WO2010017254A2

WO2010017254A2 - Integrated cockpit and front module assembly and method

Info

Publication number: WO2010017254A2
Application number: PCT/US2009/052774
Authority: WO
Inventors: Saeed Siavoshani; Paul Rohrer; Thomas Mettler; David L. Chapman; Andon Samurkas; Ashish Kotnis; Selamawit Asfaw; Keith L. Kauffmann; Jay M. Tudor
Original assignee: Dow Global Technologies Inc.
Priority date: 2008-08-08
Filing date: 2009-08-05
Publication date: 2010-02-11
Also published as: WO2010017254A3

Abstract

A front of dash (FOD) assembly and a method thereof, more particularly to a unique integrated front of dash assembly including a composite sandwich construction. The FOD (20) including an engine dash-mat member (30) and a heat shield layer (34) disposed on the outer surface; a firewall member (50); a cabin dash-mat member (60); and at least one component connected to the at least one attachment member and disposed on front of dash assembly composite panel member selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line, wherein the above components are assembled together prior to installation in the motor vehicle.

Description

INTEGRATED COCKPIT AND FRONT MODULE ASSEMBLY AND METHOD

CLAIM OF PRIORITY

The present application claims the benefit of the filing date of U.S. Provisional

Application Serial No. 61/087,241, filed August 08, 2008, hereby incorporated by reference.

FIELD OF THE INVENTION

[0001] The present invention relates to a front of dash assembly a method thereof, more particularly to a unique integrated front of dash assembly including a composite sandwich construction.

BACKGROUND OF THE INVENTION

[0002] Within the automotive and transportation industry, the design and assembly of vehicles is a complicated and expensive proposition. Many governmental and customer related requirements and needs must be met in order to produce satisfactory products. One particularly difficult areas of a vehicle to effectively design and produce in the interface area between the engine compartment and the passenger compartment. The interface (known as a "Front of Dash" or "FOD") between these compartments must provide a barrier function, a pass-though function at the same time at least not significantly reducing the overall structural strength of the vehicle. The barrier function to minimize noise, vibration, and harshness (NVH), fluid transmission (e.g. fumes, liquids, or any other environmental conditions) to enter the passenger compartment from the engine compartment. The barrier also helps minimize the heat transfer from the engine compartment to the passenger compartment. The pass-though function to allow for the required control connections (e.g. brakes, steering, electrical, etc.) to pass-through to and from the engine compartment to the passenger compartment. The Front of Dash may consist of a number of components including: an engine heat shield, an engine dash-mat, a firewall, structural reinforcements, a cabin dash-mat, and control assemblies (electrical, pneumatic, and hydraulic). Traditionally, there have been two different methods in making and assembling the Front of Dash. One is known as cockpit 1 and the other is known as cockpit 1 ^ΛA.

[0003] In a cockpit 1 assembly, a firewall is first assembled to the vehicle.

Then any number of additional components are attached to and through the firewall (on both the engine side and the passenger side), such as heating and cooling assemblies (HVAC), brake sled, brake booster, electric box, as well as other components. Typically, these components are installed on a typical firewall and are loaded one by one.

[0004] In a cockpit 1.5 assembly, the HVAC, brake sled and some other parts are installed in conjunction with segment of the firewall called the modular plate connected into the cross beam of the instrument panel ("IP") assembly. The whole assembly then is loaded through the doors of the vehicle via a robot hand and attached to the painted vehicle body in white.

[0005] Cockpit 1 and Cockpit 1/5 have their own shortcomings. For example, poor vehicle NVH through the firewall, fit finish, sealing implementation due to many holes, complexity of assembly, blind operation, HVAC alignment and a lack of integration assembly and process can create quality issues in regard to the functionality of the cockpit. Cockpit 1 is practiced by most manufactures, while cockpit 1.5 has only been adopted by a few. Examples of current state of the art FOD systems may be found in US and Foreign patent documents US4391465A; US4597461 A; US5005898A; US5358300 A; US5863093 A; US6276739; US6581967 B1 ; US6591927 B1; US6736439 B2; WO1999005019A1; and EP672576 B1, incorporated herby by reference for all purposes.

[0006] The goal of this invention is to provide a new and unique product and method to help improve the issues described in both Cockpit 1 and Cockpit 1.5. It is believed that the way to resolve this is to incorporate the firewall, cabin and engine dash-mat as well as the engine heat shield, and at least some of the accessories such as the brake sled, brake booster, electric box, HVAC, etc and the IP into one subsystem with at least a partial composite sandwich construction.

