AU2002250119B2 - Instrument panel beam assembly and methods of manufacture - Google Patents

Instrument panel beam assembly and methods of manufacture Download PDF

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Publication number
AU2002250119B2
AU2002250119B2 AU2002250119A AU2002250119A AU2002250119B2 AU 2002250119 B2 AU2002250119 B2 AU 2002250119B2 AU 2002250119 A AU2002250119 A AU 2002250119A AU 2002250119 A AU2002250119 A AU 2002250119A AU 2002250119 B2 AU2002250119 B2 AU 2002250119B2
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AU
Australia
Prior art keywords
beam member
duct
assembly
defrost
accordance
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
AU2002250119A
Other versions
AU2002250119A1 (en
Inventor
Marc Black
Daniel Woodman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SABIC Global Technologies BV
Original Assignee
SABIC Innovative Plastics IP BV
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Filing date
Publication date
Application filed by SABIC Innovative Plastics IP BV filed Critical SABIC Innovative Plastics IP BV
Publication of AU2002250119A1 publication Critical patent/AU2002250119A1/en
Application granted granted Critical
Publication of AU2002250119B2 publication Critical patent/AU2002250119B2/en
Assigned to SABIC INNOVATIVE PLASTICS IP B.V. reassignment SABIC INNOVATIVE PLASTICS IP B.V. Request for Assignment Assignors: GENERAL ELECTRIC COMPANY
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08Front or rear portions
    • B62D25/14Dashboards as superstructure sub-units
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60HARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00514Details of air conditioning housings
    • B60H1/0055Details of air conditioning housings the housing or parts thereof being integrated in other devices, e.g. dashboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60HARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00557Details of ducts or cables
    • B60H1/00564Details of ducts or cables of air ducts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60HARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00Heating, cooling or ventilating [HVAC] devices
    • B60H1/24Devices purely for ventilating or where the heating or cooling is irrelevant
    • B60H1/241Devices purely for ventilating or where the heating or cooling is irrelevant characterised by the location of ventilation devices in the vehicle
    • B60H1/242Devices purely for ventilating or where the heating or cooling is irrelevant characterised by the location of ventilation devices in the vehicle located in the front area
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08Front or rear portions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08Front or rear portions
    • B62D25/14Dashboards as superstructure sub-units
    • B62D25/142Dashboards as superstructure sub-units having ventilation channels incorporated therein

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Body Structure For Vehicles (AREA)
  • Instrument Panels (AREA)
  • Air-Conditioning For Vehicles (AREA)

