GB2335396A - A dashboard assembly for a vehicle - Google Patents

A dashboard assembly for a vehicle Download PDF

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Publication number
GB2335396A
GB2335396A GB9806018A GB9806018A GB2335396A GB 2335396 A GB2335396 A GB 2335396A GB 9806018 A GB9806018 A GB 9806018A GB 9806018 A GB9806018 A GB 9806018A GB 2335396 A GB2335396 A GB 2335396A
Authority
GB
United Kingdom
Prior art keywords
dashboard assembly
foam body
support member
outer shell
dashboard
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.)
Withdrawn
Application number
GB9806018A
Other versions
GB2335396A8 (en
GB9806018D0 (en
Inventor
Michael Mellor
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.)
MG Rover Group Ltd
Original Assignee
MG Rover Group Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by MG Rover Group Ltd filed Critical MG Rover Group Ltd
Priority to GB9806018A priority Critical patent/GB2335396A/en
Publication of GB9806018D0 publication Critical patent/GB9806018D0/en
Publication of GB2335396A publication Critical patent/GB2335396A/en
Publication of GB2335396A8 publication Critical patent/GB2335396A8/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/04—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
    • B60R21/045—Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings associated with the instrument panel or dashboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00514—Details of air conditioning housings
    • B60H1/0055—Details of air conditioning housings the housing or parts thereof being integrated in other devices, e.g. dashboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00557—Details of ducts or cables
    • B60H1/00564—Details of ducts or cables of air ducts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
    • B60H1/24—Devices purely for ventilating or where the heating or cooling is irrelevant
    • B60H1/241—Devices purely for ventilating or where the heating or cooling is irrelevant characterised by the location of ventilation devices in the vehicle
    • B60H1/242—Devices 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K37/00—Dashboards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/20—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components
    • B60R21/205—Arrangements for storing inflatable members in their non-use or deflated condition; Arrangement or mounting of air bag modules or components in dashboards

Abstract

A dashboard assembly 10 for a vehicle 16 comprises a rigid cross-car beam 12 encased in a foam body 20, which is covered by a thin outer shell 26 such as a glass mat thermoplastic. The foam body 20 is formed in first and second sections 22, 24 which are bonded to each other, to the cross-car beam 12 and to the outer shell 26. Integrally formed with the assembly 10 are ducts 28, 30, 36 for a ventilation system, a recess 40 for an air bag module and a passageway 44 for a steering column.

