This invention is directed at the control of electronics modules in a motor vehicle center console, overhead console, center stack and instrument panel using one or more faceplates which are attachably disassociated from the specific module being controlled, and which, in order to minimize tolerance stack-up, include a faceplate designed to align any pass-through media slots with their corresponding chassis. Thus, the fit and finish of the interior of the vehicle is greatly improved by minimizing the number of faceplates and stack-up tolerances between the periphery of mating components by transferring the tolerances to a bezel that bridges the gap between the faceplate and the pass-through media chassis.
Instrument panels or dashboards for modern vehicles (cars, truck, buses, airplanes, boats, etc.) are generally comprised of a series of modules integrated together to form a rather complex cockpit assembly which may be installed as a single unit into a forward portion of the vehicle occupant space. The instrument panel reinforcement structure serves as a skeleton or support base which various major components to be mounted upon, such as a steering column assembly, pedal assembly, glove box, passenger-side air bag assembly, instrument cluster, entertainment/information system, heating/ventilation/air conditioning (HVAC) unit, radio, tape deck, CD player, clock, and telematics devices such as global positioning systems (GPS). The “center stack” area of the vehicle instrument panel generally is where many of these components are “stacked” so that their controls are within easy reach of the driver. The center stack area may comprise a number of these components in vertical alignment in the center of the instrument panel or may comprise a center console, a separate molded structure that contains the components and extends back between the front seats of the vehicle, to provide additional storage capacity as well as an area for the vehicle shifting lever. More recent designs include an overhead console extending along the length of the vehicle at the center line of the headliner and a floor console that extends back between the rear seats.
With the current demand by consumers for additional comfort features in today's motor vehicles and the proliferation of electronic devices in the vehicle, space in the center console area of the vehicle is at a premium. In addition, the center console area comes under close scrutiny by the vehicle occupants for a pleasing fit of components as well as for ease of access, without confusion, to control the multitude of electronically controlled features.
Today's center console area (which may comprise a overhead console, center stack, and floor console between seats) may include the controls for a wide variety of vehicle functions such as the heating/ventilation/air conditioning (HVAC) system, radio, CD player, global positioning system (GPS), telephone, laptop computer, window raising/lowering mechanism, door lock/unlock mechanism, rear window defogger, rear window wiper, side mirror adjustment mechanism, hood release mechanism, trunk latch, cassette player, fog lights, and numerous other comfort and safety features. To interface the switch controls, faceplates, sockets, connectors, plugs and chassis for this myriad of features, the precise location and tolerancing of many molded and assembled subcomponents is required. Since many of these features are dealer options and sold to the consumer as packages, the assembly plant that manufactures the vehicle must schedule and coordinate a large number of variations of trim panels which may include controls for some or all of the various options. Further, substantial assembly time and labor is expended making the hard connections and testing to ensure that the connections are electronically sound.
The use of hard connections between the faceplates, control switches and chassis for these features results in a large stack-up of tolerances due to the multiplicity of mating components and often yields an uneven and unsightly appearance that does not provide an aesthetically pleasing fit where gaps are uniform and adjoining surfaces are flush with each other.
By incorporating a systems integration approach to the center console area of the vehicle, the controls, displays, vents, and storage content of the audio, HVAC, and multifunction systems can be incorporated into one trim bezel, or “faceplate”. With a single faceplate design, there is a significant improvement in the fit and finish of the vehicle interior since only one mating interface is required between faceplate to instrument panel, rather than a stack-up of multiple mating components; such as the radio, HVAC, multifunction switch bank, and trim bezels. To get the same level of fit and finish craftsmanship using current center stack design component methodology would greatly increase piece and tooling costs due to the additional components required. Further, geometric dimensioning and tolerancing (GD&T) would demand additional molded features in the various components. Additionally, by disassociating the faceplate from electronics modules or chassis (using flex circuits, jumpers or wiring harnesses) it is possible to move the electronics modules in some cases out of the instrument panel. A complete plastic structure for the I/P center stack carrier may then be designed to meet all OEM structural requirements while offering advantages in cost and weight, preferably without the need for metal brackets and reinforcements. The center stack structure can then also be designed to provide additional attachment and packaging opportunities for the radio, HVAC, additional media storage, and cup holder.