Description

WO 03/078187 PCT/US02/04785 INSTRJMENT PANEL BEAM ASSEMBLY AND METHODS OF MANUFACTURE BACKGROUND OF THE INVENTION [0001] Known instrument panel assemblies include a beam structure and at least one decorative instrument panel attached to the beam structure. Some of the decorative panels act as knee bolsters to protect the knees of vehicle occupants in the event of an impact. An instrumlnent panel assembly is mounted inside the passenger compartment of an automobile with the beam structure attached to the automobile body, typically to the A-pillar. Known instrument panel beam structures are fabricated from steel, aluminum, magnesium, or plastic.
[0002] A number of vehicle systems are housed within an instrument panel, for example, the heating, ventilating, and air conditioning (IHVAC) system.
The HVAC system includes a number of air distribution ducts housed within the instrument panel. In known instrument panels the HVAC ducts are separate components attached to the instrument panel beam structure. Multiple components increases complexity of the assembly which increases fabrication time and increases labor costs.
[0003] U.S. Patent 5,312,133 describes an instrument panel assembly that includes a steel beam and a duct system attached to the steel beam that does not deform and absorb energy. The duct system includes a front channel member and a rear channel member bonded together with adhesive to form the duct system.
[0004] U.S. Patent 5,549,344 describes an instrument panel assembly that includes a metal support beam, a plastic base member, and a plurality of ducts.
The ducts are separately formed and then hot plate heat welded to the base member to form an integral unit. The base member and ducts are then attached to the metal support beam.
t [0005] U.S. Patent 5,676,216 describes an instrument panel assembly that includes a knee bolster assembly, an instrument panel, a reinforcement assembly, a Sbeam duct assembly, and a fastening assembly. The beam assembly has a two piece beam structure that includes an integrated air distribution system. Each piece of the kn I 5 beam structure is formed from sheet molding compound (SMC) and are bonded together with adhesive. The reinforcement assembly includes separate metal _reinforcement members to support the knee bolsters of the instrument panel.
S[0006] U.S. Patent 5,762,395 describes a instrument panel assembly .I that includes a one piece plastic cross car support structure that has a plurality of laterally extending, upwardly opening U-shaped duct channels. The assembly also includes an instrument panel that is continuously secured to upward facing edges of the U-shaped duct channels to form closed ducts in the assembly.
[0006A] The discussion of publications and other knowledge does not constitute an admission that such material was published, known, or part of the common general knowledge in the art.
BRIEF DESCRIPTION OF THE INVENTION [0007] According to an aspect of the present invention, there is provided an instrument panel beam assembly including: an elongate front beam member including a plurality of duct channels and a plurality of energy absorbers; and an elongate rear beam member including a plurality of duct channels corresponding to said front beam member duct channels, said front beam member coupled to said rear beam member forming a beam structure so that said plurality of corresponding duct channels in said front and rear beam members form a plurality of ducts in said beam structure, wherein said front beam member further includes a C-channel support rod extending between at least two of said energy absorbers.
[0008] According to another aspect of the present invention there is provided a method of producing an instrument panel beam assembly including: molding an elongate front beam member from a thermoplastic material, the front beam member including a plurality of duct channels and a plurality of energy absorbers; molding an elongate rear beam member from a thermoplastic material, the rear beam member including a plurality of duct channels corresponding to the front beam member duct channels; and coupling the front beam member to the rear beam member forming a beam structure so that the plurality of corresponding duct channels in the 2W Sas\ 5 s mend W Saskia\725445 sp~ea amrend front and rear beam members form a plurality of ducts in the beam structure, wherein the front beam member further includes a C-channel support rod extending between at least two energy absorbers.
[0009] According to yet another aspect of the present invention there is provided an instrument panel beam assembly including: a thermoplastic front beam member including a plurality of molded-in duct channels and a plurality of energy absorbers; a thermoplastic rear beam member including a plurality of molded-in duct channels corresponding to said front beam member duct channels, said front beam member coupled to said rear beam member forming a beam structure so that said 1 0 plurality of corresponding duct channels in said front and rear beam members form a plurality of ducts in said beam structure; and a thermoplastic defrost plenum member including at least one defrost duct channel corresponding to and aligning with at least one defrost duct channel in said rear beam member so that said defrost duct channels of said plenum member and said rear beam member form at least one defrost duct, said 1 5 plenum member coupled to said rear beam member.
BRIEF DESCRIPTION OF THE DRAWINGS [0010] Figure 1 is a perspective view of an instrument panel beam assembly in accordance with an embodiment of the present invention.
[0011] Figure 2 is an exploded perspective front view of the instrument panel beam assembly shown in Figure 1.
[0012] Figure 3 is an exploded perspective rear view of the instrument panel beam assembly shown in Figure 1.
DETAILED DESCRIPTION OF THE INVENTION [0013] An instrument panel beam assembly that includes a thermoplastic beam structure having integrally molded-in HVAC ducts and energy absorbers is described below in detail. The thermoplastic beam structure supports the decorative panel(s) of the instrument panel. The integrally molded-in HVAC ducts and energy absorbers result in fewer parts than known instrument panel structures which provides for simplified instrument panel fabrication and lower fabrication labor costs.
