Vehicle Instrument Panel Bracket with Deformable Impact Absorption
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Solution Overview
Problem
Conventional mounting structures for center stack modules in vehicle instrument panels face challenges in balancing stiffness and collapsibility to meet both structural support and head impact requirements, with plastic cages being costly and insufficiently rigid, leading to squeak and rattle issues.
Innovation Solution
A bracket comprising two halves made of mild steel with deformable elements, such as raised portions or accordion profiles, that can collapse under impact force, providing the necessary stiffness for module support while absorbing energy during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a plastic cage structure is used to meet head impact requirements, then the mounting structure becomes collapsible, but the structural rigidity is insufficient leading to squeak and rattle issues
Solution Approach 1:
The mounting structure uses a composite design combining rigid metal bracket components with a collapsible plastic cage structure. The metal brackets provide structural rigidity and strength to prevent squeak and rattle, while the plastic cage sections provide collapsibility to meet head impact requirements. This composite approach allows both contradictory requirements to be satisfied simultaneously.
Solution Approach 2:
The mounting structure is divided into separate functional segments: rigid metal bracket portions that provide structural support and rigidity, and collapsible plastic cage portions that provide impact absorption. This segmentation allows each material to perform its optimal function without compromising the other.
2Strength
If a rigid mounting structure is used to provide sufficient stiffness, then structural support is improved, but the structure cannot collapse to meet head impact requirements
Solution Approach 1:
The mounting structure uses a composite design combining rigid metal bracket components with a collapsible plastic cage structure. The metal brackets provide structural rigidity and strength to prevent squeak and rattle, while the plastic cage sections provide collapsibility to meet head impact requirements. This composite approach allows both contradictory requirements to be satisfied simultaneously.
Solution Approach 2:
Different parts of the mounting structure have different mechanical properties: the metal bracket portions are designed with high rigidity for structural support, while the plastic cage portions are designed with controlled collapsibility for impact absorption. This local differentiation of material properties allows the structure to meet both stiffness and impact requirements.
3Stability of the object's composition
If a plastic cage structure is used to meet head impact requirements, then the mounting structure becomes collapsible, but manufacturing costs increase due to complex tooling
Solution Approach 1:
The mounting structure is divided into separate functional segments: rigid metal bracket portions that provide structural support and collapsible plastic cage portions that provide impact absorption. This segmentation allows each material to perform its optimal function without compromising the other.
4Strength
If a metal bracket is used to provide sufficient rigidity, then structural support is improved, but the structure cannot be collapsible for head impact
Solution Approach 1:
The mounting structure uses a composite design combining rigid metal bracket components with a collapsible plastic cage structure. The metal brackets provide structural rigidity and strength to prevent squeak and rattle, while the plastic cage sections provide collapsibility to meet head impact requirements. This composite approach allows both contradictory requirements to be satisfied simultaneously.
Solution Approach 2:
Different parts of the mounting structure have different mechanical properties: the metal bracket portions are designed with high rigidity for structural support, while the plastic cage portions are designed with controlled collapsibility for impact absorption. This local differentiation of material properties allows the structure to meet both stiffness and impact requirements.
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 offers a strong yet collapsible bracket that meets both structural support and safety requirements, reducing manufacturing costs and minimizing squeak and rattle issues, while maintaining durability and stability over the vehicle's lifespan.
Implementation Method 1
The body includes a deformable element collapsible by an impact force
Implementation Method 2
the deformable element includes a raised portion protruding from the first main surface of the first bracket half and the second main surface of the second bracket half
Data Source
AI summary
A bracket for mounting center stack modules in an instrument panel assembly of a vehicle is provided. The bracket comprises a first bracket half and a second bracket half, each extending substantially at a longitudinal direction of the vehicle and spaced apart laterally. Each of the first and second bracket halves comprises a first end, a second end and a body between the first end and second end. The first end is connected to a cross car beam, and the second end is connected to the center stack module. The body includes a deformable element collapsible by an impact force. Further, the first bracket half includes a first main surface and the second bracket half includes a second main surface which are substantially perpendicular to a floor of the vehicle.