Description

2335396 A Dashboard Assembly for a Vehicle This invention relates to
dashboard assemblies for vehicles and in particular to a dashboard assembly producable as an integrated subassembly prior to fitment thereof to the vehicle and to a method of producing such a dashboard assembly.
The high number of features included in some vehicles in the region of the driver mean that it is becoming ever more complicated to assemble the dashboard. For example, many items such as ventilation channels must be assembled and connected in place before the dashboard is fitted to the vehicle. The cost of assembling the dashboard increases with the length of time it takes to assemble.
It is an object of this invention to provide an improved dashboard assembly for a vehicle and to provide an improved method of producing such a dashboard assembly.
According to the invention there is provided a dashboard assembly for a vehicle comprising a substantially rigid support member attachable to the vehicle, a foam body surrounding and united to a portion of the support member and a thin outer shell substantially complimentary to an outer portion of the foam body and united thereto, whereby the dashboard - 2 " assembly is producable as an integrated sub-assembly prior to it being fitted to the vehicle.
The dashboard assembly may further comprise a substantially hollow passageway defined in the foam body, whereby a link may be provided 5 between two portions of the dashboard assembly.
The outer shell may define at least one aperture substantially aligned with the passageway so as to provide at least one ventilation duct for a ventilation system. The at least one duct may include means for fixing a ventilator into said duct.
1 1 The dashboard assembly may define at least one hollow extending through the outer shell and into the foam body, whereby at least one subunit of the vehicle may be fitted into the dashboard assembly. The subunit may be attachable to a fixing point of the support member. The subunit may, for example, comprise an air bag module or a passenger compartment 15 heater unit.
The dashboard assembly may further comprise an integrally formed knee bolster.
The support member may include support arms extending outwardly through the foam body and towards the outer shell, whereby the support arms provide increased rigidity of the dashboard assembly.
The support member may comprise a structural cross-car beam and may comprise a hollow and lightweight metal beam. The cross car beam in a preferred embodiment of this invention comprises a hollow magnesium alloy die-casting which provides the advantage of light weight. When in place, the cross-car beam of a preferred embodiment is a structural member of the vehicle and it braces the body between the A-pillars and further provides a mounting structure for a passenger-side air-bag module and a bracing point for the steering column.
The foam body may comprise a homogenous close cell skin forming foam. One example of a suitable raw material for producing the foam for the foam body is an expandable bead material marketed by Shell Chemicals Europe under the trade mark "Caril".
The outer shell may comprise a thermoplastic composite material, such as a glass mat thermoplastic.
The invention also provides a method of producing a dashboard assembly for a vehicle, including the steps of.
- 4 " a) surrounding a portion of a substantially rigid support member with a foam body and uniting said foam body to said support member; and b) covering an outer portion of said foam body with a thin outer shell and uniting said outer shell to said foam body.
The method may also include forming the foam body in two sections, interposing the support member between the two sections and bonding the two sections to each other and to the support member.
The method may also include defining a substantially hollow passageway in the foam body, whereby a link may be provided between two portions of the dashboard assembly.
The method may also include defining at least one aperture substantially aligned with the passageway so as to provide at least one ventilation duct for a ventilation system.
The method may also include defining at least one hollow in the dashboard assembly extending through the outer shell and into the foam body, whereby at least one sub-unit of the vehicle may be fitted into the dashboard assembly.
The method may also include fixing the at least one sub-unit to the support member.
The invention will now be described by way of example with reference to the accompanying drawings, in which; Figure 1 is a perspective view of a dashboard assembly according to the invention; Figure 2 is a section through the dashboard assembly of Figure 1 on the line A-A; Figure 3 is a section through the dashboard assembly of Figure 1 on the line B-B; and Figure 4 is a section through the dashboard assembly of Figure 1 on the line C-C.
Referring to the figures, a dashboard assembly 10 comprises a structural and rigid support member in the form of a die-cast magnesium 15 alloy box section cross-car beam 12.
The cross-car beam 12 has fixing points 14 provided at each end, so that it is attachable to the vehicle 16 (not shown fully) transverse to a firewall 18 -6 and between a pair of front door mounting pillars known in the art as Apillars (not shown).
The dashboard assembly 10 further comprises a foam body 20 having a fine and homogenous close cell structure which is skin forming. The foam body 20 is formed in a first section 22 and in a second section 24 which envelope the beam 12 and are bonded both to it and to each other.
The foam body 20 is covered on a visible outer surface by a thin outer shell 26 which is formed from a thermoplastic composite material in the form of a glass mat thermoplastic and the outer shell 26 is bonded to the outer surface of the foam body 20.
The first section 22 of the foam body 20 has a ventilation duct 28 formed in it during the expansion process of the foam. The duct 28 has a demister outlet 30 which passes through the foam body 20 and terminates in an aperture in the outer shell 26 to supply heated air through a windscreen demister nozzle 32.
The duct 28 also has a cabin duct 34 which passes through the foam body 20 and terminates in an aperture in the outer shell 26 in the form of a cabin outlet 36 to supply heated air into the passenger compartment through a cabin nozzle 38.
The demister and cabin nozzles 32, 38 are retained in place in their respective apertures by mechanical fixings (not shown) which capture the nozzles 32, 38 in position. One example of a suitable fixing means would be a barbed member on the each of the nozzles 32, 38 which is arranged to dig into the foam body 20 so as to reduce the ease with which the nozzles 32, 38 can be withdrawn after insertion through their respective apertures.
A hollow 40 is cut out of the dashboard 10 through the outer shell 26 and into the foam body 20. The hollow 40 is arranged to accept a passenger side air bag module 42 and is cut sufficiently into the foam body 20 to expose a portion of the cross-car beam 12 to which the air bag module 42 can be fixed.
A passageway 44 is defined in the dashboard assembly 10 to permit the passage of a steering column (not shown) therethrough. A mounting 46 for the steering column is provided on the cross-car beam 12 and includes a fixing mechanism (not shown) for bracing the steering column to the crosscar beam 12.
This invention enables a dashboard 10 to be produced as an integrated assembly separately from the rest of the vehicle 16 and which can then be fitted into the vehicle 16 as a single unit, thus reducing the problem of the lengthy assembly time of some known dashboard arrangements which are assembled in situ.
The dashboard assembly 10 of this invention is produced by: forming the first and second sections 22, 24 of the foam body 20; surrounding the cross-car beam 12 with them; bonding the sections 22, 24 to each other and to the beam 12; and covering the foam body 20 with the bonded outer shell 26.
The ducts 28, 30, 34, the recess 40 and the passageway 44 may be formed during the expansion process of the foam used to form the foam body 20 and during the manufacture of the outer shell 26 or may be cut out after the production of the dashboard assembly 10.
i The foam body 20 reduces the complexity of known ventilation systems by the incorporation of the ducting 28, 30, 34 into its foam body 20 and, being a large body of foam, the foam body 20 also reduces the intrusion of noise, vibration and harshness into the passenger compartment from the rest of the vehicle 16.
Additional passageways may also be provided in the foam body 20 in a similar fashion to the ventilation ducts 28, 30, 34 so as to provide additional links between portions of the dashboard assembly 10. These links may be used, for example, as a conduit to assist in the routing of an electrical wiring harness.
In a modification of this invention, the cross-car beam 12 includes rigid arms extending outwardly through the foam body 20 and towards the outer 5 shell 26, so as to increase the overall stiffness of the dashboard assembly 10.
In a second modification, fixing points 48 are incorporated into the dashboard assembly 10 top and bottom at a face which abuts the firewaH 18 so that the dashboard assembly 10 can be attached to the firewall 18. These fixings 48 reduce relative movement between the dashboard assembly 10 and the firewall 18 along an abutting edges and thus reduce the likelihood of squeaks which might irritate a vehicle user.
In a third modification of this invention, a knee bolster portion is incorporated into the foam body 20 and the outer shell 26 is formed to cover it, so as to provide an integral knee bolster in the dashboard assembly 10.
Rather than forming the foam body in more than one section and bonding it to and around the cross-car tube, it is also possible to include the cross-car tube in a foam box used to form the foam body and to form the foam body around the tube.

