Vehicle Exterior Sound Output Structure With Sink-Mark Control
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Solution Overview
Problem
Existing sound output devices for vehicles face issues with the formation of sink marks on the exterior component due to volume shrinkage of molten plastic, affecting the appearance and requiring additional components for vibration transmission, which can reduce durability and increase costs.
Innovation Solution
The sound output device integrates a vibration generator with interposed portions made of hard plastic, featuring a plate-shaped joining portion that protrudes inwardly to reduce sink marks and eliminate the need for cushion materials and adhesive members, enhancing vibration transmission efficiency and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the exterior component and the interposed portion are integrally formed of plastic, then the manufacturing process is simplified and component count is reduced, but sink marks form on the outer surface due to volume shrinkage differences during cooling
Solution Approach 1:
The interposed portion is segmented into two distinct parts: an attachment portion made of plastic that is integrally formed with the exterior component, and a joining portion made of a different material (such as metal or hard resin) that is separately attached to the attachment portion. This segmentation allows the plastic parts to be molded together without sink marks while the joining portion provides the necessary structural and vibrational properties.
Solution Approach 2:
The interposed portion uses composite construction by combining plastic material in the attachment portion with a different material (metal or hard resin) in the joining portion. This composite approach allows each material to contribute its optimal properties: the plastic provides integral forming capability while the other material provides structural integrity and vibration transmission without causing sink marks.
2Reliability
If additional components (cushion materials and adhesive members) are used to transmit vibration between the vibration generator and exterior component, then vibration transmission is achieved, but device complexity increases and durability may be reduced
Solution Approach 1:
The attachment portion and joining portion are merged into a single integrated interposed portion structure. The attachment portion is integrally formed with the exterior component, and the joining portion is directly attached to it, creating a continuous vibration transmission path from the vibration generator to the exterior component without requiring separate cushion materials or adhesive members.
Solution Approach 2:
The interposed portion acts as an intermediary structure between the vibration generator and the exterior component. By designing this intermediary with a plastic attachment portion and a different material joining portion, it provides effective vibration transmission while simplifying the overall structure and eliminating the need for additional cushioning and adhesive components.
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 configuration effectively transmits vibrations with reduced energy loss, improves the appearance by preventing sink marks, and simplifies the structure, reducing component count and costs while maintaining high durability.
Implementation Method 1
transmit vibration of the vibration generator to the exterior component via the interposed portion to cause sound waves to be emitted from the exterior component
Data Source
AI summary
A sound output device for a vehicle includes an exterior component forming a part of an outer shell of the vehicle, a vibration generator disposed inward of the exterior component in an outward-inward direction of the vehicle, and an interposed portion disposed between the exterior component and the vibration generator and having an attachment portion to which the vibration generator is attached. The sound output device for the vehicle is configured to transmit vibration of the vibration generator to the exterior component via the interposed portion to cause sound waves to be emitted from the exterior component. The interposed portion includes a plate-shaped joining portion between the exterior component and the attachment portion, the joining portion protruding inward in the outward-inward direction from the exterior component. The exterior component and the interposed portion are integrally formed of a plastic.