Instrument Panel Split Bracket Attachment Mechanism
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Solution Overview
Problem
Conventional vehicle instrument panel attachment strategies require the removal of multiple vehicle components, such as the windshield, to access the instrument panel joint for servicing or replacement, making repairs time-consuming and costly, and risking damage to these components.
Innovation Solution
A split bracket assembly with a 'bottom up' attachment strategy, where a cross-vehicle strut bracket is secured to a bridging bracket, which is in turn attached to the vehicle cowl, allowing the instrument panel to be removed without disassembling overlaying components or removing the windshield, utilizing through-bores and fasteners for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional top-down attachment strategy is used to secure the instrument panel to the vehicle cowl, then the instrument panel achieves structural integrity and rigidity, but servicing or replacement requires removal of multiple overlaying components including the windshield, increasing labor time and risk of damage
Solution Approach 1:
The attachment system is divided into two separate brackets: a first bracket attached to the instrument panel and a second bracket attached to the vehicle cowl. This segmentation allows the instrument panel to be detached by removing only the fasteners connecting the two brackets, without requiring removal of overlaying components like the windshield.
Solution Approach 2:
The second bracket attached to the vehicle cowl serves as an intermediary structure that provides attachment points for the fasteners. This intermediary bracket enables the instrument panel to be securely mounted while maintaining accessibility for servicing, as the fasteners can be accessed from below the instrument panel.
2Ease of repair
If the instrument panel is made removable to allow component servicing, then ease of maintenance is improved, but the structural rigidity and stability of the instrument panel assembly may be compromised
Solution Approach 1:
The attachment system transitions from a permanent fixed connection to a dynamic removable connection using fasteners. This allows the instrument panel to be securely attached during normal operation, maintaining structural rigidity, while enabling easy removal for servicing by simply detaching the fasteners without compromising the structural design.
Solution Approach 2:
By dividing the attachment system into separate brackets and fasteners, the structure maintains its rigidity when assembled while allowing controlled disassembly for maintenance. The segmented design ensures that the structural integrity is preserved during operation but can be easily modified when servicing is required.
3Ease of operation
If multiple components are removed to access the instrument panel joint for repair, then complete access to the joint is achieved, but labor time and associated costs increase significantly
Solution Approach 1:
The second bracket attached to the vehicle cowl acts as an intermediary that positions the attachment joint in an accessible location. The fasteners connecting the first and second brackets can be accessed from below the instrument panel, eliminating the need to remove overlaying components and significantly reducing labor time for servicing.
Solution Approach 2:
Instead of accessing the attachment joint from above by removing the instrument panel and its components, the design allows access from below by positioning the second bracket and fasteners in a location that is accessible from the vehicle's interior or underneath, reversing the traditional access approach.
4Ease of manufacture
If a simple bracket design is used for instrument panel attachment, then manufacturing complexity is reduced, but the design cannot accommodate modern instrument panels with tightly packaged components and limited space
Solution Approach 1:
The attachment system is segmented into two separate brackets that can be independently designed and manufactured. This segmentation allows each bracket to be optimized for its specific function while maintaining overall manufacturing simplicity, and enables adaptation to modern instrument panels with tightly packaged components by providing flexible mounting options.
Solution Approach 2:
The two-bracket attachment system serves multiple functions: it provides secure structural attachment, enables easy servicing by allowing access from below, and can be adapted to various instrument panel designs including modern tightly packaged configurations. This multi-functionality makes the design versatile without significantly increasing manufacturing complexity.
Data Source
AI summary
A vehicle instrument panel attachment joint assembly includes a first bracket associated with a strut holding a portion of the instrument panel and a second bracket associated with a portion of the vehicle. The assembly is configured whereby the second bracket underlies the first bracket on attachment. One or fasteners pass first through one or more second bracket through-bores and next through one or more first bracket through-bores to attach the first and second brackets one to the other. The first bracket includes one or more associated cooperating fastener receivers aligned with the one or more first bracket through-bores.