SUMMARY OF THE INVENTION

[0007] The present invention relates to a multi-layer modular front of dash product and method that allows an off-line build (prior to assembly to the vehicle) and will simplify the assembly line process by eliminating sub-assemblies. It also may help eliminate blind assembly operations when individual parts are brought to the vehicle part by part, as is currently done today. The multi-layer modular approach may also help improve fit and finish and reduce noise transmission from the engine compartment by integrating the cabin and engine dash mat as well as the engine heat shield. The invention is a unique design and method to provide a modular approach to build the FOD assembly. The module could include the engine and cabin dash mats, master cylinder, pedals and supports power steering and brake lines, brake booster, engine shielding, electrical pass through via connectors, HVAC, and the instrument panel sub assembly (optional). These components would be assembled offline and loaded to the front of the dash using studs or fasteners which could be molded in or preassembled to the FOD. Once the assembly is completed, the whole unit may be brought to a bonding cell for the dispensing of the adhesive or loaded to a vehicle using an assist arm and mechanically fastened. If required, sealant could be applied to the periphery of the module prior to final assembly stage. [0008] In one aspect, the present invention pertains to an integrated cockpit and front end module assembly for use in separating an engine compartment and a passenger compartment of a motor vehicle comprising: a front of dash assembly composite panel member, wherein the member includes: an engine dash-mat member including (i) a base layer formed of a first batting material, the base layer having an outer surface that faces the engine compartment when installed in the vehicle and an inner surface that faces the passenger compartment when installed in the vehicle, the inner surface having a porous surface, and a total base layer thickness EMT and (ii) a heat shield layer disposed on the outer surface; a molded polymeric firewall member including a firewall base layer formed of a rigid filled polymer, the firewall base layer including (i) a firewall outer surface facing the inner surface of the engine dash-mat member and at least partially connectively intertwined thereto so that a first mechanical bond is formed over at least part of an firewall and engine dash-mat interface region, the first mechanical bond being at least partially formed by an interspersion of the firewall base layer through the porous surface and at least partially into the EMT of base layer of the engine dash-mat member, and the firewall base layer also including (ii) a firewall inner surface facing the passenger compartment of the motor vehicle, including surface features to increase a surface area of the firewall inner surface; a cabin dash-mat member including a cabin base layer formed of a second batting material, the cabin base layer having a total thickness CMT, (i) a cabin outer surface facing the passenger compartment when installed in the motor vehicle, (ii) a cabin inner surface facing the firewall inner surface of the molded firewall member and at least partially connectively intertwined thereto so that a second mechanical bond is formed over at least part of an firewall and cabin dash-mat interface region, the second mechanical bond being at least partially formed by an interspersion of the cabin inner surface onto the surface features of the firewall inner surface; at least one attachment member disposed in the molded polymeric firewall member; at least one reinforcement portion disposed between the cabin inner surface of the cabin dash- mat member and the firewall inner surface of the molded firewall member; at least one through-hole disposed through the cabin dash-mat member, the firewall member and the engine dash-mat member; and at least one component connected to the at least one attachment member and disposed on front of dash assembly composite panel member selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line, wherein the above components are assembled together prior to installation in the motor vehicle.

[0009] This aspect may further be characterized by one or any combination of the following features: the first batting material comprises a polyurethane foam; the polyurethane foam is an open cell foam; the first batting material comprises a fibrous shotty; the firewall base layer intersperses into the EM_T of base layer of the engine dash-mat member by no more than 40% of the EM_T.

[0010] In a second aspect, the present invention contemplates a method of producing an integrated cockpit and front end module assembly for a motor vehicle including the steps of providing a preformed engine dash-mat assembly layer including a porous surface and including at least one aperture for accepting at least one pass through member ; placing the preformed engine dash-mat assembly layer into a firewall mold; placing the at least one pass through member through the at least one aperture; placing at least one reinforcement member into the firewall mold; introducing a resin to the firewall mold on top of the components of steps 1-4, wherein the resin at least partially intersperses into the engine dash-mat assembly layer; forming a firewall assembly from the resin and the components of steps; removing the firewall assembly from the firewall mold; placing the firewall assembly into a secondary mold; introducing a foam resin into the secondary mold on top of the firewall assembly; forming a second firewall assembly from the firewall assembly and the foam resin; removing the second firewall assembly from the secondary mold; providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly.

[0011] This second aspect may further be characterized by one or any combination of the following features: including the steps of providing at least one mounting member for mounting the at least one component to the integrated cockpit and front end module assembly; and placing the at least one mounting member into the firewall mold prior to the introduction of the resin; the at least one mounting member is a center locator for locating the integrated cockpit and front end module assembly to a vehicle body in white; including the step of installing the integrated cockpit and front end module assembly into the motor vehicle via the open space provided by a door side opening; the resin includes a long glass fiber polypropylene; the foam resin includes an expandable polyurethane; including the step of adhesively bonding the integrated cockpit and front end module assembly to the motor vehicle; at least one of the at least one pass through member comprises an electrical connector assembly; including the steps of providing an electrical wiring harness assembly and inserting the electrical wiring harness assembly into the secondary mold such that it is at least partially over molded by the introduction of the foam resin into the secondary mold.

[0012] In a third aspect of the invention, there is contemplated a method of producing an integrated cockpit and front end module assembly for a motor vehicle including the steps of: providing a preformed engine dash-mat assembly layer including a porous surface and including at least one aperture for accepting at least one pass through member ; placing the preformed engine dash-mat assembly layer into a firewall mold; placing the at least one pass through member through the at least one aperture; placing at least one reinforcement member into the firewall mold; introducing a resin to the firewall mold on top of the components of steps 1-4, wherein the resin at least partially intersperses into the engine dash-mat assembly layer; forming a firewall assembly from the resin and the components of steps 1-4; removing the firewall assembly from the firewall mold; providing a preformed cabin dash-mat assembly; attaching the preformed cabin dash-mat assembly to the firewall assembly forming a second firewall assembly from the firewall assembly and the preformed cabin dash-mat assembly; providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly.

