Knee Airbag Housing Relocation on Instrument Panel
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Solution Overview
Problem
The existing assembly of instrument panels for motor vehicles requires significant development and manufacturing efforts to accommodate both versions with and without a knee airbag, leading to increased costs and complexity due to the need for different panels based on regional safety regulations.
Innovation Solution
The housing for the knee airbag is relocated from the instrument panel to a separate formed part that extends from the lower section, allowing the same instrument panel to be used for both variants, with optional cover elements and a clip connection to the instrument panel for stability, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing for the knee airbag is integrated into the instrument panel, then the structural stability and safety performance are improved, but the device complexity and manufacturing costs increase due to requiring different instrument panels for regions with and without knee airbags
Solution Approach 1:
The instrument panel assembly is segmented into two independent parts: the main instrument panel and a separate formed part (footwell cladding). The knee airbag housing is integrated into the formed part rather than the main instrument panel. This segmentation allows the main instrument panel to remain identical across all vehicle versions, while only the formed part needs to vary based on knee airbag equipment status.
Solution Approach 2:
The knee airbag housing and its associated formed part are extracted from the main instrument panel structure. This extraction allows the main instrument panel to be standardized across all vehicle types, while the formed part can be selectively equipped with knee airbag housing based on regional safety requirements.
2Reliability
If different instrument panels are manufactured for vehicles with and without knee airbag, then the safety requirements are met, but the manufacturing time and expenses increase significantly
Solution Approach 1:
By segmenting the instrument panel into a main panel and a separate formed part, the manufacturing process can produce large quantities of identical main panels. The formed parts are manufactured separately and can be selectively equipped with knee airbag housing, allowing parallel production and reducing overall manufacturing time and costs.
Solution Approach 2:
The main instrument panel is designed as a universal component that can be used in all vehicle versions regardless of knee airbag equipment. This universality allows a single mold and production line to serve all market segments, significantly improving manufacturing efficiency and reducing tooling costs.
3Device complexity
If the housing is relocated to a separate formed part, then the manufacturing complexity is reduced, but the connection stability and gap prevention become critical issues
Solution Approach 1:
The formed part is designed to merge with the main instrument panel to form an integrated appearance. Connection elements such as clips or fasteners are incorporated to ensure stable mechanical coupling between the formed part and the main panel, preventing gaps while maintaining the visual continuity of the instrument panel assembly.
Data Source
AI summary
An airbag housing is carried on a formed part extending from a lower section of an instrument panel for a motor vehicle. The formed part forms at least a front section of an upper wall of a footwell assigned to the vehicle occupants. A knee airbag is disposed in the airbag housing.