Each of the major components and modules assembled into the center stack of the vehicle has its own dimensional tolerances which are built into the design, materials and processes used to manufacture and assemble the component or module. Since plastic parts shrink in size upon molding and cooling, this size reduction must be factored into the design of the component to ensure a pleasing fit. Likewise, metal assemblies, such as a radio chassis, are composed of a series of smaller sub-components fitted together, and bring along a stacking of tolerances from each of the individual components. Matching the shrinkage of plastic parts and the stack-up of tolerances on metal assemblies to provide a predictable fit having no gaps or rattles and reliable electrical connectivity is an ongoing problem in the automotive industry.
What is needed is a center console design (center stack, overhead, between seats, etc.) which provides for the control for a multitude of electronics modules to be incorporated into preferably a single faceplate which is disassociated from the modules it controls in a manner which compensates for tolerance stack-up between mating components, while yielding a pleasing appearance to the vehicle occupants, minimizing aggravating rattles during use and providing more reliable electronic connectivity.
It is an object of the present invention to provide a single faceplate for a center stack or console which includes a multitude of human interfaces to provide greatly improved fit and finish appearance and reduced tolerance stack-up.
It is a further object of the present invention to attachably disassociate the faceplate for a center stack or console from the electronic modules, components or chassis that it interfaces with by using jumpers, flexible flat wire harnesses and the like to allow the location of the faceplate to not be controlled by the positioning of the electronics module, component or chassis.
It is a still further object of the present invention to allow the electronics modules, components and chassis to be located remote from the faceplate, even outside of the center stack area to allow the console structure to be molded entirely of plastic and not require steel brackets or reinforcements.
It is a still further object of the present invention to provide a single aesthetically-pleasing faceplate for a center console area which includes the controls and displays for a multitude of features and which is aligned with a pass-through media slot for a DVD, CD, memory stick, memory disc, cassette and the like.
It is a still further object of the present invention to provide an alignment guide or bezel for pass-through media between the faceplate of the current invention and the corresponding chassis which provides a ramp feature for the pass-through media and transfers the stack-up of tolerances from the periphery of the faceplate of the many mating components to the interface between the single faceplate and the pass-through media chassis.
An improved fit and finish appearance is provided for a vehicle center stack or console by integrating the faceplates for the myriad of features located therein preferably into a single faceplate. The faceplate is separately positioned relative to the individual electronics modules or chassis, and may include a printed circuit board (PCB) which is electronically connected through jumpers, flat wire connectors or other conductive devices to the various chassis. Any tolerance stack-up is transferred to an alignment bezel which fits between the faceplate and a pass-through media slot to ramp the media into place.
For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which like elements are given the same or analogous reference numbers and wherein:
Instrument panel assemblies in current motor vehicles are generally a series of modules assembled to a complex molded plastic or composite substructure. The substructure often is reinforced with metal brackets, cross-car beams or composite moldings containing reinforcing materials. The surface of the substructure may be integrally formed of thermoplastic to form a hard panel and may be covered with a soft thin skin of vinyl, urethane or olefin, backed with a soft foam layer, to yield a plush feeling surface.
The molded plastic substructure is generally injection molded due to its complex and varied shape which may include undercuts, dielocks, ribs, bosses and attachment features. In some instances, other processes such as blow molding, compression molding, structural RIM (glass reinforced) urethane and insert-molding of reinforcing beams and brackets have been used. See, e.g., U.S. Pat. Nos. 5,364,159 and 5,556,153 commonly assigned to the assignee of the present invention and included herein by reference.
Often, due to the multitude of requirements placed on these structures, for instance, to provide controlled crush resistance, to sustain high heat loads without deflection, to provide structural support for the steering column, pedal and air bag assemblies, all styled into a smooth pleasing aesthetic appearance, the structure may comprise a series of major modules fastened together. Generally, these may comprise a cross-car beam and instrument panel retainer, cross-car ducting for the HVAC system and a separate center stack assembly housing. Since there are numerous smaller components and modules subsequently attached to the cross-car structure, it is often impossible to mold all the features, angles, die locks, etc. in a single injection mold.
