WO2000050292A1 - Ensemble tableau de bord modulaire - Google Patents

Ensemble tableau de bord modulaire Download PDF

Info

Publication number
WO2000050292A1
WO2000050292A1 PCT/US2000/004885 US0004885W WO0050292A1 WO 2000050292 A1 WO2000050292 A1 WO 2000050292A1 US 0004885 W US0004885 W US 0004885W WO 0050292 A1 WO0050292 A1 WO 0050292A1
Authority
WO
WIPO (PCT)
Prior art keywords
instrument panel
panel assembly
base
modular instrument
cover
Prior art date
Application number
PCT/US2000/004885
Other languages
English (en)
Inventor
Jan Gustafsson
Jim Ankersson
Original Assignee
Lear Corporation
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 Lear Corporation filed Critical Lear Corporation
Publication of WO2000050292A1 publication Critical patent/WO2000050292A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/14—Dashboards as superstructure sub-units
    • B62D25/142—Dashboards as superstructure sub-units having ventilation channels incorporated therein

Definitions

  • the present invention relates to a modular instrument panel assembly including an instrument panel base, a cross car beam and an instrument panel cover, each preferably manufactured from a common family of plastic materials to provide a lightweight, energy-absorbing, recyclable structure.
  • vehicle instrument panel assemblies include a large injection molded instrument panel substrate that is covered by a layer of foam and skin for aesthetic and energy absorption purposes.
  • the substrate carries the various instrument panel control devices thereon.
  • a metal cross car beam is provided within the substrate for attachment to A-pillars of a vehicle.
  • Such a typical vehicle instrument panel assembly is heavy, expensive to manufacture, limited in energy absorption capacity, and limited in recyclability. In fact, many designs require a knee-impact sheet metal piece for energy management. Accordingly, it is desirable to provide an improved vehicle instrument panel assembly that provides improved energy abso ⁇ tion, improved recyclability and reduced weight.
  • the invention overcomes the shortcomings of the prior art by providing an improved modular instrument panel assembly for use with a motor vehicle, wherein the instrument panel assembly provides improved energy abso ⁇ tion, improved recyclability and reduced weight. Furthermore, the instrument panel assembly may be installed in a vehicle as a single unit.
  • the modular instrument panel assembly comprises a base having an elongated aperture. A beam is disposed in the aperture and is adapted to be attached to the vehicle.
  • the modular instrument panel assembly further includes a cover connected to the base for covering the beam.
  • the base, the beam and the cover each comprise a plastic material from a common family of plastic materials. With such a configuration, the modular instrument panel assembly may be recycled as a unit.
  • the modular instrument panel assembly includes a base having a foam body, and the body has an elongated upwardly opening cavity.
  • a beam is disposed in the cavity and is adapted to be attached to the vehicle.
  • a cover is connected to the base for covering the beam.
  • the base, the beam and the cover preferably comprise polypropylene.
  • the base is preferably a thick, polypropylene foam component having significant energy abso ⁇ tion characteristics.
  • the base may also include a skin layer that covers at least a portion of the foam so as to provide a desired surface finish.
  • the skin layer is a thermal polyolefin (TPO) film.
  • the cover also preferably comprises polypropylene foam that may be at least partially covered with a TPO film.
  • the beam is preferably has a polypropylene sandwich construction that includes at least one layer of polypropylene foam sandwiched between at least two layers of solid polypropylene.
  • a sandwich construction has high strength characteristics and is light weight.
  • the beam may comprise polypropylene reinforced with fiberglass.
  • the base, the beam and the cover each preferably have integrally formed air passages that cooperate to distribute air away from the instrument panel assembly.
  • the modular instrument panel assembly includes a base having a first expanded polypropylene foam substrate and a first thermal polyolefin skin covering at least a portion of the first substrate.
  • the first substrate has an elongated upwardly opening cavity.
  • a beam is disposed in the cavity and is adapted to be attached to the vehicle.
  • the beam includes first and second panels connected together, and each of the panels includes a layer of polypropylene foam sandwiched between two layers of solid polypropylene.
  • a cover is connected to the base for covering the beam.
