Instrument Panel Support Connector for Dissimilar Material Joints
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Solution Overview
Problem
Existing instrument panel support structures face challenges in connecting support parts made of different materials, particularly in meeting strength requirements when these parts are arranged offset to each other, as traditional connection methods are complex, expensive, and fail to meet load requirements.
Innovation Solution
A support structure with a metal connector comprising a base part and a bracket part, where the connector is materially bonded to the support part using an adhesive bond, with the base and bracket parts joined through a heat supply process, allowing for a strong and vibration-dampening connection between support parts of varying materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support parts made of different materials (e.g., steel and aluminum) are connected using traditional welding methods, then material bonding strength is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent introduces a connector as an intermediary component between support parts made of different materials. This connector provides standardized connection interfaces that can accommodate various materials without requiring direct material-to-material joining, thereby simplifying the connection process while maintaining strength requirements.
Solution Approach 2:
The patent replaces traditional welding (a thermal/mechanical process) with mechanical connection methods using connectors. This substitution eliminates the complexity of welding dissimilar materials while achieving comparable or sufficient connection strength through standardized mechanical interfaces.
2Device complexity
If support parts made of different materials are connected using fasteners, then manufacturing complexity is reduced, but connection strength deteriorates
Solution Approach 1:
The patent segments the connection system into multiple functional components: the connector body, connection interfaces, and fastening elements. This segmentation allows each component to be optimized for its specific function, with the overall assembly achieving both simplicity and strength through coordinated design of its parts.
Solution Approach 2:
The connector itself may be constructed from composite materials or material combinations that provide both the mechanical strength needed for load-bearing connections and the ease of manufacture associated with simpler joining methods. This allows the connector to bridge the gap between strength requirements and manufacturing simplicity.
3Adaptability or versatility
If support parts are arranged offset to each other to create space for vehicle units, then adaptability is improved, but connection reliability deteriorates
Solution Approach 1:
The patent employs connectors that can accommodate offset arrangements by utilizing three-dimensional spatial configuration. The connectors are designed with geometric features that allow connection between support parts positioned at different locations and orientations, thereby maintaining connection reliability despite spatial offsets required for vehicle unit installation.
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
This solution enables simple and effective connection of support parts made of different materials while meeting strength requirements, allowing for weight reduction and improved vibration behavior, and prevents contact corrosion through galvanic separation.
Implementation Method 1
the metal connector in the area of its support part enclosure is materially bonded to the support part by an adhesive bond
Implementation Method 2
the bracket part is connected to the base part as a result of a joining process carried out with the supply of heat
Data Source
AI summary
A support structure for a motor vehicle instrument panel support having a support part, which follows the longitudinal extension of the instrument panel support, and a metal connector for connecting the support part to another structure. The support part is made of a different material than the metal connector. The metal connector has a multi-part construction including a base part and a bracket part. The base part has a support part connection surface supported on the lateral surface of the support part. The bracket part encloses the support part opposite to the support part connection surface to provide a support part enclosure together with the support part connection surface of the base part. The metal connector is connected in a materially bonded manner to the support part in the area of its support part enclosure. The bracket part is connected to the base part via a joining process using heat.