3Saia72 5 spae W Z~askia\725445 smea =end WO 03/078187 PCT/US02/04785 [0014] The thermoplastic beam structure can be molded from one of many thermoplastic materials. Suitable thermoplastic materials include, but are not limited to, acrylonitrile-butadiene-styrene (ABS), polycarbonate, polycarbonate/ABS blend, a copolycarbonate-polyester, acrylic-styrene-acrylonitrile (ASA), acrylonitrile- (ethylene-polypropylene diamine modified)-styrene (AES), phenylene ether resins, glass filled blends of polyphenylene oxide and polystyrene, blends of polyphenylene ether/polyamide (NORYL GTX® from General Electric Company), blends of polycarbonate/PET/PBT, polybutylene terephthalate and impact modifier (XENOY® resin from General Electric Company), polyamides, phenylene sulfide resins, polyvinyl chloride PVC, high impact polystyrene (HIPS), low/high density polyethylene, polypropylene and thermoplastic olefins (TPO).
[0015] Referring to the drawings, Figure 1 is a perspective view of an instrument panel beam assembly 10 in accordance with an exemplary embodiment of the present invention, and Figures 2 and 3 are exploded perspective front and rear views of beam assembly 10 respectively. Instrument panel beam assembly includes a molded thermoplastic beam structure 12, with a steering column support 14, a center stack 16 and end brackets 18 and 20 attached to beam structure 12. A floor bracket 21 couples center stack 16 to a floor pan (not shown) of an automobile.
[0016] Beam structure 12 is formed by a front beam member 22, a rear beam member 24, and a defrost plenum member 26. Front beam member 22 includes molded-in HVAC duct channels, specifically, side window defrost duct channel 28 and main air conditioning duct channel 32. Rear beam member 24 includes corresponding HVAC duct channels molded into a first side 34 of rear beam member 24. Specifically, side window defrost duct channels 36 and 38, and main air conditioning duct channel 40 are molded into first side 34 of rear beam member 24.
Front and rear beam members are coupled together with corresponding side window defrost duct channels 28, 36, and 38 forming side window defrost ducts 42 and 44, and main air conditioning duct channels 32 and 40 forming a main air conditioning duct 46. Front beam member 22 also includes a plurality of air conditioning duct outlets 48.
WO 03/078187 PCT/US02/04785 [0017] A second side 50 of rear beam member 24 includes a moldedin front window defrost duct channel 52. Defrost plenum 26 includes corresponding molded-in duct channels, specifically, a front window defrost duct channel 54 and side window defrost duct connection channels 56 and 58. Rear beam member 24 and defrost plenum 26 are coupled together with corresponding front window defrost duct channels 52 and 54 forming a front window defrost duct 60, and side window defrost duct connection channels 56 and 58 connecting to side window defrost ducts 42 and 44.
[0018] Front beam member 22 and rear beam member 24, in one exemplary embodiment, are coupled by vibration welding, and in alternate embodiments by at least one of heat bonding, adhesive bonding, and fasteners. Also, rear beam member 24 and defrost plenum 26, in one exemplary embodiment, are coupled by vibration welding, and in alternate embodiments by at least one of heat bonding, adhesive bonding, and fasteners.
[0019] A plurality of energy absorbers 66 extend from a bottom side edge 68 of front beam member 22. Energy absorbers 66 and a main body portion of front beam member 22 are molded as one piece. Knee bolsters (not shown) are part of an instrument panel and are supported by energy absorbers 66. During an impact situation, energy is transferred from a passenger knee to a knee bolster and to energy absorbers 66. The deformation of energy absorbers 66 dissipates the energy and prevents injury to the passenger knee. In the exemplary embodiment, energy absorbers 66 have a substantially D-shape configuration. In alternate embodiments, energy absorbers 66 can have any suitable shape that is capable of deforming from the force of a vehicle occupant's knee against the knee bolster in an impact event, and thereby absorbing energy from the occupant's knee. A C-channel support rod 72 extends between energy absorbers 66. C-channel support rod 72 includes a glove box hinge 74.
[0020] A plurality of stiffening ribs 76 extend from an outer surface 78 of front beam member 22. Stiffening ribs 76 are positioned between side window defrost duct channels 28 and 30 and main air conditioning duct channel 32.
[0021] Steering column support 14 is formed from an upper steering column support member 80 and a lower steering column support member 82. Upper Sand lower steering support members 80 and 82 are coupled together with, for example, fasteners. Steering column support 14 is coupled to beam structure 12 with, for ,i 5 example, fasteners. Lower steering support member 82 includes a pedal bracket portion 84 for attaching the vehicle accelerator and brake pedals 86 and 88.
[0022] End brackets 18 and 20 attach to opposing ends 90 and 92 of ibeam structure 12. End brackets 18 and 20 are configured to attach to an automobile N body to secure beam structure 12 within a passenger compartment of an automobile.
[0023] The above described instrument panel beam assembly 10 that includes a thermoplastic beam structure 12 having integrally molded-in HVAC ducts and energy absorbers 66 supports the decorative panel(s) of the instrument panel. The integrally molded-in HVAC ducts 42, 44, and 46, and energy absorbers 66 result in fewer parts than known instrument panel structures which provides for simplified instrument panel fabrication and lower fabrication labor costs.
[0024] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims [0025] Throughout the description and claims of the specification the word "comprise" and variations thereof, such as "comprising" and "comprises" is not intended to exclude other additives, components, integers or steps.
6 W \Sashka\725445 spet amend