  • the cover has a second expanded polypropylene foam substrate and a second thermal polyolefin skin covering at least a portion of the second substrate.
  • FIGURE 1 is a perspective view of a modular instrument panel assembly in accordance with the present invention installed in a motor vehicle and supporting a steering column;
  • FIGURE 2 shows an exploded perspective view of the modular instrument panel assembly shown in Figure 1 with the steering column removed, wherein the modular instrument panel assembly includes a base, a crossbeam disposed within the base, and a cover attached to the base;
  • FIGURE 3 is a top view of the base shown in Figure 2;
  • FIGURE 4 is a front view of the modular instrument panel assembly corresponding with the embodiment of Figure 1 ;
  • FIGURE 5 is a cross-sectional view of the modular instrument panel assembly taken along line 5-5 of Figure 4;
  • FIGURE 6 is an enlarged view of a portion of the crossbeam shown in Figure 5 ;
  • FIGURE 7 is an exploded perspective view of the crossbeam.
  • FIGS 1 and 2 show a modular instrument panel assembly 10 according to the invention for use with a motor vehicle 11.
  • the modular instrument panel assembly 10 includes a base 12 having an upper portion 13 and a console 14 that are preferably formed as a single, unitary component. Alternatively, the upper portion 13 and the console 14 may be formed as separate components that are attached together, or the base 12 may be provided without a console 14.
  • the upper portion 13 has an elongated aperture 16 for receiving a crossbeam 18 therein.
  • the crossbeam 18 is configured to be attached at opposing ends 20 and 21 to A pillars of the vehicle 11 such as with any suitable fasteners.
  • the modular instrument panel assembly 10 also includes a cover 22 that is positioned over the base 12 to enclose the crossbeam 18 within the aperture 16.
  • the base 12, crossbeam 18 and cover 22 each comprise a plastic material from the same family of plastic materials so that the modular instrument panel assembly 10 is recyclable as a unit.
  • the base 12, crossbeam 18 and cover 22 include air ducts or passages for receiving air from a heating, ventilating and air conditioning (HVAC) unit 24, and distributing air away from the modular instrument panel assembly 10.
  • HVAC heating, ventilating and air conditioning
  • the crossbeam 18 may include two upper ducts 26, two middle ducts 28 and two lower ducts 30 that are in fluid communication with the HVAC unit 24.
  • the base 12 may include bottom ventilation ducts 32 that receive air flow from the crossbeam 18.
  • the cover 22 may include a forward duct 36, a main defrost duct 38, and defrost airbleed ducts 40 that also receive air flow from the crossbeam 18 and/or directly from the HVAC unit 24.
  • side ventilation end caps 42 and 44 are provided at opposing ends 45 and 46 of the base 12.
  • the side ventilation end caps 42 and 44 receive air flow from the upper ducts 26 and middle ducts 28 of the crossbeam 18, and may, for example, direct cool air through ventilation ducts 47 to passengers of the vehicle 11 , or hot air through side defrost ducts 48 to side windows for defrosting the windows.
  • the base 12, crossbeam 18 and cover 22 may be provided with any suitable air passage configuration.
  • the airbleed ducts 40 may be eliminated from the cover 22, and replaced with a plurality of small channels or ducts formed in a front portion of the base 12 just below the cover 22.
  • one or more of the air passages may be provided with a duct liner made of any suitable material, such as blow molded plastic, for improving air flow through the air passages.
  • the base 12 includes knee impact areas 50 and 52 with substantial energy abso ⁇ tion characteristics.
  • the base 12 has a first body or substrate 54 that preferably comprises expanded polypropylene (EPP) foam, which provides significant energy abso ⁇ tion characteristics, thereby eliminating the need for knee-impact sheet metal.
  • EPP foam is also light weight, temperature resistant up to 130°C, non-squeaking, non-fogging and fully recyclable.
  • EPP foam may be formed by expanding extruded polypropylene beads in a mold using a heat source such as steam, and is available from Fagerdala World Foams of Gustavsberg, Sweden.
  • the density and thickness of the substrate 54 may be varied to achieve desired energy abso ⁇ tion characteristics.
  • the density of the substrate 54 is in the range of 25 to 80 kilograms per cubic meter, and the thickness of the substrate 54 at the knee impact areas 50 and 52 is in the range of 5 to 20 centimeters .
  • the base 12 may also include a first cover layer or skin layer 56 that covers some or all of the substrate 54.
  • the skin layer 56 may comprise any suitable material
  • the skin layer 56 preferably comprises a thermal polyolefin (TPO) foil, which may be vacuum formed over the substrate 54 without requiring any surface grinding of the substrate 54.
