Instrument Cluster Frame Member with Wings to Restrict Dial Sheet Bending
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Solution Overview
Problem
Existing vehicle instrument cluster assemblies with TFT LCD screens face issues of dial sheet bending and visibility of non-illuminated indicators, which can distract drivers, especially in bright sunlight, and lack effective protection for heat staking securing the frame members.
Innovation Solution
A frame member design with a base portion, extending wings, and a display overlapping portion that restricts dial sheet bending and includes a smoked polycarbonate dial sheet to minimize visibility of non-illuminated indicators, using heat staking for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If frame members are secured to the dial sheet using heat staking, then the frame member is firmly mounted to the dial sheet, but the dial sheet may bend which can damage the heat staking and reduce reliability
Solution Approach 1:
The frame member is designed with pre-formed wings that extend beyond the dial sheet edges before mounting. These wings are positioned in advance to provide structural support and prevent dial sheet bending during and after the heat staking process, protecting the mounting integrity without requiring additional reinforcement steps
Solution Approach 2:
The frame member is divided into a base portion for mounting and multiple wings extending from it. This segmentation allows the wings to independently support different areas of the dial sheet, distributing mechanical stresses and preventing bending at critical heat staking locations while maintaining firm mounting through the base portion
2Illumination intensity
If traditional transparent dial sheets are used, then the display screen is clearly visible, but non-illuminated indicators remain visible which can distract the driver especially in bright sunlight
Solution Approach 1:
The dial sheet transitions from uniform transparency to having locally varied optical properties. The smoked or tinted regions are applied specifically to indicator areas that should remain hidden when not illuminated, while the display screen areas maintain full transparency. This local differentiation allows the dial sheet to selectively control visibility based on location and illumination state, reducing driver distraction without compromising display clarity
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
The frame member effectively prevents dial sheet bending and reduces visibility of non-illuminated indicators, enhancing the appearance and safety of the instrument cluster assembly by maintaining the integrity of heat staking and reducing driver distraction.
Implementation Method 1
one or more frame members, often including circular or semicircular rings, are overlaid onto the dial sheet and secured thereto with heat staking
Implementation Method 2
a dial sheet that reduces the visibility of non-illuminated indicators on the dial sheet would be desirable in order to enhance the appearance of the dial sheet and prevent the driver from being distracted
Data Source
AI summary
A frame member of an instrument cluster assembly. The frame member includes a base portion, a first wing extending from a first side of the base portion, and a second side of the base portion that is opposite to the first side. A display overlapping portion extends from the base portion between the first side and the second side, and is configured to be mounted to a display area of a dial sheet that the frame member is coupled to. The first wing is configured to restrict bending of the dial sheet that the frame member is coupled to.