Claims (20)

  1. A dashboard assembly for a vehiclep comprising a substantially rigid support member attachable to the vehicle, a foam body surrounding and united to a portion of the support member and a thin outer shell substantially complimentary to an outer portion of the foam body and united thereto, whereby the dashboard assembly is producable as an integrated sub-assembly prior to it being fitted to the vehicle.
  2. 2. A dashboard assembly according to Claim 1 further comprising a substantially hollow passageway defined in the foam body, whereby a link is provided between two portions of the dashboard assembly.
  3. 3.
    A dashboard assembly according to Claim 2, the outer shell defining at least one aperture substantially aligned with the passageway so as to provide at least one ventilation duct for a ventilation system.
  4. A dashboard assembly according to Claim 3, wherein the at least one duct includes means for fixing a ventilator into said duct.
  5. 5. A dashboard assembly according to any preceding claim, defining at least one hollow extending through the outer shell and into the foam body, whereby at least one sub-unit of the vehicle can be fitted into the dashboard assembly.
  6. 6. A dashboard assembly according to Claim 5 wherein the sub-unit is attachable to a fixing point of the support member.
  7. A dashboard assembly according to any preceding claim, further comprising an integrally formed knee bolster.
  8. 8. A dashboard assembly according to any preceding claim, the support member including support arms extending outwardly through the foam body and towards the outer shell, whereby the support arms provide increased rigidity of the dashboard assembly.
  9. 9. A dashboard assembly according to any preceding claim, the support member comprising a structural cross-car beam.
  10. 10. A dashboard assembly according to any preceding claim, the support member comprising a hollow and lightweight metal beam.
  11. 11. A dashboard assembly according to any preceding claim, the foam body comprising a homogenous close cell skin forming foam.
  12. 12. A dashboard assembly according to any preceding claim, the outer shell comprising a thermoplastic composite material.
  13. 13. A dashboard assembly substantially as described herein with reference to the accompanying drawings.
  14. 14. A method of producing a dashboard assembly for a vehicle, including the steps of.
    a) surrounding a portion of a substantially rigid support member with a foam body and uniting said foam body to said support member; and b) covering an outer portion of said foam body with a thin outer shell and uniting said outer shell to said foam body.
  15. 15. A method according to Claim 14, including forming the foam body in two sections, interposing the support member between the two sections and bonding the two sections to each other and to the support member.
  16. 16. A method according to Claim 14 or Claim 15, including defming a substantiafly hoHow passageway in the foam body, whereby a link is provided between two portions of the dashboard assembly.
  17. 17. A method according to Claim 16, including defining at least one aperture substantially aligned with the passageway so as to provide at least one ventilation duct for a ventilation system.
  18. 18. A method according to any of Claims 14 to 17, including defining at least one hollow in the dashboard assembly extending through the outer shell and into the foam body, whereby at least one sub-unit of the vehicle can be fitted into the dashboard assembly.
  19. 19. A method according to Claim 18 including fixing the at least one sub-unit to the support member.
  20. 20. A method of producing a dashboard assembly substantially as described herein with reference to the accompanying drawings.
GB9806018A 1998-03-20 1998-03-20 A dashboard assembly for a vehicle Withdrawn GB2335396A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9806018A GB2335396A (en) 1998-03-20 1998-03-20 A dashboard assembly for a vehicle

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9806018A GB2335396A (en) 1998-03-20 1998-03-20 A dashboard assembly for a vehicle

Publications (3)

Publication Number Publication Date
GB9806018D0 GB9806018D0 (en) 1998-05-20
GB2335396A true GB2335396A (en) 1999-09-22
GB2335396A8 GB2335396A8 (en) 2000-02-23