  • TPO foil is lightweight, thin, recyclable, and provides excellent aging properties.
  • the substrate 54 may be molded using colored EPP, and because the substrate 54 may be provided with a high quality surface finish or A- class surface, the skin layer 56 may not be required.
  • the substrate 54 may be formed in a tool that includes steam nozzles made of sintered, permeable material. Such nozzles sufficiently dissipate steam thereby reducing surface imperfections on the substrate 54.
  • the base 12 may include one or more openings for receiving such components as an instrument cluster, a radio, a compact disc player, and the like.
  • the base 12 includes an aperture 58 that extends to the crossbeam 18 for receiving a steering column, and a cavity 60 for receiving a passenger restraint unit such as an air bag module 62.
  • a frangible seam, such as a indented or perforated seam 63 may also be provided in the substrate 54 and/or skin layer 56 to facilitate deployment of the air bag module 62.
  • the cover 22 has a second body or substrate 64 that preferably comprises EPP foam.
  • the cover 22 may also include a second cover layer or skin layer 66 that covers some or all of the substrate 64.
  • the skin layer 66 preferably comprises TPO foil.
  • the cover 22 is preferably connected to the base 12 with fasteners 68. Alternatively, the cover 22 may be connected to the base 12 in any suitable manner such as with an adhesive.
  • the end caps 42 and 44 are also preferably formed in a manner similar to the base 12 and the cover 22.
  • the base 12, cover 22 and end caps 42 and 44 may comprise any suitable plastic material.
  • the crossbeam 18 preferably includes first and second generally vertical panels 70 and 72, respectively, that are joined at opposite ends.
  • the crossbeam 18 further includes a pair of upper, generally horizontal panels 74, and a pair of lower, generally horizontal panels 76 disposed between the generally vertical panels 70 and 72.
  • Each of the panels 70-76 preferably comprises at least one polypropylene foam layer 78 sandwiched between at least two solid polypropylene layers 80.
  • the layer 78 preferably has a thickness in the range of 4 to 8 millimeters (mm), while the layers 80 preferably have a thickness in the range of 1 to 3 mm.
  • the overall thickness of each of the panels 70-76 is preferably in the range of 8 to 12 mm.
  • Such a sandwich construction provides high strength characteristics and is light weight.
  • each of the layers 78 and 80 may comprise any suitable plastic material.
  • the panels 70-76 are preferably stamped or otherwise cut from large sheets of material, and are molded or otherwise shaped to achieve a desired configuration. While the panels 70-76 may be connected together in any suitable manner, such as with fasteners or an adhesive, the panels 70-76 are preferably welded together, such as by sonic or vibration welding.
  • the crossbeam 18 may have any suitable configuration and may comprise any suitable material such as aluminum, manganese, or a plastic material combined with reinforcing fibers.
  • the crossbeam 18 may comprise polypropylene combined with fiberglass.
  • the crossbeam 18 may be formed in any suitable manner.
  • the crossbeam 18 may be formed by molding two plastic pieces, and then welding the pieces together to obtain a similar configuration as shown in Figure 2.
  • the crossbeam 18 may be connected to the base 12 in any suitable manner, such as with fasteners 78 shown in Figure 5, so as to provide support to the base 12 when the modular instrument panel assembly 10 is installed in the vehicle 11.
  • the crossbeam 18 may also provide support for various components.
  • the air bag module 62 may be connected to the crossbeam 18 using any suitable fasteners.
  • a steering column may be connected to the crossbeam 18 using any suitable fasteners such as bolts or screws.
  • the modular instrument panel assembly 10 may be preassembled prior to installation in the vehicle 11. Furthermore, components such as the HVAC unit 24, air bag module 62, instrument cluster, radio and compact disk player, as well as associated wiring and controls, may be preassembled to the base 12, crossbeam 18 and/or cover 22. After the crossbeam 18 has been connected to the A-pillars or other suitable structure of the vehicle 11, the end caps 42 and 44 may be attached to the base 12, crossbeam 18 and/or cover 22. Alternatively, the end caps 42 and 44 may be connected to side doors (not shown) of the vehicle 11 so that the end caps 42 and 44 are disposed adjacent the base 12 when the side doors are closed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Instrument Panels (AREA)
  • Laminated Bodies (AREA)