[0013] This third aspect may further be characterized by one or any combination of the following features: The method according to claim 15 further including the steps of: providing at least one mounting member for mounting the at least one component to the integrated cockpit and front end module assembly; and placing the at least one mounting member into the firewall mold prior to the introduction of the resin; the at least one mounting member is a center locator for locating the integrated cockpit and front end module assembly to a vehicle body in white; including the step of installing the integrated cockpit and front end module assembly into the motor vehicle via the open space provided by a door side opening; the resin includes a long glass fiber polypropylene.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Fig. 1 depicts an exploded perspective view of an illustrative example according to the teachings of the present invention.

[0015] Fig. 2 depicts a sectional view of an illustrative dash assembly composite panel member according to the teachings of the present invention.

[0016] Fig. 2A depicts another sectional view of an illustrative dash assembly composite panel member according to the teachings of the present invention.

[0017] Fig. 3 depicts a sectional view an illustrative step of the manufacturing process according to the teachings of the present invention.

[0018] Fig. 4 depicts a side view of an illustrative FOD according to the teachings of the present invention.

[0019] Fig. 5 depicts a side view of an illustrative FOD and a vehicle according to the teachings of the present invention.

[0020] Fig. 6 depicts an exploded view of an illustrative FOD and front windshield frame assembly according to the teachings of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention is directed generally to a modular front of dash

(FOD) product and method that allows an off-line build (prior to assembly to the vehicle) and will simplify the assembly line process by eliminating sub-assemblies. As described in the paragraphs below and shown in figures 1-6, the FOD assembly of the present invention is taught.

[0022] The FOD 20 according to the present invention may be comprised of a front of dash assembly composite panel member 100 which include at least the following components: an engine dash-mat 30 (optionally including an engine heat shield); a firewall member 50; and a cabin dash-mat 60. Generally, it is contemplated that the engine dash-mat 30 and the cabin dash-mat 60 are at least coextensive with the firewall member 50, although either mat may be cross- sectionaly larger or smaller than the firewall member 50. Each of these components are described in further detail below, as well as other possible components that may be included within the full FOD 20 assembly. In a later section, the method of assembly and construction of the FOD 20 is discussed.

[0023] The engine dash-mat 30 primarily functions as an initial barrier between the NVH and environmental conditions of the engine compartment and the passenger compartment. The engine dash-mat 30, when assembled to the FOD 20, may be at least partially connectively disposed on an outer surface 22 (engine side surface) of the firewall member. The mat 30 may also fully or partially encompass certain control or communications devices (e.g. wiring harnesses, mechanical, electrical, pneumatic, and/or hydraulic connectors, brake booster units, HVAC components, etc.). The mat may also include grommets 110 that aid in the closing out of these devices. The mat may also include an outer (engine side) layer 32 that includes a covering that functions as a protective heat shield 34. Examples of such heat shields include, but are not limited to, reflective foil (e.g. aluminum foil) and polymeric and/or ceramic based heat reflectors. The heat shield may be a single layer or a multilayer construction.

[0024] In one preferred embodiment, the engine dash-mat 30 is comprised of an engine dash-mat 30 member including (i) a base layer 36 formed of a first batting material, the base layer 36 having an outer surface 32 that faces the engine compartment 70 when installed in the vehicle and an inner surface 38 that faces the passenger compartment 80 when installed in the vehicle, the inner surface 38 having a porous surface, and a total base layer thickness EM_T and (ii) a heat shield layer 34 disposed on the outer surface 32. It is contemplated that the thickness EM_T could range from about 8mm to 50mm or more. Preferably, the thickness EM_T will range from about 10mm to 40mm, more preferably from about 15mm to 35mm, and most preferably from about 20mm to 30mm. It should be appreciated that these thickness ranges may depend upon factors such as packaging envelope, performance requirements, and material selection. It is also preferred that the mat contain through-holes 48 or apertures that allow for any subsequent components (e.g. wiring harnesses, mechanical, electrical, pneumatic, and/or hydraulic connectors, brake booster units, HVAC components, grommets, etc) to traverse the thickness of the mat.

