Latticed Cabin Storage Door With Living Hinge and Class A Surface

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Solution Overview

Problem

Automotive OEMs face challenges in integrating additive manufacturing techniques to create innovative, customer-desirable cabin comfort features that balance aesthetic appeal and functional performance, particularly in producing Class A surfaces and customizable components like knee bolsters and console bolsters.

Innovation Solution

The integration of lattice structures and multi-material components using additive manufacturing to produce components with shock absorption, thermal and acoustic insulation, and reduced weight, allowing for high customization and integration of features such as handles, lighting, and environmental or acoustic management systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional manufacturing methods are used to produce cabin interior components, then manufacturing precision and surface quality are maintained, but design flexibility and customization capability are limited

Engineering Contradiction:

Improvedesign flexibilityVSAvoidsurface quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The cabin interior components are divided into multiple latticed panels that can be independently manufactured and then assembled together. This segmentation allows each panel to be customized with additive manufacturing while maintaining overall precision through controlled assembly processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lattice structure parameters (cell size, density, geometry) are varied across different regions of the component to achieve both aesthetic customization and functional requirements. This parameter control enables design flexibility while maintaining manufacturing precision through digital modeling and controlled additive manufacturing processes

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If additive manufacturing is used to create complex geometries and customized components, then design flexibility and customization are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecustomization capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Complex cabin interior components are segmented into multiple manageable latticed panels that can be manufactured separately using additive manufacturing. This reduces the complexity of each individual manufacturing operation while enabling high customization through digital design of each panel

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The latticed panel design serves multiple functions simultaneously: it provides structural support, enables customization, facilitates assembly, and allows for integrated features like storage compartments and acoustic treatments. This multi-functionality reduces overall system complexity despite the customization capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If lattice structures with varying density are used to optimize comfort and aesthetics, then adaptability and comfort are improved, but structural strength may be compromised

Engineering Contradiction:

Improvecomfort customizationVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The lattice structure employs varying cell densities and geometries in different regions of the panel. Areas requiring higher strength (such as mounting points and structural supports) use denser lattice configurations, while areas prioritizing comfort and aesthetics use optimized lower-density patterns. This local variation maintains overall structural integrity while enabling comfort customization

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If multiple materials with different durometer values are integrated into single components, then functional performance and comfort are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefunctional performanceVSAvoidcomponent complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cabin interior components integrate multiple materials with different durometer values within the lattice structure. Softer materials are used in contact areas for comfort, while harder materials provide structural support and durability. This composite approach enhances functional performance and comfort while the additive manufacturing process manages the complexity of integrating multiple materials

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250319827A1Automotive systems with latticed components

Publication Date: 2025.10.16 FORD GLOBAL TECH LLC

AI summary

Automotive systems are presented. In one example, a cabin interior storage compartment includes a continuous latticed panel. The latticed panel has a portion defining a door for the cabin interior storage compartment and a living hinge portion defining a seam configured to permit rotation of the door about the seam for access to the cabin storage compartment. Other examples are also provided.