Claims (23)

1. An instrument panel beam assembly including: ;Z an elongate front beam member including a plurality of duct channels and a Ni 5 plurality of energy absorbers; and an elongate rear beam member including a plurality of duct channels corresponding to said front beam member duct channels, said front beam member O coupled to said rear beam member forming a beam structure so that said plurality of N' corresponding duct channels in said front and rear beam members form a plurality of ducts in said beam structure, Ni wherein said front beam member further includes a C-channel support rod extending between at least two of said energy absorbers.
2. An assembly in accordance with claim 1 further including an upper steering column support coupled to said beam structure.
3. An assembly in accordance with claim 2 further including a lower steering column support coupled to said upper steering column support and to said beam structure.
4. An assembly in accordance with any one of claims 1 to 3 wherein each said energy absorber comprises a substantially D-shape configuration.
5. An assembly in accordance with any one of the preceding claims further including a center stack coupled to said beam structure, said center stack is sized to receive automobile system controls.
6. An assembly in accordance with any one of the preceding claims further including a first end bracket attached to a first end of said beam structure and a second end bracket attached to a second end of said beam structure.
7. An assembly in accordance with any one of the preceding claims further including a defrost plenum member coupled to said rear beam member, said defrost plenum member including at least one defrost duct channel corresponding to and aligning with at least one defrost duct channel in said rear beam member so that said 7WSaSk 4 pe ed W:A.aSkia\725445 spmc ,lernJ O defrost duct channels of said plenum member and said rear beam member form at least one defrost duct.
An assembly in accordance any one of the preceding claims wherein said in plurality of ducts in said beam structure include a front defrost duct, side window defrost ducts, and main air conditioning ducts, and said front beam member includes at least one air conditioning duct outlet.
9. An assembly in accordance any one of the preceding claims wherein said front N' and rear beam members include a thermoplastic material.
A method of producing an instrument panel beam assembly including: molding an elongate front beam member from a thermoplastic material, the front beam member including a plurality of duct channels and a plurality of energy absorbers; molding an elongate rear beam member from a thermoplastic material, the rear beam member including a plurality of duct channels corresponding to the front beam member duct channels; and coupling the front beam member to the rear beam member forming a beam structure so that the plurality of corresponding duct channels in the front and rear beam members form a plurality of ducts in the beam structure, wherein the front beam member further includes a C-channel support rod extending between at least two energy absorbers.
11. A method in accordance with claim 10 further including: molding a defrost plenum member from a thermoplastic material, the defrost plenum member comprising at least one defrost duct channel; and coupling the defrost plenum member to the rear beam member so that the at least one defrost duct channel of the plenum member aligns with corresponding at least one defrost duct channel in the rear beam member to form at least one defrost duct.
12. A method in accordance with claim 10 or 11 further including: forming an upper steering column support; forming a lower steering column support; coupling the upper steering column support member to the lower steering column support member to form a steering column support; and 8 W \Saskia\725445 sPeo a=end il.-UL. 243 10:19 PHILLIPS ORMONDE FITZPATRICK NQ. 4899 P. 3/4 o coupling the steering column support to the beam structure.
13. A method in accordance with any one of claims 10 to 12 wherein each energy absorber comprises a substantially D-shape configuration.
14. A method in accordance with any one of claims 10 to 1.3 further including: molding a center stack from a thermoplastic material1; and coupling the center stack to the beam structure.
A method in accordance with any one of claims 10 to 14 further including: cxl forming a first end bracket and a second end bracket; atahn0h is n rce oafrtedo h emsrcue n attaching the first end bracket to a irst end of the beam structure.
16. A method in accordance with any one of claims 10 to 1S wherein coupling the front beam member to the rear beam member comprises coupling the front beam member to the rear beam member with at least one of vibration welding, heat bonding, adhesive bonding, and fasteners.
17. A instrument panel beam assembly including- a thermoplastic front beam member including a plurality of molded-in duct channels and a plurality of energy absorbers; a thermoplastic rear beam member including a plurality of molded-in duct channels corresponding to said front beam member duct channels, said front beam member coupled to said rear beam member forming a beam structure so that said plurality of corresponding duct channels in said front and rear beam members form a plurality of ducts in said beam structure; and a thermoplastic defrost plenum member including at least one defrost duct channel corresponding to and aligning with at least one defrost duct channel in said rear beam member so that said defrost duct channels of said plenum member and said rear bean, member form at least one defrost duct, said plenum member coupled to said rear beam member; wherein said front beam member further includes a C-channel support rod extending between at least two energy absorbers.
18. An assembly in accordance with claim 17 further including a steering column support coupled to said beam structure, said steering coluim support including an 725'45 sped omon COMS ID No: ARCS-152320 Received by IP Australia: Time 10:20 Date 2007-07-11 upper steering column support member and a lower steering column support member coupled to said upper steering column support member.
19. An assembly in accordance with claim 17 or 18 wherein said front beam member further includes a C-channel support rod extending between at least two of said energy absorbers, said C-channel support rod including a glove box hinge.
An assembly in accordance with any one of claims 17 to 19 further including a center stack coupled to said beam structure, said center stack sized to receive automobile system controls.
21. An assembly in accordance with any one of claims 17 to 20 wherein said front beam member is coupled to said rear beam member by at least one of vibration welding, heat bonding, adhesive bonding, and fasteners.
22. An assembly in accordance with any one of claims 17, 18, 19 or 21 further includng a center stack integrally molded with said thermoplastic front beam member, said center stack sized to receive automobile system controls.
23. An assembly substantially as hereinbefore described with reference to the drawings. W .Saska\?25445 speo arnend
AU2002250119A 2002-02-19 2002-02-19 Instrument panel beam assembly and methods of manufacture Ceased AU2002250119B2 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2002/004785 WO2003078187A1 (en) 2002-02-19 2002-02-19 Instrument panel beam assembly and methods of manufacture