[0025] The engine dash-mat 30 may be constructed of any number of materials, including composite layers of dissimilar materials, examples including expanded polymeric based foams, polymeric plates, artificial and natural fibrous batts (e.g. cotton shotty, polyester batts and/or synthetic fibers, or the like). Examples of preferred materials are as follows: cotton shoddy, fiber glass mixed with polyester, natural fiber and high temperature foam (such as melamine foam). [0026] In one preferred embodiment, the inner surface 38 of the mat has a porous surface. This may be defined as a surface that allows fluid materials to penetrate below the outer layers of the material and into at least a portion of the main body thereof. In one example, an additional barrier layer of material (not shown) is at least partially disposed on or near a portion of the inner surface 38 of the mat to help regulate the porosity of the inner surface. For example, the barrier layer (not shown) may include a film or mesh component that allows a desired amount of penetration of the mat by the firewall member 50 during manufacture of the front of dash assembly composite panel member 100 or to function as an adhesion promoter (discussed in further detail in the method of assembly and construction of the FOD section below). [0027] The firewall member 50 primarily functions a close-out member between the engine compartment 70 and the passenger compartment 80. It also may function to structurally reinforce the front wall 90 of the passenger compartment. It also may include a plurality of through-holes 58, providing pass-though points for any subsequent components. The firewall member 50 may vary in size (e.g. length and width) depending upon the hole in the front wall 90 that it closes-out and preferably completely fills the hole. A plurality of attachment features or mounting member (e.g. screws, nuts, clips, or the like) may be included within and/or projecting from the firewall member. In a preferred embodiment, at least one mounting member is a center locator 52 for locating the FOD to a painted vehicle body in white. It is also contemplated that grommets 110 (e.g. elastomeric grommets) which could be utilized for all the components mounted manually on FOD can also be incorporated into the firewall member 50. The firewall member 50 may include an intrusion beam (not shown) when required by the vehicle structure/NVH requirements. The intrusion beam could be manufactured as apart of the firewall member or a separate component (Steel, Aluminum, Magnesium, Carbon Fiber, Thermoset or Thermoplastic) mechanically or adhesively bonded to the member. [0028] It is contemplated that the firewall member 50 may substantially comprise materials such as polymeric, metallic, carbon fiber, glass fiber, or any combination thereof. It could be a single layer or combination of different layers (e.g. a sandwich) such as aluminum foil, glass fiber, LFI, PU foam, cotton shoddy, polyester and/or polypropylene fiber, natural fiber, glass fiber, TPO, EVA, long-glass fiber polypropylene (LGPP), Epoxy, or any other thermoplastic or thermoset materials. In a preferred embodiment, the firewall member is a polymeric material and even more preferably a filled polymeric material. The filler may include talc, glass and/or carbon fibers, minerals, or any combination thereof. In a non-limiting illustrative example of preferred fillers include: Mica, which may improve parallel and perpendicular reinforcement and balances the elongation, tensile and flex properties versus using the long glass fiber; Wollastonite or milled glass fibers for directional reinforcement which may act similar to mica but much more reinforcement in one direction versus another; CaCO3 and/or wood fibers as a low cost filler with little or no reinforcement function; wood fiber - low cost filler with no reinforcement; Glass or ceramic microspheres, which are balloons that allow a lower density (can be chosen for compressive strength so they stay intact during processing); a mix with the long glass fiber, hemp or other natural fibers so include green content in the filler; including carbon fiber for part of the long glass fiber; carbon nanotubes or graphene which may bring static dissipative capabilities when used in conjunction with the other fillers; aluminum trioxides may be used as flammability co-fillers; metal flakes like aluminum for reinforcement and/or conductivity; and rubber (natural or synthetic), barium sulphate or magnitite which may increase sound deadening. [0029] It is contemplated that the firewall member could be manufactured with various techniques such as: stamped steel, injection molding, compression molding and reaction injection molding.

[0030] In one preferred embodiment, the firewall member 50 includes a firewall base layer 54 formed of a rigid filled polymer. The firewall base layer 54 including (i) a firewall outer surface 56 facing the inner surface 38 of the engine dash-mat member. The firewall base layer also including (ii) a firewall inner surface 58 facing the passenger compartment 80 of the motor vehicle, including surface features to increase a surface area of the firewall inner surface 58 (e.g. surface graining, geometric projections and/or depressions, etc.). The firewall base layer 54 has a wall thickness F_τ that could range from about 1mm to 10mm or more. Preferably, the thickness F_τ will range from about 1mm to 8mm, more preferably from about 2mm to 7mm, and most preferably from about 2mm to 5mm. It should be appreciated that these thickness ranges may depend upon factors such as packaging envelope, performance requirements, and material selection. It is also contemplated that the firewall member 50 may include a plurality of ribs or reinforcement structures (not shown) projecting from the base layer 54.

[0031] In another preferred embodiment, the firewall member 50 includes some or all of the fillers described above in local areas of the base layer 54. This may allow for "tuning" of the member to have desired physical characteristics in certain areas (e.g. sound deadening and/or stiffness or reinforcement) while maintain the overall member 50 properties.

[0032] For example, the addition of a sound deadening filler to various areas of the member 50 is contemplated. Preferably, the sound deadening filler is located in area(s) near the middle (length, width and/or thickness) of the member 50 may be desirable. In a preferred embodiment, the sound deadening filler is present in localized areas of the member 50 in a quantity about 40% or less of the member 50 (by volume), preferably in about 30% or less, more preferably in about 15% or less. It is believed that if an excess of these sound deadening fillers are used, then other desirable properties (e.g. stiffness) may be compromised in the member 50. [0033] In another example, the addition of a reinforcing and or stiffening filler to various local areas of the member 50 is contemplated. Preferably, the stiffening filler is located in localized area(s) near or coextensive with inserts, attachment points, pass-through holes or components and/or where specific load paths may be desired. In a preferred embodiment, the localized stiffening filler is present in about 30% or less of the member 50 (by volume), preferably in about 20% or less, more preferably in about 10% or less. It is believed that if an excess of these stiffening fillers are used, then other desirable properties (e.g. sound deadening) may be compromised in the member 50.