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB9806018A Withdrawn GB2335396A (en) 1998-03-20 1998-03-20 A dashboard assembly for a vehicle

Country Status (1)

Country Link
GB (1) GB2335396A (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1155944A1 (en) 2000-05-18 2001-11-21 Faurecia Industries Dashboard, corresponding dashboard module and fabrication module
EP1294591A1 (en) * 2000-06-05 2003-03-26 Textron Automotive Company Inc. Vehicle interior panel and method of making
WO2003029054A1 (en) * 2001-10-04 2003-04-10 Intier Automotive Inc. Instrument panel having flexible steering wheel column closeout and method for assembling same
EP1510454A1 (en) * 2003-08-28 2005-03-02 The Boeing Company Interior panel integrated with insulation and air ducts
DE102009017526A1 (en) * 2009-04-17 2010-10-21 Autoliv Development Ab Safety device for use in motor vehicle, is provided with instrument panel and airbag module, which has folded or consolidated airbag and housing, in which airbag is arranged
WO2023083482A1 (en) 2021-11-15 2023-05-19 Lotus Tech Innovation Centre Gmbh A cross-car beam assembly with an inner ventilation duct

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3904222A (en) * 1973-12-03 1975-09-09 Gen Motors Corp Occupant restraint system
US3922429A (en) * 1971-11-03 1975-11-25 Gen Tire & Rubber Co Composite impact absorbing safety structure
GB2074515A (en) * 1980-04-26 1981-11-04 Freudenberg Carl Dashboards for motor vehicles
US4455338A (en) * 1980-03-28 1984-06-19 Gebr. Happich Gmbh Reinforced foam body for vehicle dashboards, or the like
US4663210A (en) * 1983-10-11 1987-05-05 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Paneling member for the interior of automotive vehicles, especially a dashboard
GB2222983A (en) * 1988-07-12 1990-03-28 Honda Motor Co Ltd Molding of foam resin having a hollow preformed member.
US5333901A (en) * 1993-04-26 1994-08-02 General Motors Corporation Air bag deployable instrument panel cover
US5622402A (en) * 1995-04-19 1997-04-22 Davidson Textron Inc. Panel with integral energy absorber and air duct

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3922429A (en) * 1971-11-03 1975-11-25 Gen Tire & Rubber Co Composite impact absorbing safety structure
US3904222A (en) * 1973-12-03 1975-09-09 Gen Motors Corp Occupant restraint system
US4455338A (en) * 1980-03-28 1984-06-19 Gebr. Happich Gmbh Reinforced foam body for vehicle dashboards, or the like
GB2074515A (en) * 1980-04-26 1981-11-04 Freudenberg Carl Dashboards for motor vehicles
US4663210A (en) * 1983-10-11 1987-05-05 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Paneling member for the interior of automotive vehicles, especially a dashboard
GB2222983A (en) * 1988-07-12 1990-03-28 Honda Motor Co Ltd Molding of foam resin having a hollow preformed member.
US5333901A (en) * 1993-04-26 1994-08-02 General Motors Corporation Air bag deployable instrument panel cover
US5622402A (en) * 1995-04-19 1997-04-22 Davidson Textron Inc. Panel with integral energy absorber and air duct

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1155944A1 (en) 2000-05-18 2001-11-21 Faurecia Industries Dashboard, corresponding dashboard module and fabrication module
EP1294591A1 (en) * 2000-06-05 2003-03-26 Textron Automotive Company Inc. Vehicle interior panel and method of making
EP1294591A4 (en) * 2000-06-05 2004-07-21 Textron Automotive Co Inc Vehicle interior panel and method of making
WO2003029054A1 (en) * 2001-10-04 2003-04-10 Intier Automotive Inc. Instrument panel having flexible steering wheel column closeout and method for assembling same
US7150488B2 (en) 2001-10-04 2006-12-19 Intier Automotive Inc. Instrument panel having flexible steering wheel column closeout
EP1510454A1 (en) * 2003-08-28 2005-03-02 The Boeing Company Interior panel integrated with insulation and air ducts
DE102009017526A1 (en) * 2009-04-17 2010-10-21 Autoliv Development Ab Safety device for use in motor vehicle, is provided with instrument panel and airbag module, which has folded or consolidated airbag and housing, in which airbag is arranged
DE102009017526B4 (en) * 2009-04-17 2014-02-06 Autoliv Development Ab safety device
WO2023083482A1 (en) 2021-11-15 2023-05-19 Lotus Tech Innovation Centre Gmbh A cross-car beam assembly with an inner ventilation duct

Also Published As

Publication number Publication date
GB2335396A8 (en) 2000-02-23
GB9806018D0 (en) 1998-05-20

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)