Patent Application
20060232055
The present invention relates generally to a lower instrument panel support structure for an automotive vehicle.
The current technology for managing occupant kinetic energy of a passenger during a crash within the structural support for a lower instrument panel assembly involves the use of energy absorbing metal stampings. These stampings are attached to a member reaction surface within the vehicle and extend to the top area of the compartment surround. At the top of the compartment surround, the stampings are attached to a component of the member reaction surface assembly that outlines the compartment cover opening.
Upon impact by an occupant within the vehicle, the compartment cover assembly transfers the load to the lower instrument panel support structure, which in turn transfers the load to the energy absorbing metal stampings which collapse against the member reaction surface assembly. The occupant kinetic energy is dissipated through the collapse of the energy absorbing stampings. This technology creates inherent inefficiency of support when an impact occurs between the metal stampings. To compensate for this, prior technology uses additional and/or larger metal stampings.
This system performs at a cost penalty due to the number of parts, assembly complexity, added weight, and added tooling. Further, the present technology is hindered because the energy absorbing stampings are placed in a localized area of the instrument panel. The energy absorption of the metal stampings is less efficient when the impact of the occupant on the lower instrument panel is not aligned with the localized positioning of the energy absorbing metal stampings.
Therefore, there is a need for a lower instrument panel structural support that provides efficient energy absorption that is not dependant upon the position of the occupant knee impact, and provides a less complex, cost effective energy absorbing structure.
The present invention provides a lower instrument panel assembly for an automotive vehicle comprising a compartment surround mounted within a vehicle instrument panel, a lower compartment cover mounted over the compartment surround, and an energy absorbing structure mounted between the compartment surround and a member reaction surface within the vehicle, the energy absorbing structure being aligned between the member reaction surface and the compartment surround perpendicular to the load vector of an occupant frontal impact on the lower instrument panel assembly from within the vehicle.
In one aspect, the energy absorbing structure is a single piece component that may span the entire width of the compartment cover. In another aspect, the energy absorbing structure is generally hollow and includes a plurality of structural ribs spaced evenly therein. In still another aspect, the structural ribs within the energy absorbing structure are oriented along the line of loading between the compartment surround and the member reaction surface. The distal ends of the structural ribs within the energy absorbing structure are contoured to match the shape of the member reaction surface and are positioned at a distance from the member reaction surface such that a gap is defined therebetween.
In yet another aspect, the energy absorbing structure can be attached to the compartment surround or integrally formed with the compartment surround, or alternatively, the energy absorbing structure can be attached to a substrate layer of the instrument panel or integrally formed with a substrate layer of the instrument panel, additionally the energy absorbing structure can be attached directly to the member reaction surface.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
Referring to
Referring to
The energy absorbing structure 18 may be attached to the compartment surround 14 or formed integrally with the compartment surround 14, as shown in
If the energy absorbing structure 18 is integrally formed with either the compartment surround 14 or the substrate layer 28 of the instrument panel 12, then the energy absorbing structure 18 is made from the same material as the compartment surround 14 or the substrate layer 28 of the instrument panel 12. If the energy absorbing structure 18 is mounted onto the compartment surround 14 or the substrate layer 28 of the instrument panel 12, then the energy absorbing structure 18 may be made from plastic or any other suitable material that has appropriate structural characteristics. The energy absorbing structure 18 can be attached to the compartment surround 14 or the substrate layer 28 of the instrument panel 12 by mechanical means, adhesive, welded or any other conventional attachment method.
Referring to
The uniformity of the structural ribs 30 spaced within the hollow energy absorbing structure 18a, provides steady energy transfer of the impact loads to the member reaction surface 20, thereby eliminating load spikes and providing a consistent force response. The quantity, size, shape, and material of the structural ribs 30 can be varied to accommodate different types of loads and to provide different types of response in managing the transfer of energy to the member reaction surface 20.
Distal ends 32 of the structural ribs 30 within the energy absorbing structure 18a are contoured to match the shape of the member reaction surface 20. Referring to
The energy absorbing structure 18 can also be made from more than one piece, such as the energy absorbing structure 18c shown in
Referring again to
The foregoing description of the embodiments described herein has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