[0034] The cabin dash-mat 60 primarily functions as a NVH barrier between the passenger compartment 80 and the front of the vehicle. The cabin dash-mat 60, when assembled as a part of the front of dash assembly composite panel member 100, may be at least partially connectively disposed on an inner surface 58 (passenger compartment side surface) of the firewall member 50. The mat 60 may be substantially coextensive with the firewall member 50 or extend further than the firewall member 50. The mat may also fully or partially encompass certain control or communications devices (e.g. wiring harnesses, mechanical, electrical, pneumatic, and/or hydraulic connectors, brake booster units, HVAC components, etc.). The mat 60 may also include grommets 110 that aid in the closing out of these devices. [0035] In one preferred embodiment, the cabin dash-mat 60 includes a cabin base layer 62 formed of a second batting material, the cabin base layer 62 having a total thickness CM_T, (0 a cabin outer surface 64 facing the passenger compartment 80 when installed in the motor vehicle, (ii) a cabin inner surface 66 facing the firewall inner surface 58 of the firewall member and at least partially connectively intertwined thereto so that a second mechanical bond is formed over at least part of an firewall and cabin dash-mat interface region, the second mechanical bond being at least partially formed by an interspersion of the cabin inner surface onto the surface features of the firewall inner surface. It is contemplated that the thickness CM_T could range from about 10mm to 50mm or more. Preferably, the thickness CM_T will range from about 10mm to 40mm, more preferably from about 15mm to 35mm, and most preferably from about 20mm to 30mm. It should be appreciated that these thickness ranges may depend upon factors such as packaging envelope, performance requirements, and material selection. It is also preferred that the mat contain through- holes or apertures that allow for any subsequent components (e.g. wiring harnesses, mechanical, electrical, pneumatic, and/or hydraulic connectors, brake booster units, HVAC components, grommets, etc) to traverse the thickness of the mat 60. [0036] The cabin dash-mat 60 may be constructed of any number of materials, including composite layers of dissimilar materials, examples including expanded polymeric based foams, polymeric plates, artificial and natural fibrous batts (e.g. cotton shoddy, polyester batts and/or synthetic fibers, or the like). Examples of preferred materials are similar to that of the engine dash-mat. [0037] As shown in Fig.2A, another view of the possible layering of the front of dash assembly composite panel member 100 is presented. In this example, the cabin dash-mat is shown as a multilayer construction with an intermediate layer 65 between the firewall member and the cabin dash-mat of a commonly used damping material. An example of this dampening material commercially available from Dow Chemical under the Betadamp trademark.

[0038] It is contemplated that the full FOD assembly 20 may include at least one component connected to the at least one attachment member and disposed on front of dash assembly composite panel member 100 selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line. It is also contemplated that any or all of the above components are assembled together prior to installation in the motor vehicle. It is also contemplated, as seen in Fig. 6, that the front of dash assembly composite panel member 100 may be mated to a front window frame assembly 120 and then assembled to the full vehicle. MANUFACTURING METHOD

[0039] A method of manufacturing the full FOD assembly 20, and more specifically the front of dash assembly composite panel member 100 in contemplated by the present invention. It should be appreciated that the steps discussed and described below may be performed an order that varies from those listed and is not intended to limit the scope of the invention. [0040] Generally, the front of dash assembly composite panel member may be defined as the combination of the engine dash-mat 30 (possibly including a heat shield), the firewall member 50 and the cabin dash-mat 60. These components may be joined together by various techniques or combinations thereof, such as over- molding, adhesive bonding, and mechanical fastening. The integrating of these components preferably occurs prior to the installation of the FOD into a vehicle, but it is contemplated that one or more of these components may be added at a later time in the vehicle assembly process.

[0041] It is contemplated that the full FOD will be an amalgamation of components and sub-assemblies, incorporated together for installation into a vehicle as a modular assembly. The main sub-assemblies may include the front of dash assembly composite panel member and any number of components and component assemblies (e.g. wiring harnesses, mechanical, electrical, pneumatic, and/or hydraulic connectors, brake booster units, HVAC components, grommets, etc) that are integral to or later attached to the front of dash assembly composite panel member. Several preferred embodiments and illustrative examples are presented below.

