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Thermoplastic Glass Mat Reinforced Knee Bolster Development
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English
Abstract
The desire to combine the roles of the instrument panel carrier with structural functions traditionally fulfilled by steel reinforcement and tie bars provided the catalyst to search for a material and construction capable of combining the advantages of plastic processing with the structural characteristics of steel. Candidate materials and constructions were initially judged against a criteria list of design flexibility, tooling cost and leadtime, piece cost, developmental leadtime, product maturity, weight,and physical properties. The most promising alternates were tooled and tested with a knee impactor and a barrier sled in order to assess performance to occupant safety objectives. Ultimately, a thermoplastic composite proved capable of meeting all the structural requirements while enhancing design flexibility and reducing tooling leadtime and cost, piece cost, and vehicle mass.