Vehicle Interior Trim Self-Supporting Carrier Structure
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Solution Overview
Problem
Current interior trim parts in vehicles, despite weight reduction efforts through bionic topology optimization, still require additional functional elements that increase weight and complicate manufacturing, limiting further weight reduction and efficiency.
Innovation Solution
Integration of functional entities directly within the self-supporting carrier structure using hollow and solid support elements, which also serve as air ducts and receptacles for air treatment devices, allowing for reduced material usage and simplified manufacturing by forming intersections and fusion sections, enabling optimized load paths and reduced dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional functional elements are added to interior trim parts, then functionality is improved, but weight increases and manufacturing becomes more complex
Solution Approach 1:
The patent merges multiple functional elements (air ducts, structural supports, receptacles) into a single integrated carrier structure. The hollow support elements serve dual purposes as both structural components and air ducts, while functional entities are formed by combining support elements to create integrated solutions rather than separate parts.
Solution Approach 2:
The hollow support elements are designed to perform multiple functions simultaneously: providing structural support, serving as air ducts for climate control, and forming functional entities for additional features. This multi-functionality eliminates the need for separate components and reduces overall weight.
2Adaptability or versatility
If additional functional elements are added to interior trim parts, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. The carrier structure with integrated air ducts, support elements, and functional entities is produced in one piece without assembly steps, eliminating the complexity of manufacturing and assembling separate components.
Solution Approach 2:
The additive manufacturing process used in the patent can directly create complex geometries and integrated features that would require multiple manufacturing steps with conventional methods. This universal manufacturing approach simplifies production by handling structural and functional elements in a single process.
3Weight of moving object
If material volume is reduced for weight reduction, then weight decreases, but structural strength may be compromised
Solution Approach 1:
The carrier structure is segmented into a network of hollow and solid support elements arranged according to load path analysis. This segmentation allows material to be placed precisely where needed for structural strength while maintaining overall weight reduction, as each element is optimized for its specific structural role.
Solution Approach 2:
The patent applies local quality by varying the density and configuration of support elements based on local structural requirements. Load-bearing areas have denser arrangements of solid support elements, while less critical areas use hollow elements or sparser configurations, optimizing strength-to-weight ratio throughout the structure.
Data Source
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Figure 9A~10
AI summary
The present disclosure relates to an interior trim part (10) of a vehicle (14), comprising a self-supporting carrier structure (15), the self-supporting carrier structure (15) comprising a network of a plurality of hollow support elements (16) and solid support elements (18) arranged according to the results of a load path analysis, wherein the hollow support elements (16) form at least one manifold (16) used as an air duct comprising at least one air inlet (18) for introducing air into the hollow support elements (16) and at least one air outlet (20) for guiding the air into a passenger compartment (13) of a vehicle (14), wherein at least one of the hollow support elements (16) and/or one of the solid support elements (18) form at least one functional entity (26) by which a function can be integrated into the interior trim part (10). Furthermore, the present disclosure is directed to a process for manufacturing an interior trim part and a vehicle equipped with such a trim part (10).