Modification panel for accommodating NFC (near field communication) module

Abstract

The invention provides a modification panel for accommodating an NFC (Near Field Communication) module. An instrument panel assembly includes a substrate configured to be secured to a vehicle body structure. An intermediate structure is secured to the substrate. The intermediate structure includes an opening therethrough and at least one connector extending from a rear side of the intermediate structure adjacent the opening. A near field communication (NFC) module is positioned in the opening of the intermediate structure. An outer panel is secured to the intermediate structure and extends over the opening in the intermediate structure and over the NFC module. The outer panel has an outer surface including a decorative class A surface.

Description

Technical Field

[0001] This disclosure generally relates to near field communication (NFC) modules in vehicles, and more specifically, to an arrangement that does not require a separate bracket for mounting the NFC module adjacent to the dashboard. Background Technology

[0002] Vehicles can utilize NFC modules to allow users to access and operate the vehicle without physical keys. Various mounting arrangements for NFC modules have been developed. Summary of the Invention

[0003] One aspect of this disclosure is an instrument panel assembly for a motor vehicle. The instrument panel assembly includes an instrument panel base plate configured to be fixed to a vehicle body structure in front of the driver's compartment. An intermediate structure is fixed to the base plate, whereby the rear side of the intermediate structure faces the main instrument panel base plate, and the front side of the intermediate structure faces away from the main instrument panel base plate. The intermediate structure includes an opening therethrough and a plurality of hook-type (e.g., snap-fit) connectors extending from the rear side of the intermediate structure around the opening. The instrument panel assembly also includes a near-field communication (NFC) module positioned to align with the opening of the intermediate structure. The NFC module is held by the hook-type connectors. An outer panel is fixed to the intermediate structure and extends above the opening in the intermediate structure and above the NFC module. The outer panel has an inner surface facing the NFC module and an outer surface facing away from the NFC module. At least a portion of the outer surface of the outer panel may include a decorative Class A surface.

[0004] - The intermediate structure may include a molded polymer structure, and the decorative Class A surface of the outer panel may include in-mold particles.

[0005] - The barbed connector may include a snap-fit ​​connector that can be integrally formed with material extending around an opening in the intermediate structure.

[0006] The hook-and-loop fastener connector may include a flexible post structure having a tapered distal surface and a retaining surface that extends laterally from an inner edge portion of the tapered distal surface. During installation of the NFC module, the NFC module may initially engage the tapered distal surface and bend the post structure, after which the post structure snaps back to its unbent shape, wherein the retaining surface engages the surface of the NFC module, thereby holding the NFC module to the intermediate structure.

[0007] The NFC module may have an elongated rectangular shape formed by a peripheral surface extending between the front and rear surfaces of the near field communication (NFC) module. The peripheral surface may include end segments extending between opposing side segments. The intermediate structure may include at least two hook-and-loop fastener connectors adjacent to each side segment of the peripheral surface of the NFC module.

[0008] - The retaining surface of the hook-type snap-fit ​​connector can contact the rear surface of the NFC module.

[0009] - The front side of the intermediate structure may include a surface surrounding an opening in the intermediate structure, the surface being substantially coplanar with the front surface of the NFC module.

[0010] - When the dashboard assembly is installed in a vehicle, the surface of the intermediate structure surrounding the opening may be set at an acute angle relative to a vertical plane. The opening through the intermediate structure may be rectangular and may include upper and lower edges adjacent to the upper and lower edges of the NFC module, respectively. The intermediate structure may include a plurality of upper barb-type snap-fit ​​connectors and a plurality of lower barb-type snap-fit ​​connectors adjacent to the upper and lower edges of the opening through the intermediate structure, respectively. The flexible column structures of the upper barb-type snap-fit ​​connectors and the lower barb-type snap-fit ​​connectors may each define the length and width of their cross-sections, and the width of the lower barb-type snap-fit ​​connectors may be greater than the width of the upper barb-type snap-fit ​​connectors.

