Vehicle Instrument Panel Rib Structure for Skin Joint Support
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Solution Overview
Problem
The existing methods for manufacturing vehicle instrument panels with multiple skin materials face challenges in maintaining design properties due to the collapse of skin joining parts during the foaming process, which hinders uniform filling of the foaming crude liquid and affects the intended design.
Innovation Solution
Incorporating ribs on the base material to support the skin joining parts, ensuring the flow path for the foaming crude liquid and preventing collapse, allowing for uniform filling and improved design integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple skin materials are used to enhance design properties, then the aesthetic versatility is improved, but the skin joining part collapses during foaming process
Solution Approach 1:
The rib is formed on the base material surface before the foaming process begins. This preliminary structural preparation provides immediate support to the skin joining part when the foaming crude liquid is injected, preventing collapse during the molding process while allowing multiple skin materials to be used for design purposes.
Solution Approach 2:
The rib acts as an intermediary support structure between the base material and the skin joining part. It mediates the mechanical stress during foaming, distributing the pressure and preventing the skin joining part from collapsing inward, thus enabling the use of multiple soft skin materials without compromising structural integrity.
2Ease of manufacture
If skin joining part is not supported during molding, then the manufacturing process is simpler, but the flow path of foaming crude liquid is narrowed
Solution Approach 1:
The rib structure is pre-formed on the base material before molding. This preliminary action ensures that when the foaming crude liquid is injected, there is already a defined flow path maintained by the rib, preventing the skin joining part from collapsing and blocking the flow, thus ensuring uniform filling without complicating the overall manufacturing process.
3Stability of the object's composition
If rib is added to support skin joining part, then the structural stability is improved, but the device complexity increases
Solution Approach 1:
The base material is segmented with ribs at specific locations where skin joining parts are positioned. This segmentation provides targeted support only where needed, rather than requiring a completely rigid base material structure. The ribs are simple protrusions that can be integrated into the base material molding process, adding minimal complexity while effectively preventing skin joining part collapse.
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 solution maintains design properties while using multiple skin materials, enhances space efficiency, reduces manufacturing complexity, and lowers costs and environmental impact by supporting the skin joining parts with ribs during the molding process.
Implementation Method 1
injecting urethane (a foaming crude liquid) between the base material and the skin material, and foaming and solidifying the urethane
Data Source
AI summary
A vehicle instrument panel, includes: a base material extending in a vehicle width direction, at a front part of a vehicle cabin interior of a vehicle; a skin provided with a pair of skin materials, each of the skin materials having an end part thereof joined together at a skin joining part, and the skin forming a design face at the vehicle cabin interior, and a cushion part provided between the base material and the skin and formed of a foamed resin. The base material is provided with a rib at a position facing the skin joining part of the skin.