Integrated modular instrument panel assembly

• US 6,073,987 A
• Filed: 12/28/1998
• Issued: 06/13/2000
• Est. Priority Date: 01/02/1998
• Status: Expired due to Term

• Current Assignee: The Dow Chemical Company (Dow, Inc.), Prince Technology Corporation, Yanfeng Luxembourg Automotive Interior Systems Leasing S.a.r.l.
• Original Assignee: Prince (Wellman Holdings, Inc.)
• Inventors: Wilkinson, James T., Lindberg, Kenneth M., Tittle, Joaquin R., Giba, Richard J., Duesterberg, Marjorie M., Chapman, David L.
• Primary Examiner(s): Dayoan, D. Glenn
• Assistant Examiner(s): Coletta, Lori L.
• Application Number:
  US09/221,493
• Time in Patent Office: 533 Days
• Field of Search: 296/70, 296/194, 296/208, 296/192, 296/191, 180/90
• US Class Current: 296/70
• CPC Class Codes: B62D 25/142 having ventilation channels incorporated therein
• CPC Class Codes: B62D 65/14 the sub-units or components being passenger compartment fittings, e.g. seats, linings, trim, instrument panels

Abstract

A modular instrument panel assembly for a vehicle wherein the assembly includes a base module having a transverse vertical wall located between the occupant compartment and the forward compartment of the vehicle and a transverse horizontal plenum above the wall and acting with the wall to provide structural support. The assembly further includes an air distribution module having an air distribution plenum providing air outlets for selectively distributing air to the occupant compartment, where the plenum provides additional structural support. The two modules are secured to one another and when installed in a vehicle provide structural support for the vehicle body and further provide a separating barrier between the forward compartment and the occupant compartment.

Claims

1. An integrated modular instrument panel assembly for a vehicle body of the type having a forward compartment located toward the front of the vehicle and an occupant compartment located rearward of the forward compartment, the assembly comprising:

a base module having a transverse, generally vertically extending first wall located between the occupant compartment and the forward compartment of the vehicle and a generally horizontally extending second wall, and one or more transverse, generally horizontal plenums disposed on said second wall above said first wall, said horizontal plenum providing structural support to said base module;

an air distribution module having an air distribution plenum defined therein, said air distribution plenum providing one or more air outlets for selectively distributing air from said air distribution plenum to the occupant compartment of the vehicle, said air distribution plenum further providing structural support to said air distribution module; and

wherein said base module and said air distribution module are integrally secured to one another thereby providing structural support for the vehicle body and further provide a separating barrier between the forward compartment and the occupant compartment of the vehicle body when said first wall is secured to the vehicle body.

2. The assembly of claim 1 further comprising a steering column module secured to said base module.

3. The assembly of claim 2 wherein said steering column module is further comprised of:

a steering column assembly providing a steering column having a steering shaft disposed therein, said steering shaft having a steering wheel fixed to a first end of said steering shaft; and

a steering column support having said steering column assembly attached thereto, said steering column support being secured to said base module thereby supporting said steering column assembly relative to said base module.

4. The assembly of claim 1 further comprising an electrical distribution assembly.

5. The assembly of claim 4 wherein said electrical distribution assembly is further comprised of:

a junction box having sockets and connectors therein for receiving and electrically connecting one or more electrical components selected from a group of relays, fuses, connectors, and electronic control modules, said junction box selectively providing electrical and electronic communication between one or more of said components; and

a wire harness having one or more wires therein, and a connector attached to an end of said wire harness, said connector being coordinated with and engageable with one or more sockets and connectors.

6. The assembly of claim 1 further comprising a blower assembly mounted to said base module and coordinated with an inlet aperture of one of said transverse generally horizontal plenums.

7. The assembly of claim 6 wherein said blower assembly is further comprised of:

a housing having an air inlet, an air outlet, and a chamber located intermediate said inlet and said outlet, said air inlet coordinated with and in communication with said inlet aperture; and

a blower motor for drawing air into and forcing air out through said air distribution module, said blower motor being secured to said housing.

8. The assembly of claim 1, said base module further comprising:

a substantially planar elongated generally rectangular plenum top having a first edge;

a generally rectangular plenum bottom having a second edge, said first edge and said second edge being coordinated to provide mating surfaces between said plenum top and said plenum bottom such that a cavity is formed therebetween when said plenum top and said plenum bottom are joined along said mating surfaces;

a platform having said vertically extending first wall and a generally horizontal second wall extending rearward from a top portion of said first wall; and

a pair of generally opposed end brackets coordinated to enclose opposite transverse ends of said plenum top, said plenum bottom, and said platform when said plenum top, said plenum bottom, and said platform are secured to one another, wherein said cavity and said end brackets define one of said generally horizontal plenums.

9. The assembly of claim 1, said air distribution module further comprising:

a front duct assembly;

a rear duct assembly;

a closeout duct assembly; and

a pair of generally opposed end brackets coordinated to enclose opposite transverse ends of said front duct and said rear duct when said front duct, said rear duct, and said pair of end brackets are fixedly secured to one another and thereby forming a distribution plenum having one or more air outlets, at least one of said air outlets having flanges thereon, said closeout duct being removably secured to said flanges of said one of said air outlets.