[0011] The main instrument panel base plate may include multiple openings and at least one retaining clip structure adjacent to each opening. The intermediate structure may include multiple tapered protrusions projecting from the rear side of the intermediate structure. The tapered protrusions may be disposed in the openings and may engage the retaining clip structures to secure the intermediate structure to the main instrument panel base plate.

[0012] The intermediate structure may include a plurality of upright wall sections having attachment openings therethrough, and the outer panel may include a plurality of connecting structures projecting from the inner surface of the outer panel. The connecting structures may be received in the attachment openings of the intermediate structure.

[0013] The outer panel may include a positioning surface adjacent to the connecting structure, and the positioning surface may engage the upright wall section of the intermediate structure to position the outer panel relative to the intermediate structure, at least in the front-rear direction. The outer panel may include a plurality of positioning posts received in the positioning openings of the intermediate structure to position the outer panel at least vertically relative to the intermediate structure. The connecting structure may include polymer hot-melt pillars that are melt-formed to secure the outer panel to the intermediate structure.

[0014] Another aspect of this disclosure is a method of manufacturing an instrument panel structure for a motor vehicle. The method includes forming a main instrument panel substrate and an intermediate structure. The intermediate structure has an opening therethrough and a plurality of connectors adjacent to the opening. The method also includes forming an outer panel having an outer surface including a decorative Class A surface. An NFC module is secured to the intermediate structure by moving it to engage with the connectors. The method further includes attaching the intermediate structure to the outer panel and attaching the intermediate structure to the main instrument panel substrate.

[0015] - An intermediate structure can be attached to an outer panel using a hot-melt process, thereby bringing the intermediate structure into contact with the outer panel, and then melting at least a portion of the intermediate structure or the outer panel.

[0016] - After the intermediate structure is attached to the outer panel, the NFC module can be fixed to the intermediate structure.

[0017] The method may include electrically connecting the NFC module to the main wiring harness of the dashboard.

[0018] - After the NFC module is fixed to the intermediate structure, the intermediate structure can be attached to the main instrument panel substrate.

[0019] - The intermediate structure may include a polymer material, and the connector may include an integrally formed barbed connector protruding from the rear side of the intermediate structure.

[0020] - The NFC module can be secured to the intermediate structure by causing the NFC module to slidably contact the barbed connector to bend the barbed connector, thereby snapping the NFC module into place, wherein the barbs of the barbed connector engage the surface of the NFC module, thereby holding the NFC module in place on the intermediate structure.

[0021] Another aspect of this disclosure is a motor vehicle including a body structure having an interior space including a driver's compartment. An instrument panel assembly is disposed in the interior space in front of the driver's compartment. The instrument panel assembly includes a main instrument panel base plate fixed to the vehicle body and an intermediate structure fixed to the main instrument panel base plate. The intermediate structure has an opening therethrough and at least one resilient snap-fit ​​connector disposed adjacent to the opening. A near-field communication (NFC) module is fixed to the intermediate structure adjacent to the opening via the at least one resilient snap-fit ​​connector. An outer panel is fixed to the intermediate structure and extends above the opening in the intermediate structure and above the NFC module. The outer panel has an inner surface facing the NFC module and an outer surface facing away from the NFC module, wherein at least a portion of the outer surface includes a decorative Class A surface.

[0022] The NFC module may have a rectangular perimeter, and the opening in the intermediate structure may also be rectangular. The NFC module may be tightly received within the opening in the intermediate structure. The intermediate structure may comprise a polymer material, and the at least one resilient snap-fit ​​connector may comprise a plurality of cantilevered barbed connectors extending from the rear side of the intermediate structure adjacent to at least two opposing side edges of the rectangular opening. The NFC module may be operatively connected to the main dashboard wiring harness via a wire extending from the NFC module to the wiring harness.

