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Integrated TPO rib and PU Foam structures in Automotive Interior Acoustical Dashmats for Tibia/Ankle protection

IP.com Disclosure Number: IPCOM000012282D
Publication Date: 2003-Apr-24
Document File: 1 page(s) / 802K

Publishing Venue

The IP.com Prior Art Database

Related People

Charles A. Haba: INVENTOR [+3]

Abstract

This concept design consists of integrating molded rib patterns into an interior dashmat acoustical barrier molded from thermoplastic resins such as TPO. The rib pattern can be achieved in either injection molding parts as standing ribs or in thermoformed dashmats as double wall ondulations. The rib pattern is filled with either cast PU foam acoustical absorber, die-cut slab PU foam acoustical absorber or higher energy absorbing foams such as STRANDFOAM PP foam depending on the specific energy management requirements of the system. The combination of the heavy layer material such as TPO and the energy absoring foam can be engineered to provide energy absorption to meet Tibia and Ankle protection targets upon deformation and intrusion of the front of dash panel following a front end collision. The concept design targets Tibia and Ankle failure modes associated with the submarining of the occupant against the front of dash following a collision and/or loading of the front of dash by the occupant during a crash avoidance maneuver.

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Integrated TPO rib and PU Foam structures in Automotive Interior Acoustical Dashmats for Tibia/Ankle protection:

This concept design consists of integrating molded rib patterns into an interior dashmat acoustical barrier molded from thermoplastic resins such as TPO. The rib pattern can be achieved in either injection molding parts as standing ribs or in thermoformed dashmats as double wall ondulations. The rib pattern is filled with either cast PU foam acoustical absorber, die-cut slab PU foam acoustical absorber or higher energy absorbing foams such as STRANDFOAM PP foam depending on the specific energy management requirements of the system. The combination of the heavy layer material such as TPO and the energy absoring foam can be engineered to provide energy absorption to meet Tibia and Ankle protection targets upon deformation and intrusion of the front of dash panel following a front end collision.  The concept design targets Tibia and Ankle failure modes associated with the submarining of the occupant against the front of dash following a collision and/or loading of the front of dash by the occupant during a crash avoidance maneuver. 

Current Tibia and Ankle protection targets are met by placing a separate foam block behind the Dashmat.  The proposed concept design allows for the elimination of such separate foam blocks.

Chuck Haba.