10. An integrated modular instrument panel assembly for a vehicle body of the type having a forward compartment and an occupant compartment located rearward of the forward compartment, the vehicle body providing an unobstructed passage between the forward compartment and the occupant compartment, the instrument panel assembly comprising:

a base module including a platform having a transverse generally vertical wall coordinated with and attachable to the vehicle body to separate and provide a barrier between the occupant compartment and the forward compartment, said platform further including a transverse generally horizontal wall located above and integrally formed with said generally vertical wall, said base module further including a plenum top and a plenum bottom separately formed and integrally secured to said horizontal wall of said platform, said plenum top and said plenum bottom forming a cavity therebetween;

an air distribution module including a generally rectangular transverse front duct assembly and a generally rectangular transverse rear duct assembly, said front duct assembly and said rear duct assembly being separately formed and integrally secured to one another, said front duct assembly and said rear duct assembly providing a transverse distribution plenum in communication with said cavity formed between said plenum top and said plenum bottom, said air distribution module being integrally secured to said base module prior to attaching said generally vertical wall to the vehicle body;

wherein said base module and said air distribution module provide structural rigidity to the vehicle body when said vertical wall is attached to the vehicle body.

11. The assembly of claim 10 further comprising a steering column module secured to said base module.

12. The assembly of claim 11 wherein said steering column module is further comprised of:

a steering column assembly providing a steering column having a steering shaft disposed therein, said steering shaft having a steering wheel fixed to a first end of said steering shaft; and

a steering column support having said steering column assembly attached thereto, said steering column support being secured to said base module thereby supporting said steering column assembly relative to said base module.

13. The assembly of claim 10 further comprising an electrical distribution assembly.

14. The assembly of claim 13 wherein said electrical distribution assembly is further comprised of:

a junction box having sockets and connectors therein for receiving and electrically connecting one or more electrical components selected from a group of relays, fuses, connectors, and electronic control modules, said junction box selectively providing electrical and electronic communication between one or more of said components; and

a wire harness having one or more wires therein, and a connector attached to an end of said wire harness, said connector being coordinated with and engageable with one or more sockets and connectors.

15. The assembly of claim 10 further comprising a blower assembly mounted to said base module and coordinated with an inlet aperture of one of said transverse generally horizontal plenums.

16. The assembly of claim 15 wherein said blower assembly is further comprised of:

a housing having an air inlet, an air outlet, and a chamber located intermediate said inlet and said outlet, said air inlet coordinated with and in communication with said inlet aperture; and

a blower motor for drawing air into and forcing air out through said air distribution module, said blower motor being secured to said housing.

17. An integrated modular instrument panel assembly for a vehicle body of the type having a forward compartment and an occupant compartment located rearward of the forward compartment, the vehicle body providing an unobstructed passage between the forward compartment and the occupant compartment, the instrument panel assembly comprising:

a generally planar elongated transverse plenum top made of a polymeric material having a peripheral edge;

an elongated generally rectangular transverse plenum bottom made of a polymeric material having a peripheral edge coordinated with a portion of said peripheral edge of said plenum top;

a platform made of a polymeric material and having a generally vertical transverse first wall and a generally horizontal transverse second wall projecting rearward of said first wall, said platform having a peripheral edge about said second wall coordinated with said peripheral edge of one of said plenum top and said plenum bottom, said second wall further providing a lip extending rearward of said coordinated peripheral edge;

a pair of base module end brackets made of polymeric material and coordinated with opposite transverse ends of said plenum top, said plenum bottom, and said second wall of said platform, wherein said plenum top, said plenum bottom, and said platform are secured together about said coordinated peripheral edges and said pair of base module end brackets are secured to said ends, thereby forming a base module;

a generally rectangular transverse front duct assembly made of polymeric material and having a first portion of a transverse distribution duct formed therein, and having a peripheral edge;

a generally rectangular transverse rear duct assembly made of a polymeric material and having a second portion of a transverse distribution duct therein, and having a peripheral edge coordinated with said peripheral edge of said front duct assembly;

a pair of air distribution module end brackets made of a polymeric material and coordinated with opposite transverse ends of said front duct assembly and said rear duct assembly, wherein said front duct assembly and said rear duct assembly are secured together about said coordinated peripheral edges and said pair of air distribution module end brackets are secured to said ends, thereby forming an air distribution module;

wherein said air distribution module is secured to said base module along said lip extending from said second wall of said platform such that an integrated assembly is formed.

18. The assembly of claim 17 further comprising a steering column module secured to said base module.

19. The assembly of claim 18 wherein said steering column module is further comprised of:

a steering column assembly providing a steering column having a steering shaft disposed therein, said steering shaft having a steering wheel fixed to a first end of said steering shaft; and

a steering column support having said steering column assembly attached thereto, said steering column support being secured to said base module thereby supporting said steering column assembly relative to said base module.

20. The assembly of claim 17 further comprising an electrical distribution assembly.

21. The assembly of claim 20 wherein said electrical distribution assembly is further comprised of:

a junction box having sockets and connectors therein for receiving and electrically connecting one or more electrical components selected from a group of relays, fuses, connectors, and electronic control modules, said junction box selectively providing electrical and electronic communication between one or more of said components; and

a wire harness having one or more wires therein, and a connector attached to an end of said wire harness, said connector being coordinated with and engageable with one or more sockets and connectors.

22. The assembly of claim 17 further comprising a blower assembly mounted to said base module and coordinated with an inlet aperture of one of said transverse generally horizontal plenums.

23. The assembly of claim 22 wherein said blower assembly is further comprised of:

a housing having an air inlet, an air outlet, and a chamber located intermediate said inlet and said outlet, said air inlet coordinated with and in communication with said inlet aperture; and

a blower motor for drawing air into and forcing air out through said air distribution module, said blower motor being secured to said housing.