One-Piece Instrument Panel Crossmember for Crash Force Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing instrument panel crossmembers in motor vehicles require numerous separately formed components for additional functional elements, leading to high assembly effort and inadequate force dissipation/absorption during crashes, with potential buckling or breaking.
Innovation Solution
A one-piece instrument panel crossmember with a transverse crossbeam and adjoining plate, incorporating instrument openings and U-shaped structures for force dissipation, HVAC integration, and cable/ventilation routing, produced as a single casting from lightweight metal alloy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional separately formed components are fastened to the crossmember for functional elements, then the crossmember can accommodate various cockpit functions, but the assembly effort increases significantly
Solution Approach 1:
The patent integrates multiple functional components directly into the crossmember structure itself, merging what were previously separate parts into a single monolithic component. This eliminates the need to fasten additional separately formed components to the crossmember, thereby maintaining versatility while dramatically reducing assembly effort.
Solution Approach 2:
The crossmember is designed as a multi-functional component that directly incorporates various cockpit functions within its integrated structure. This universal design allows the single component to perform multiple functions that previously required separate parts, reducing both complexity and assembly steps.
2Strength
If the crossmember extends exclusively between A pillars with additional supporting elements, then it provides structural support, but it fails to dissipate forces effectively in crashes and suffers from buckling or breaking
Solution Approach 1:
The patent incorporates curved or angled force-dissipating elements into the crossmember structure. These curved geometries are designed to redirect and dissipate crash forces more effectively through controlled deformation paths, preventing buckling and breaking while maintaining structural support.
Solution Approach 2:
The crossmember structure includes varying wall thicknesses and structural parameters along its length, with thicker sections strategically positioned to absorb and dissipate crash forces. This parameter variation allows the component to maintain strength where needed while providing controlled deformation zones for force dissipation.
3Adaptability or versatility
If multiple separately formed components are used for instrument fastening, then functional requirements are met, but the number of individual parts increases assembly complexity
Solution Approach 1:
The patent integrates instrument reception openings and fastening features directly into the monolithic crossmember structure. This merging of instrument mounting functionality into the main structural component eliminates the need for separate fastening elements, thereby maintaining instrument accommodation capability while significantly improving assembly efficiency.
Data Source
AI summary
An instrument panel crossmember of a motor vehicle including a crossbeam. The crossbeam extends transversely to a longitudinal direction of the motor vehicle from an A pillar to an opposite A pillar. The crossbeam is adjoined in a direction of the vehicle front by a plate. At least one instrument opening configured for reception of an instrument is formed in the plate.