[0042] First focusing on the front of dash assembly composite panel member, it is contemplated that this assembly may be created by a series of over molding, adhesive bonding or mechanical fastening steps. In one preferred method, the engine dash-mat 30 is preformed and placed (nested) in a mold, including any desired other components (e.g. grommets, electrical connectors, reinforcement members, or the like). The firewall member 50 is then formed by over molding a polymer over at least one surface of the mat 30, the firewall member obtaining a near net shape based upon the shape of the mold. The polymer of the firewall member at least partially intertwining with and penetrating the surface of the mat 30. It is contemplated that the mat 30 may include a layer of material that acts to aid in adhesion or to aid/control penetration. This firewall-mat assembly then being taken to a second mold (or remaining in the first mold if it is dual use mold) and placed into the second mold, again with any desired other components. Then a cabin dash-mat is molded over the firewall-mat assembly. The cabin dash-mat 60 is then formed by over molding a polymer over at least one surface of the firewall-mat assembly, the cabin dash-mat 60 obtaining a near net shape based upon the shape of the mold. Adhesion may be obtained by the cabin dash-mat polymer flowing and interlocking with surface features located on the mating surface of the firewall-mat assembly. Once the over molding process is complete, a front of dash assembly composite panel member is formed. It is contemplated, but not preferred, that any one of the components described immediately above may be preformed and attached to one- another by other techniques, such as adhesive bonding or mechanical fastening. [0043] In one preferred embodiment, a method of producing the FOD may include the steps of: 1. providing a preformed engine dash-mat assembly layer including a porous surface and including at least one aperture for accepting at least one pass through member; 2. placing the preformed engine dash-mat assembly layer into a firewall mold; 3. placing the at least one pass through member through the at least one aperture; 4. placing at least one reinforcement member into the firewall mold; 5. introducing a resin to the firewall mold on top of the components of steps 1-4, wherein the resin at least partially intersperses into the engine dash-mat assembly layer; 6. forming a firewall assembly from the resin and the components of steps 1-4; 7. removing the firewall assembly from the firewall mold; 8. placing the firewall assembly into a secondary mold; 9. introducing a foam resin into the secondary mold on top of the firewall assembly; 10. forming a second firewall assembly from the firewall assembly and the foam resin; 11. removing the second firewall assembly from the secondary mold; 12. providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and 13. attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly.

[0044] Optionally, in addition to the above one preferred embodiment, the method may further include the steps of: providing at least one mounting member for mounting the at least one component to the integrated cockpit and front end module assembly; and placing the at least one mounting member into the firewall mold prior to the introduction of the resin. The at least one mounting member may be a center locator for locating the integrated cockpit and front end module assembly to a vehicle body in white. It also may include the step of installing the integrated cockpit and front end module assembly into the motor vehicle via the open space provided by a door side opening. The resin may include a long glass fiber polypropylene or the foam resin includes expandable polyurethane. The method may include the step of adhesively bonding the integrated cockpit and front end module assembly to the motor vehicle. At least one of the at least one pass through member comprises an electrical connector assembly. The method may include the steps of providing an electrical wiring harness assembly and inserting the electrical wiring harness assembly into the secondary mold such that it is at least partially over molded by the introduction of the foam resin into the secondary mold.

[0045] In a second preferred embodiment, a method of producing the FOD may include the steps of: 1. providing a preformed cabin dash-mat assembly layer including a porous surface and including at least one aperture for accepting at least one pass through member; 2. placing the preformed cabin dash-mat assembly layer into a firewall mold; 3. placing the at least one pass through member through the at least one aperture; 4. placing at least one reinforcement member into the firewall mold; 5. introducing a resin to the firewall mold on top of the components of steps 1-4, wherein the resin at least partially intersperses into the cabin dash-mat assembly layer; 6. forming a firewall assembly from the resin and the components of steps 1-4; 7. removing the firewall assembly from the firewall mold; 8. providing a preformed engine dash-mat assembly; 9. attaching the preformed engine dash-mat assembly to the firewall assembly forming a second firewall assembly from the firewall assembly and the preformed engine dash-mat assembly; 10. providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and 11. attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly. [0046] Optionally, in addition to the above second preferred embodiment, the method may further include the steps of: providing at least one mounting member for mounting the at least one component to the integrated cockpit and front end module assembly; and placing the at least one mounting member into the firewall mold prior to the introduction of the resin. The at least one mounting member is a center locator for locating the integrated cockpit and front end module assembly to a vehicle body in white. The method may include the step of installing the integrated cockpit and front end module assembly into the motor vehicle via the open space provided by a door side opening. The resin includes a long glass fiber polypropylene. [0047] In a third preferred embodiment, a method of producing the FOD may include the steps of: 1. providing a preformed firewall member and including at least one aperture for accepting at least one pass through member; 2. placing the preformed firewall member into a engine dash-mat mold; 3. placing the at least one pass through member through the at least one aperture; 4. placing at least one reinforcement member into the engine dash-mat mold; 5. introducing a resin to the mold on top of the components of steps 1-4, wherein the resin at least partially interlocks the engine dash-mat to the preformed firewall member; 6. forming an engine dash-mat/firewall assembly from the resin and the components of steps 1-4; 7. removing the engine dash-mat/firewall assembly from the engine dash-mat mold; 8. providing a preformed cabin dash-mat assembly; 9. attaching the preformed cabin dash-mat assembly to the engine dash-mat/firewall assembly forming a second firewall assembly from the engine dash-mat/firewall assembly and the preformed cabin dash-mat assembly; 10. providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and 11. attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly.