Abstract

Cette invention concerne un ensemble tableau de bord modulaire (10) pour véhicule automobile. Cet ensemble comprend une base (12) présentant une ouverture allongée (16). Une poutre (18) est disposée dans cette ouverture (16) et est conçue pour être attachée au véhicule. De plus, cet ensemble tableau de bord modulaire (10) comprend un revêtement (22) relié à la base (12) qui sert à recouvrir la poutre (18). En outre, la base (12), la poutre (18) et le revêtement (22), contiennent chacun une matière plastique appartenant à une famille commune de matières plastiques.
PCT/US2000/004885 1999-02-25 2000-02-25 Ensemble tableau de bord modulaire WO2000050292A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12136699P 1999-02-25 1999-02-25
US60/121,366 1999-02-25

Publications (1)

Publication Number Publication Date
WO2000050292A1 true WO2000050292A1 (fr) 2000-08-31

Family

ID=22396225

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/004885 WO2000050292A1 (fr) 1999-02-25 2000-02-25 Ensemble tableau de bord modulaire

Country Status (1)

Country Link
WO (1) WO2000050292A1 (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001074627A1 (fr) * 2000-03-31 2001-10-11 Delphi Technologies, Inc. Poutre structurale avec absorbeurs d'energie pour les genoux
US6497775B2 (en) 2001-04-11 2002-12-24 Delphi Technologies, Inc. Method and apparatus for manufacturing a vehicle cross car beam or other structural, functional articles out of multiple materials with optimum material utilization
US6497432B2 (en) 2000-02-22 2002-12-24 Delphi Technologies, Inc. Structural attachment system and method for a vehicle
US6517114B1 (en) 2000-02-22 2003-02-11 Delphi Technologies Inc Steering column structural support system and method
US6520849B1 (en) 2000-03-31 2003-02-18 Delphi Technologies, Inc. Integrated structural HVAC system
US6648402B2 (en) 2000-02-22 2003-11-18 Delphi Technologies, Inc. Structural support brace
DE102004053377A1 (de) * 2004-11-02 2006-05-11 Johnson Controls Interiors Gmbh & Co. Kg Fahrzeugcockpit
US8534739B2 (en) 2011-05-27 2013-09-17 Ford Global Technologies, Llc Cross car beam assembly including reinforced polymerized elements
RU2570920C2 (ru) * 2011-01-20 2015-12-20 Ман Трак Унд Бас Аг Аэродинамически оптимизированный корпус на лобовом стекле автомобиля
WO2023174157A1 (fr) * 2022-03-18 2023-09-21 北京车和家汽车科技有限公司 Dispositif de raccordement de dégivrage latéral et véhicule

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2623776A1 (fr) * 1987-12-01 1989-06-02 Renault Poste de conduite preassemble pour habitacles de vehicules automobiles
US5364159A (en) * 1993-06-15 1994-11-15 Davidson Textron Inc. Structural instrument panel carrier assembly
US5556153A (en) * 1994-10-14 1996-09-17 Davidson Textron Inc. Instrument panel assembly

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2623776A1 (fr) * 1987-12-01 1989-06-02 Renault Poste de conduite preassemble pour habitacles de vehicules automobiles
US5364159A (en) * 1993-06-15 1994-11-15 Davidson Textron Inc. Structural instrument panel carrier assembly
US5556153A (en) * 1994-10-14 1996-09-17 Davidson Textron Inc. Instrument panel assembly

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6497432B2 (en) 2000-02-22 2002-12-24 Delphi Technologies, Inc. Structural attachment system and method for a vehicle
US6517114B1 (en) 2000-02-22 2003-02-11 Delphi Technologies Inc Steering column structural support system and method
US6648402B2 (en) 2000-02-22 2003-11-18 Delphi Technologies, Inc. Structural support brace
WO2001074627A1 (fr) * 2000-03-31 2001-10-11 Delphi Technologies, Inc. Poutre structurale avec absorbeurs d'energie pour les genoux
US6520849B1 (en) 2000-03-31 2003-02-18 Delphi Technologies, Inc. Integrated structural HVAC system
US6497775B2 (en) 2001-04-11 2002-12-24 Delphi Technologies, Inc. Method and apparatus for manufacturing a vehicle cross car beam or other structural, functional articles out of multiple materials with optimum material utilization
DE102004053377A1 (de) * 2004-11-02 2006-05-11 Johnson Controls Interiors Gmbh & Co. Kg Fahrzeugcockpit
RU2570920C2 (ru) * 2011-01-20 2015-12-20 Ман Трак Унд Бас Аг Аэродинамически оптимизированный корпус на лобовом стекле автомобиля
US8534739B2 (en) 2011-05-27 2013-09-17 Ford Global Technologies, Llc Cross car beam assembly including reinforced polymerized elements
WO2023174157A1 (fr) * 2022-03-18 2023-09-21 北京车和家汽车科技有限公司 Dispositif de raccordement de dégivrage latéral et véhicule

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