Hollow Heel Rest Assembly with Deformable Wall
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Solution Overview
Problem
Existing assemblies for receiving a vehicle user's heel under pedals or footrests in motor vehicles are costly due to the need for specific molding operations and high material costs, particularly when using blocks of polystyrene, polypropylene, or expanded polyurethane, which increase production expenses and logistical complexities.
Innovation Solution
A hollow casing receiving element with a rigid rear transverse wall, deformable side walls, and a hooking mechanism for acoustic foam retention, designed to dissipate kinetic energy during impacts without requiring extensive foam shaping or high-cost materials, is integrated between the acoustic absorbent layer and the carpet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a block of polystyrene, polypropylene, or expanded polyurethane is used as the receiving element, then the heel support function is provided, but the manufacturing cost and logistics cost increase significantly
Solution Approach 1:
The receiving element is divided into multiple functional parts: a base plate for support, a heel support portion with specific geometry for heel reception, and a front support portion for additional stability. This segmentation allows each part to be optimized independently and manufactured separately, reducing overall manufacturing complexity and cost while maintaining the heel support function.
Solution Approach 2:
The patent replaces expensive reusable foam blocks with a cost-effective alternative structure made from simpler materials. The design accepts that the receiving element may have limited service life but compensates by using inexpensive materials and simple manufacturing processes, making replacement more economical than maintaining expensive original components.
2Stability of the object's composition
If the acoustic foam is molded on the receiving element to ensure cohesion, then the structural integrity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The receiving element is designed with pre-formed geometric features including recesses, protrusions, and attachment points that are created during simple manufacturing processes. These preliminary structural features enable subsequent assembly operations to be simplified, eliminating the need for complex in-situ foam molding while maintaining structural cohesion.
Solution Approach 2:
The patent introduces an intermediate acoustic foam layer that serves as a bonding medium between the receiving element and the carpet assembly. This intermediary foam layer provides cohesion without requiring direct molding to the receiving element, simplifying the manufacturing process while maintaining structural integrity.
3Reliability
If a block of expanded polystyrene of great length is used, then the adhesion surface of the foam is increased, but the cost of the receiving element increases considerably
Solution Approach 1:
Instead of increasing the length of the receiving element in one dimension to provide sufficient adhesion surface area, the patent distributes the adhesion function across multiple surfaces and dimensions. The base plate provides a large contact area with the floor, while the heel support portion and front support portion provide additional attachment surfaces, achieving adequate adhesion without requiring excessive material length or cost.
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 reduces manufacturing costs, enhances shock management precision, and provides a flexible design while maintaining effective heel support and energy dissipation, making it suitable for cost-controlled production in entry-level vehicles.
Implementation Method 1
at least one horizontal transverse wall, comprising a front end fixed to the floor of the vehicle, and which is able to deform in the event of an impact in order to dissipate the kinetic energy of the user's foot
Implementation Method 2
the lower end of the rear transverse wall rigid comprises a lower tab which comprises at least one hooking claw in the acoustic felt, the lower tab extends substantially along the width of the rear transverse wall and it comprises a plurality of substantially conical hooking claws intended for penetrate the acoustic felt to retain the hollow case
Data Source
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AI summary
The invention proposes an assembly (10) for receiving a heel (12) of a user of a motor vehicle under a pedal (14, 15, 16) and/or a footrest (18) of a motor vehicle passenger compartment, comprising at least a thickness of acoustic felt (22) resting on a floor (20) of the vehicle, a receiving element (24) resting on said acoustic layer (22) and comprising at least a bearing and pivoting area (12) for the heel, and a mat (28) covering said element, characterised in that the receiving element is formed from a hollow housing (24) comprising at least a rigid rear transverse wall (38), which protrudes relative to the horizontal to form the bearing and pivoting area (13) for the heel of the user and a horizontal transverse wall secured to the floor (20) of the vehicle and capable of deforming in the event of an impact.