[0048] It is also contemplated that the final assembly may be obtained by modifying the order of construction. For example, any of the major components (firewall, engine and/or cabin dash-mats) may be pre-formed and adhesively and/or mechanically attached to one another in any order. The two examples provided below are intended to illustrate two possible assembly scenarios, but should not be considered limiting as to the possible assembly scenarios of the present invention. EXAMPLE 1

[0049] In a first illustrative example, a FOD assembly is manufactured and installed in a vehicle.

[0050] The process beings with the construction of a front of dash assembly composite panel member, then the addition of various component parts, and finally with the installation of the full FOD into a vehicle. In this example, a compression molding technique is used in forming the firewall member, although other polymer processing techniques are contemplated.

[0051] 1 : a preformed engine dash-mat constructed of a fibrous batt is provided and placed in a firewall member mold. The face that includes the heat shield and the side walls of the mat are nested against the walls on one side of the mold. One face of the mat (which is at least partially porous) is open to the mold cavity. [0052] 2: additional components are added to the mold. In this example, an electrical connector is nested through a hole provided in the dash-mat and a plurality of attachment bolts are added as well. There is a corresponding cavity in the top and bottom of the mold to accept the top of the electrical connector and the bolts. [0053] 3: a plurality of pre-heated ingots of a polypropylene/glass fiber material is laid down in a plurality of positions in the mold, at least partially over the exposed face of the engine dash-mat. [0054] 4: the mold is closed, compressing the pre-heated ingots, causing them to flow, filling the mold and at least partially interspersing into the main body of the engine dash-mat through its porous surface.

[0055] 5: the mold is cooled, causing the now formed polypropylene/glass fiber part to solidify.

[0056] 6: the mold is opened and the engine-mat/firewall member assembly is removed.

[0057] 7: the assembly is placed into a foam mold, were it nests in a pocket that is adapted to hold the assembly.

[0058] 8: additional components are added to the mold. In this example, an electrical wiring harness is strung from one side wall of the foam mold to the opposite side wall.

[0059] 9: the mold is closed and an expandable polyurethane foam is injected into the foam mold. The foam expands, encapsulating the wire harness and flowing into and around any surface features on the firewall member. In an optional step, the engine-mat/firewall member assembly may be treated to enhance the adhesion of the foam (e.g. flame treated, plasma treated, and/or application of an adhesion promoter or adhesive material).

[0060] 10. the foam cures and the foam mold is opened, wherein the front of dash assembly composite panel member is complete.

[0061] 11. the front of dash assembly composite panel member is taken to an assembly station where an instrument panel assembly and a brake booster assembly are attached to the respective attachment bolts to complete the FOD.

[0062] 12: the FOD is transported to the vehicle assembly line where it is installed into the vehicle.

[0063] It should be appreciated that this example is not intended to present all possible processing steps. For example, steps known to one skilled in the art, such as trimming part edges, cleaning flash from the parts, adding other components, bolting/adhering the FOD into the vehicle or the like are assumed.

EXAMPLE 2

[0064] A second illustrative example is similar to Example 1 , and for the sake of brevity, the drawing figures are not shown.

[0065] The process beings with the construction of a front of dash assembly composite panel member, then the addition of various component parts, and finally with the installation of the full FOD into a vehicle. [0066] 1 : a preformed engine dash-mat constructed of an open cell foam is provided and placed in a firewall member mold. The face that includes the heat shield and the side walls of the mat are nested against the walls on one side of the mold. One face of the mat (which is at least partially porous due to the open cell structure) is open to the mold cavity.

[0067] 2: additional components are added to the mold. In this example, an electrical connector is nested through a hole provided in the dash-mat, a plurality of attachment bolts, and a pass-though grommet is added as well. There is a corresponding cavity in the top and bottom of the mold to accept the top of the electrical connector, the grommet and the bolts.

[0068] 3: the mold is closed, a polymer resin is injected into the mold, filling the mold and at least partially interspersing into the main body of the engine dash-mat through its porous surface.

[0069] 4: the mold is cooled, causing the now formed polymer resin to solidify.

[0070] 5: the mold is opened and the engine-mat/firewall member assembly is removed.

[0071] 6: the assembly is placed into an assembly fixture.

[0072] 7: a preformed cabin dash-mat is provided and attached to the engine- mat/firewall member assembly via mechanical and adhesive means, creating the front of dash assembly composite panel member.

[0073] 8. the front of dash assembly composite panel member is taken to another assembly station where an instrument panel assembly and a brake booster assembly are attached to the respective attachment bolts to complete the FOD. [0074] 9: the FOD is transported to the vehicle assembly line where it is installed into the vehicle.

[0075] It should be appreciated that this example is not intended to present all possible processing steps. For example, steps known to one skilled in the art, such as trimming part edges, cleaning flash from the parts, adding other components, bolting/adhering the FOD into the vehicle or the like are assumed. [0076] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0077] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints. [0078] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps.

[0079] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps. All references herein to elements or metals belonging to a certain Group refer to the Periodic Table of the Elements published and copyrighted by CRC Press, Inc., 1989. Any reference to the Group or Groups shall be to the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups. [0080] As used herein the term "polymer" is generic, and can include either or both of the more specific cases of "homo-"and copolymer" and "homo- and copolymerization", respectively.

