Vehicle Interior Plastic Component Impact Resistance Design
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Solution Overview
Problem
Plastic components in vehicle interiors face challenges in providing robust impact resistance without observable failure, as existing designs often fail to effectively distribute and absorb impact forces efficiently.
Innovation Solution
A plastic component design featuring a first piece with a support element and a second piece with cantilever portions that flex to provide resistance during impact, while a thinned-out junction within the interstice induces breakage to absorb force, hiding damage from view and preventing stress at visible surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plastic component is designed with uniform thickness throughout, then manufacturing is simpler, but impact resistance is reduced because stress concentrates at visible surfaces causing observable damage
Solution Approach 1:
The patent applies local quality by creating a non-uniform thickness distribution in the plastic component. Specifically, the component includes a visible surface region with greater thickness and an interstice region with reduced thickness. This localized variation in thickness allows the component to have enhanced impact resistance at critical visible areas while maintaining overall structural efficiency and reducing unnecessary material in non-critical areas.
2Reliability
If the plastic component uses thick uniform structure, then visible damage is prevented, but impact energy is not effectively absorbed and stress concentrates causing failure
Solution Approach 1:
The patent converts the potentially harmful concentration of stress at the interstice into a beneficial energy absorption mechanism. The reduced-thickness interstice region is designed to yield and deform under impact loading, transforming the harmful stress concentration into a controlled energy dissipation zone. This allows the component to absorb impact energy through controlled deformation in the interstice while the thicker visible surface regions remain intact and free of observable damage.
3Strength
If support elements are added to increase impact resistance, then strength improves, but the component complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the support element function directly into the main body of the plastic component through integrated molding. The support elements are not separate components that require assembly but are formed as integral parts of the molded plastic component itself. This integration achieves enhanced impact resistance while maintaining manufacturing simplicity, as the entire component including support elements can be produced in a single molding operation.
4Loss of energy
If the junction thickness is reduced to induce breakage, then impact energy is absorbed through controlled breakage, but the component may become too weak for normal use
Solution Approach 1:
The patent applies local quality by creating a controlled thin region at the interstice while maintaining adequate thickness in the visible surface regions. The junction at the interstice has reduced thickness specifically designed to yield under impact conditions, absorbing energy through controlled deformation or breakage. Meanwhile, the visible surface regions maintain sufficient thickness to provide the structural strength needed for normal use and to prevent observable damage during typical service conditions.
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 design enhances impact resistance by flexing cantilever portions to absorb forces, preventing visible damage and ensuring the plastic component remains functional and aesthetically intact during impacts, thus improving safety and reducing costly engineering changes.
Implementation Method 1
the first cantilever portion contacts the first support element of the first piece and flexes to impart resistance against the movement of the first piece
Implementation Method 2
a thinned-out junction within the interstice induces breakage to absorb force, hiding damage from view and preventing stress at visible surfaces
Data Source
AI summary
A plastic component for an interior of a vehicle comprises: a first piece including a first support element; and a second piece facing the first piece and including a second support element adjacent to the first support element within an interstice between the first piece and the second piece; wherein, the first support element extends from an interstice-facing surface of the first piece at a junction, and the junction has a junction thickness that is less thick than a thickness of the first support element adjacent to the junction. During the transition from a non-impact position to an impact position, the junction can separate to induce breakage of the first piece in the interstice between the first piece and the second piece and not viewable from the interior of the vehicle.