Vehicle Knee Bolster with Composite Panel and Embedded Foam
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing knee bolster devices for vehicles are complex, increasing manufacturing costs and the number of assembly processes due to their intricate structures, which do not effectively minimize knee injury during collisions while meeting safety regulations.
Innovation Solution
A knee bolster device utilizing a lower crash pad panel with continuous fiber thermoplastic for improved rigidity, integrated with a shock-absorbing foam mounted on the rear surface and a cowl cross bar with rear supporting brackets to absorb impact, reducing the need for additional components and assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional knee bolster structure with multiple components (knee bolster panel, shock absorbing foam, U-shaped bracket) is used, then knee protection during collision is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the knee bolster panel, shock absorbing foam, and support structure into a single integrated lower crash pad panel. The foam is embedded within the panel structure, eliminating the need for separate brackets and fasteners while maintaining collision protection functionality.
Solution Approach 2:
The lower crash pad panel serves multiple functions simultaneously: it provides structural support, absorbs impact energy through embedded foam, protects the knee during collision, and maintains aesthetic appearance. This multi-functional design replaces the need for multiple specialized components.
2Reliability
If a traditional knee bolster structure with multiple components is used, then knee protection during collision is achieved, but manufacturing cost increases
Solution Approach 1:
By integrating multiple components into a single molded panel, the patent reduces the number of parts that need to be manufactured, stored, and assembled. This consolidation significantly reduces manufacturing complexity and cost while maintaining protective functionality.
Solution Approach 2:
The lower crash pad panel is designed to match the aesthetic appearance of the dashboard, allowing it to serve both functional and cosmetic purposes. This eliminates the need for additional cosmetic cover panels, further reducing manufacturing cost and complexity.
3Reliability
If a rigid knee bolster panel is used to prevent knee from crashing further, then knee protection is improved, but impact energy absorption is reduced
Solution Approach 1:
The patent uses a composite structure combining a rigid lower crash pad panel with embedded shock absorbing foam. The rigid panel provides structural support and prevents further knee intrusion, while the foam layer absorbs impact energy through deformation, achieving both protection and energy dissipation.
Solution Approach 2:
The shock absorbing foam is strategically positioned within the lower crash pad panel at locations where impact forces are expected. This localized energy absorption enhances overall impact mitigation while maintaining the structural integrity and rigidity of the panel in critical areas.
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 effectively reduces knee impact during collisions, meets safety regulations, and decreases manufacturing costs and weight by simplifying the design and reducing the number of components.
Implementation Method 1
the shock absorbing foam 3, which is mounted to the rear of the knee bolster, absorbs impact energy while deforming together with the U-shaped bracket 2
Implementation Method 2
a continuous fiber thermoplastic (CFT), which has continuity of woven and stacked structures, is inserted into a lower crash pad panel disposed inside the vehicle to improve rigidity
Data Source
AI summary
A knee bolster device for a vehicle includes a lower crash pad panel having a composite material injection-molded thereto at a rear surface of the lower crash pad panel to improve rigidity of the lower crash pad panel. A shock absorbing foam is mounted on a rear surface of the lower crash pad panel and absorbs an impact.