Vehicle Panel Gap Hider Projection Conceals Tolerance Gaps
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Solution Overview
Problem
Manufacturing tolerances in interior vehicle panel assemblies often create gaps between adjacent panels, which can decrease the perceived quality of the vehicle by disrupting the continuous appearance intended by design.
Innovation Solution
The implementation of a projection mechanism from one panel to another, spanning the gap between the panels, either partially or fully, to conceal the gap and maintain a uniform appearance, with optional integration or attachment methods and a rubber layer for noise reduction and aesthetic uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If adjacent panels are attached directly to one another to appear as a continuous one-piece panel, then aesthetic continuity is improved, but manufacturing tolerances create gaps that decrease perceived quality
Solution Approach 1:
A gap hider component is introduced as an intermediary element between adjacent panels. This gap hider spans across the gap formed by manufacturing tolerances and attaches to both panels, visually concealing the discontinuity while maintaining the appearance of a continuous one-piece panel. The intermediary component bridges the precision gap without requiring improved manufacturing tolerances.
2Shape
If panels are designed to overlap to form a continuous appearance, then aesthetic continuity is improved, but the structural complexity and assembly difficulty increase
Solution Approach 1:
The gap hider is designed as a separate, modular component that can be independently manufactured and then attached to the panels. This segmentation allows each panel to maintain its simple, straightforward structure while the gap hider handles the continuity function. The modular approach simplifies assembly compared to designing overlapping panels, as the gap hider can be easily attached to the rear or edges of adjacent panels.
3Manufacturing precision
If a projection mechanism is added to hide the gap, then perceived quality is improved, but the device complexity increases
Solution Approach 1:
The gap hider employs local quality by concentrating the complexity only where needed - at the gap location between panels - while leaving the rest of the panel structures simple and uncomplicated. The projection mechanism is localized to the specific area requiring gap concealment rather than requiring complex modifications to the entire panel assembly, thereby minimizing overall device complexity while achieving the quality improvement.
Data Source
AI summary
Embodiments of interior vehicle panel assemblies are disclosed herein. One embodiment disclosed herein comprises a first panel having an exterior surface, an interior surface and a first edge and a second panel having an exterior surface, an interior surface and a second edge. The second edge of the second panel is aligned with the first edge of the first panel to define a gap having a height between the first edge of the first panel and the second edge of the second panel. A projection extends from one of the first and second panels in a position inward from the exterior surface and toward the respective edge of other of the first and second panels to span at least a portion of the height of the gap.