[0081] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

CLAIMSWhat is claimed is:

1. An integrated cockpit and front end module assembly for use in separating an engine compartment and a passenger compartment of a motor vehicle comprising: a front of dash assembly composite panel member, wherein the member includes: an engine dash-mat member including (i) a base layer formed of a first batting material, the base layer having an outer surface that faces the engine compartment when installed in the vehicle and an inner surface that faces the passenger compartment when installed in the vehicle, the inner surface having a porous surface, and a total base layer thickness EM_T and (ii) a heat shield layer disposed on the outer surface; a molded polymeric firewall member including a firewall base layer formed of a rigid filled polymer, the firewall base layer including (i) a firewall outer surface facing the inner surface of the engine dash-mat member and at least partially connectively intertwined thereto so that a first mechanical bond is formed over at least part of an firewall and engine dash-mat interface region, the first mechanical bond being at least partially formed by an interspersion of the firewall base layer through the porous surface and at least partially into the EM₇ of base layer of the engine dash-mat member, and the firewall base layer also including (ii) a firewall inner surface facing the passenger compartment of the motor vehicle, including surface features to increase a surface area of the firewall inner surface; a cabin dash-mat member including a cabin base layer formed of a second batting material, the cabin base layer having a total thickness CM_T, (■) a cabin outer surface facing the passenger compartment when installed in the motor vehicle, (ii) a cabin inner surface facing the firewall inner surface of the molded firewall member and at least partially connectively intertwined thereto so that a second mechanical bond is formed over at least part of an firewall and cabin dash-mat interface region, the second mechanical bond being at least partially formed by an interspersion of the cabin inner surface onto the surface features of the firewall inner surface; at least one attachment member disposed in the molded polymeric firewall member; at least one reinforcement portion disposed between the cabin inner surface of the cabin dash-mat member and the firewall inner surface of the molded firewall member; at least one through-hole disposed through the cabin dash-mat member, the firewall member and the engine dash-mat member; and at least one component connected to the at least one attachment member and disposed on front of dash assembly composite panel member selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line, wherein the above components are assembled together prior to installation in the motor vehicle.

2. The integrated cockpit and front end module assembly according to claim 1 , wherein the first batting material comprises a polyurethane foam.

3. The integrated cockpit and front end module assembly according to claim 2, wherein the polyurethane foam is an open cell foam.

4. The integrated cockpit and front end module assembly according any of claims 1 through 3, wherein the first batting material comprises a fibrous shoddy.

5. The integrated cockpit and front end module assembly according any of claims 1 through 4, wherein the firewall base layer intersperses into the EM_Tof base layer of the engine dash-mat member by no more than 40% of the EM_T.

6. A method of producing an integrated cockpit and front end module assembly for a motor vehicle including the steps of:

1. providing a preformed engine dash-mat assembly layer including a porous surface and including at least one aperture for accepting at least one pass through member;

2. placing the preformed engine dash-mat assembly layer into a firewall mold;

3. placing the at least one pass through member through the at least one aperture;

4. placing at least one reinforcement member into the firewall mold;

5. introducing a resin to the firewall mold on top of the components of steps 1- 4, wherein the resin at least partially intersperses into the engine dash-mat assembly layer;

6. forming a firewall assembly from the resin and the components of steps 1- 4;

7. removing the firewall assembly from the firewall mold; δ. placing the firewall assembly into a secondary mold;

9. introducing a foam resin into the secondary mold on top of the firewall assembly;

10. forming a second firewall assembly from the firewall assembly and the foam resin;

11. removing the second firewall assembly from the secondary mold;

12. providing at least one component selected from the group consisting of an HVAC assembly, a brake booster, at least one control pedal assembly, at least one electrical wire harness, and at least one brake line; and

13. attaching the at least one component to the second firewall assembly, thus producing an integrated cockpit and front end module assembly.

7. The method according to claim 6 further including the steps of: providing at least one mounting member for mounting the at least one component to the integrated cockpit and front end module assembly; and placing the at least one mounting member into the firewall mold prior to the introduction of the resin.

8. The method according to claim 7, wherein the at least one mounting member is a center locator for locating the integrated cockpit and front end module assembly to a vehicle body in white.

9. The method according to any of claims 6 through 8, including the step of installing the integrated cockpit and front end module assembly into the motor vehicle via the open space provided by a door side opening.

10. The method according to any of claims 6 through 9, wherein the resin includes a long glass fiber polypropylene.

11. The method according to any of claims 6 through 10, wherein the foam resin includes an expandable polyurethane.

12. The method according to claim 9 including the step of adhesively bonding the integrated cockpit and front end module assembly to the motor vehicle.

13. The method according to any of claims 6 through 12, wherein at least one of the at least one pass through member comprises an electrical connector assembly.

14. The method according to any of claims 6 through 13, including the steps of providing an electrical wiring harness assembly and inserting the electrical wiring harness assembly into the secondary mold such that it is at least partially over molded by the introduction of the foam resin into the secondary mold.