Integrated Resin Dash Panel for Gap-Free Sound Insulation
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Solution Overview
Problem
Existing dash panels with attached dash silencers face challenges in productivity and sound insulation performance due to labor-intensive attachment processes and potential gaps between the silencer and the panel, which can reduce sound insulation effectiveness.
Innovation Solution
A dash panel design where the dash silencer is integrally molded with a resin panel, eliminating the need for separate attachment and ensuring better positioning, thus improving productivity and sound insulation by eliminating gaps and enhancing the silencer's placement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dash silencer is attached to the resin panel using stud bolts, then the dash silencer can be installed on the dash panel, but labor for attaching the dash silencer is required and gaps may form between the silencer and panel
Solution Approach 1:
The dash silencer and resin panel are merged into a single integrally molded unit. The silencer is formed as a hollow structure with closed-cell foam material directly during the molding process of the resin panel, eliminating the need for separate attachment operations and ensuring continuous contact without gaps for superior sound insulation.
Solution Approach 2:
The silencer structure is preliminarily formed as an integrated part of the resin panel during the molding process. By pre-forming the silencer with the same material and structure as the panel, the need for subsequent attachment operations is eliminated, improving productivity while ensuring reliable sound insulation.
2Reliability
If the dash silencer is attached to the resin panel, then the silencer can be installed, but the silencer may not be precisely positioned at the intended location
Solution Approach 1:
The silencer and resin panel are combined into a single integrally molded structure, ensuring that the silencer is precisely positioned at the intended location during the molding process itself, eliminating positioning errors that may occur with separate attachment methods.
3Productivity
If the dash silencer is integrally molded with the resin panel, then labor for attaching the silencer is eliminated and positioning is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The silencer structure is preliminarily formed as an integrated part of the resin panel during the molding process. By pre-forming the silencer with the same material and structure as the panel, the need for subsequent attachment operations is eliminated, improving productivity while the integrated molding process manages complexity through material uniformity.
Data Source
AI summary
A dash panel includes: a resin panel that is provided at a vehicle front portion and that partitions an interior of a vehicle cabin and an exterior of the vehicle cabin; and a dash silencer that is arranged at a surface at a vehicle cabin inner side of the resin panel and that is integrally molded with the resin panel.