The instrument panel substructure or retainer, whether it comprises an integrated or separate center stack, requires the use of a relatively rigid thermoplastic to meet the aforementioned requirements. Materials such as polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) blends, polyphenylene oxide, styrene maleic anhydride (SMA), and polypropylene (PP) whether unfilled or filled with talc or glass fibers may fulfill the requirements.
In this invention, preferably either a separate center stack assembly may be attached to a main retainer, or the center stack assembly may be integrally formed as a part of the instrument panel retainer or substructure, to form the mounting openings for components, such as but not limited to, a glove box, radio, CD player, HVAC control module or telematics devices. As this is often the “communications center” of the vehicle, the optimum design must consider such factors as structure, human machine interface, electrical connections and reconfigurability between vehicle platforms.
In addition, while the Figures herein depict an instrument panel center stack area, the present invention is contemplated to provide similar efficiencies in a center floor console or overhead console in a vehicle.
By taking a systems integration approach to the center stack area, the controls, displays, vents and storage center of the audio, HVAC and multi-function systems can be incorporated into, preferably, a single faceplate or trim bezel. With a single faceplate or trim bezel covering this large area, a significant improvement in fit and finish appearance is provided over the prior art of multiple trim plates each attached to the chassis of an electronic component or module resulting in a series of gaps and non-flush conditions due to misalignment. Further, with a single faceplate and the ability to now move some of the modules remote from the their controls, media controls may be moved to higher, more easily accessible positions in the vehicle and provide greater storage space in the vehicle interior. Thus, storage and ergonomics are improved.
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One example of the remote control of an electronics module in the center stack area of a vehicle may be found in International Patent Application PCT/US03/38936, filed Dec. 9, 2003 and entitled “Non-Contact Connection For Electronics Module In Vehicle Center Stack”, assigned to the assignee of the present invention and included herein by reference. This application is directed at the use of infrared signals transmitted from a trim panel or faceplate to the respective electronic module to control the feature without the need for a physical connection.
Turning to
In addition, since such a large variety of features may reside in or be controlled from a center stack or console area of a vehicle, the faceplate 132 may include a “patch” or generic opening 56 which may provide an optional media slot or area to provide control for any of a variety of assembly plant installed options or consumer installed options. Generally, this “patch” would comprise a simple geometric shape closed out with an easily removable cover plate. In one particular embodiment, the “patch” would comprise a large opening into which an electronics device, such as a laptop computer, personal digital assistant (PDA), cell phone, DVD player, etc. may be brought from the home and easily installed on a frequent basis for accessing data or listening/viewing pleasure. Further, this electronics device may also include its own decorative trim bezel that coordinates with the surrounding panel.
The guide or bezel 100 is preferably molded from a soft plastic or rubber (thermoplastic rubber, thermoplastic elastomer, thermoplastic urethane, silicone, etc.). Additionally, a felt or soft plastic seal 102 may be provided to block light and close out any vertical gap in the faceplate slot 150. Optionally, the seal 102 may be co-molded with the guide or bezel 100 into a single article.
Preferably, common four-way and two-way locators for the faceplate, module, instrument panel retainer and center stack structure are positioned as close as possible to the electronics module for the CD, etc. and preferably on the centerline of the CD to minimize variation.
The present invention thus provides an improvement in fit and finish in the console area of a vehicle, and a reduction in part count, weight and cost by disassociating electronics modules from the single faceplate as well as a potential for improving the serviceability of the electronic modules in the center stack or console area of a vehicle.
This application is a continuation of International Application No. PCT/US2005/028579 filed Aug. 12, 2005 and published Feb. 23, 2006 as International Publication No. WO 2006/020782, designating the United States, and which claims benefit of the filing date of U.S. Provisional Application No. 60/601,071 filed Aug. 12, 2004, the teachings of which are incorporated herein by reference.
Number | Date | Country | |
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60601071 | Aug 2004 | US |
Number | Date | Country | |
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Parent | PCT/US05/28579 | Aug 2005 | US |
Child | 11674066 | US |