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AU2002250119A1 AU2002250119A1 (en) 2003-09-29
AU2002250119B2 true AU2002250119B2 (en) 2007-07-26

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AU2002250119A Ceased AU2002250119B2 (en) 2002-02-19 2002-02-19 Instrument panel beam assembly and methods of manufacture

Country Status (6)

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EP (1) EP1478534A4 (en)
JP (1) JP2005519808A (en)
KR (1) KR20040086408A (en)
CN (1) CN1620372A (en)
AU (1) AU2002250119B2 (en)
WO (1) WO2003078187A1 (en)

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FR2881708B1 (en) * 2005-02-04 2007-05-04 Valeo Systemes Thermiques STRUCTURAL BEAM FOR A VEHICLE PASSENGER HOUSING AERAULIC AIR SELECTIVE AIR DISTRIBUTION DEVICES
FR2887511B1 (en) * 2005-06-22 2008-10-03 Valeo Systemes Thermiques HOLLOW BEHIND OF AUTOMOTIVE VEHICLE CABIN EQUIPMENT SUPPORT
FR2901182B1 (en) * 2006-05-18 2008-08-08 Faurecia Interieur Ind Snc VENTILATION ASSEMBLY OF A VEHICLE CAR AND ASSOCIATED MOTOR VEHICLE.
FR2909935B1 (en) * 2006-12-19 2015-04-24 Renault Sas AIR CONDITIONING DEVICE FOR A VEHICLE COMPRISING A DEFROST PIPING NETWORK
US9623798B2 (en) * 2013-04-17 2017-04-18 Continental Automotive Systems, Inc. Vibration absorbing features for plastic assemblies
CN103738186B (en) * 2014-01-21 2016-06-08 安徽江淮汽车股份有限公司 A kind of automotive console area body structure
JP6894355B2 (en) * 2017-11-27 2021-06-30 トヨタ自動車株式会社 Resin radiator support duct
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Also Published As

Publication number Publication date
WO2003078187A1 (en) 2003-09-25
EP1478534A4 (en) 2006-03-15
JP2005519808A (en) 2005-07-07
CN1620372A (en) 2005-05-25
EP1478534A1 (en) 2004-11-24
AU2002250119A1 (en) 2003-09-29
KR20040086408A (en) 2004-10-08

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