Vehicle Trim Assembly Flexible Suspension Biasing
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Solution Overview
Problem
Existing vehicle interior trim assemblies face challenges in minimizing noise and assembly effort due to geometric clearance issues in fastening features, leading to either excessive movement causing noise or high assembly effort, and current solutions like felt tape increase costs and complexity.
Innovation Solution
Incorporating a flexible suspension system with nonlinear elements and snap fits between trim components, which biases the components to limit movement and absorb mechanical energy, reducing noise without increasing assembly costs by using geometric differences in stiffness to balance connection rigidity and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid connection methods such as heat staking are used to join trim components, then connection strength is improved, but assembly effort and complexity increase
Solution Approach 1:
The connection system is divided into two distinct elements: a rigid connection clip that provides structural strength and a flexible suspension element that absorbs movement. This segmentation allows each element to be optimized independently - the clip for strength and the suspension for ease of assembly and movement absorption.
Solution Approach 2:
The patent changes the physical state and properties of the suspension element from rigid to flexible, allowing it to deform elastically during assembly and operation. This parameter change enables the suspension to absorb geometric clearance variations and component movements without requiring complex assembly procedures or additional fastening steps.
2Ease of operation
If geometric clearance is increased in fastening features to ease assembly, then ease of operation is improved, but movement between components increases causing noise
Solution Approach 1:
The flexible suspension element acts as an intermediary between the rigid connection clip and the trim components. It mediates the geometric clearance by absorbing excess movement through elastic deformation, preventing the transmission of movement-induced noise while maintaining ease of assembly through its flexible engagement.
Solution Approach 2:
The patent employs a flexible suspension element that functions similarly to a flexible shell or film, using elastic deformation to absorb and dampen movements between components. This flexible element maintains connection while preventing the rigid transmission of movement that causes noise.
3Object-generated harmful factors
If felt tape is added to reduce noise from component movement, then noise is reduced, but device complexity and cost increase
Solution Approach 1:
The patent merges the noise reduction function into the existing suspension element by making it flexible rather than rigid. This combines the structural support function with the noise damping function in a single integrated component, eliminating the need for separate felt tape or other damping materials.
Solution Approach 2:
The flexible suspension element serves multiple functions simultaneously: it provides structural support, absorbs geometric clearance variations, dampens noise, and facilitates ease of assembly. This self-service approach eliminates the need for additional separate components like felt tape.
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 noise and assembly effort by using flexible suspensions to bias trim components, providing a quasi-permanent force that counteracts vibrations and maintains a stable connection, thus enhancing the balance between connection rigidity and ease of assembly while minimizing costs.
Implementation Method 1
The connection suspension is configured to yield an interference fit between the connection suspension and one of the first base plate or the at least one protrusion when the second trim component is assembled to the first trim component. The interference fit yields a biasing force that biases the connection clip toward the underside surface of the at least one protrusion to limit movement between the first and second trim components.
Implementation Method 2
The connection suspension is configured to yield an interference fit between the connection suspension and one of the first base plate or the at least one protrusion. The interference fit yields a biasing force that biases the connection clip toward the underside surface of the at least one protrusion to limit movement between the first and second trim components.
Implementation Method 3
The connection clip is configured to flex as the connection clip engages the ramped upper surface of the at least one protrusion to allow the opening to be positioned over the at least one protrusion. The connection clip is configured to relax and engage the underside surface of the at least one protrusion when the at least one protrusion is positioned within the opening to yield a snap fit between the connection clip and the at least one protrusion.
Data Source
AI summary
A vehicle interior trim assembly includes a first trim component and a second trim component. The first trim component includes a first base plate and a protrusion. The second trim component includes a connection clip and a connection suspension. An opening in the connection clip receives the protrusion, and the connection clip engages an underside surface of the protrusion to yield a snap fit between the connection clip and the protrusion. The snap fit secures the second trim component to the first trim component. The connection suspension is configured to yield an interference fit between the connection suspension and one of the first base plate and the protrusion when the second trim component is assembled to the first trim component. The interference fit yields a biasing force that biases the connection clip toward the underside surface of the protrusion to limit movement between the first and second trim components.