fins and flanges that overlap and connect the armrest and pull-cup units in an alternating fashion, with an attachment member securing them together, allowing for rotational movement to absorb deformation without separating, thus maintaining structural integrity and compliance with safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part construction is used for the armrest and pull-cup assembly, then manufacturing cost and assembly ease are improved, but the assembly may separate during crash events
Solution Approach 1:
The armrest assembly is divided into two separate units: an armrest unit and a pull-cup unit. This segmentation allows for independent manufacturing and assembly of each component, reducing overall manufacturing complexity and cost while maintaining the functional integrity of the complete assembly.
Solution Approach 2:
The coupling structure utilizes a multi-dimensional fin arrangement where fins extend in multiple directions (first direction, second direction, third direction perpendicular to the first two). This three-dimensional overlapping fin configuration creates a robust mechanical interlock that resists separation forces from crash events while maintaining the two-part construction benefits.
2Ease of operation
If a two-part construction is used for the armrest and pull-cup assembly, then assembly ease is improved, but the assembly may separate during crash events
Solution Approach 1:
The assembly is segmented into modular components (armrest unit and pull-cup unit) that can be independently manufactured and assembled. The coupling structure provides a straightforward mechanical connection using fins and attachment members, simplifying the assembly process while ensuring crash resistance.
Solution Approach 2:
The coupling structure employs fins extending in multiple perpendicular directions (first, second, and third directions) to create a multi-dimensional mechanical interlock. This three-dimensional arrangement simplifies assembly by providing inherent alignment and mechanical strength without requiring complex fastening mechanisms.
3Reliability
If a rigid coupling is used to prevent separation, then separation resistance is improved, but the assembly cannot absorb deformation during crash
Solution Approach 1:
The coupling structure incorporates rotational movement capability around a pivot axis, transforming the coupling from a static rigid connection to a dynamic articulated connection. This allows the armrest unit and pull-cup unit to rotate relative to each other during crash events, absorbing deformation energy while maintaining connection integrity and preventing separation.
Solution Approach 2:
The coupling structure changes its mechanical parameters during operation: under normal conditions, the fins provide a rigid mechanical interlock for separation resistance; during crash events, the structure enables rotational movement to absorb deformation. This parameter change from rigid to articulated behavior allows the coupling to adapt to different loading conditions.
4Reliability
If fins extend far from the pivot axis to increase leverage, then separation resistance is improved, but stress on the attachment member increases
Solution Approach 1:
The coupling structure features localized reinforcement at critical stress points, particularly at the pivot axis and attachment member connection points. The fin configuration is optimized with varying dimensions and positioning to distribute stresses locally, providing enhanced separation resistance through strategic placement of structural features rather than uniform reinforcement throughout.
Data Source
AI summary
A door trim assembly includes an armrest, a pull-cup unit, and an attachment structure. The attachment structure has a first portion with a first flange, a second portion with two second flanges on opposing sides of the first flange, and an attachment member engaged with the at least one first flange and the at least two second flanges. The first and second portions are respectively coupled to one each of the armrest and the pull-cup unit, which may prevent separation during and after a crash event.