[0023] By referring to the following description, claims and drawings, those skilled in the art will further understand and appreciate these and other features, advantages and objectives of the present invention. Attached Figure Description

[0024] In the attached diagram:

[0025] Figure 1 This is a partial perspective view of a portion of a vehicle dashboard according to one aspect of this disclosure;

[0026] Figure 2 It is along Figure 1 A cross-sectional view taken from line II-II;

[0027] Figure 2A yes Figure 2 A magnified fragment view of the connector;

[0028] Figure 3 This is a perspective view of the intermediate structure and NFC module according to one aspect of the present disclosure, showing the rear side of the intermediate structure and NFC module;

[0029] Figure 4This is a partial perspective view of the intermediate structure and NFC module according to one aspect of the present disclosure, showing the front side of the intermediate structure and NFC module;

[0030] Figure 5 This is a partial exploded view showing the rear side of the intermediate structure, where the cover plate is positioned on the intermediate structure before heat fusion;

[0031] Figure 5A It is along Figure 5 A cross-sectional view taken by line VA-VA;

[0032] Figure 5B It is along Figure 5 A cross-sectional view captured by the VB-VB line;

[0033] Figure 6 yes Figure 5 A magnified fragment view of the intermediate structure and a portion of the NFC module; and

[0034] Figure 7 This is a partial cross-sectional view showing the attachment of the intermediate structure to the main instrument panel substrate. Detailed Implementation

[0035] Reference will now be made in detail to the preferred embodiments of this disclosure, examples of which are illustrated in the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. In the drawings, structural elements are depicted not to scale, and some parts are enlarged relative to others for emphasis and understanding purposes.

[0036] Detailed embodiments of the present invention are disclosed herein as requested; however, it should be understood that the disclosed embodiments are merely examples of different and alternative forms in which the invention may be embodied. The accompanying drawings are not necessarily detailed designs; some schematic diagrams may be enlarged or minimized to show a functional overview. Therefore, the specific structural and functional details disclosed herein are not to be construed as limiting, but only as representative bases for teaching those skilled in the art to employ the invention in various ways.

[0037] For the purposes of this description, the terms “up,” “down,” “right,” “left,” “back,” “front,” “vertical,” “horizontal,” and their derivatives should refer to, for example, the following: Figure 1 The concept of orientation is not explicitly stated. However, it should be understood that the concept may present various alternative orientations unless explicitly stated otherwise. It should also be understood that the specific apparatus and processes shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concept defined in the appended claims. Therefore, unless otherwise expressly stated in the claims, the specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered limiting.

[0038] As used herein, the terms “or” and “and / or” when used with two or more listed items mean that any one of the listed items may be used alone, or any combination of two or more listed items may be used. For example, if a composition or device is described as containing or including components A, B, and / or C, the composition or device may contain (including): A only; B only; C only; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C. If a composition or device is described as containing or including components A and / or B and / or C, the composition or device may contain (including): A only; B only; C only; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0039] In this document, relational terms such as first and second, top and bottom are used individually to distinguish one entity or action from another, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprising,” “including,” or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article of manufacture, or apparatus that comprises a list of elements includes not only those elements but may also include other elements not expressly listed or inherent to such process, method, article of manufacture, or apparatus. Without further constraints, an element preceded by “comprising…” does not exclude the presence of additional identical elements in the process, method, article of manufacture, or apparatus that includes said element.

[0040] As used herein, the term "about" means that a quantity, size, formulation, parameter, and other quantity and characteristic is not precise, nor need it to be precise, but may be approximate and / or larger or smaller as required to reflect tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term "about" is used to describe an endpoint of a value or range, this disclosure should be understood to include both the specific value and the mentioned endpoint. Whether or not the endpoints of numerical values ​​or ranges in this specification are referred to as "about," the endpoints are intended to include both embodiments: one modified by "about" and one not modified by "about." It should also be understood that the endpoints of each of the ranges are significant both in relation to and independent of the other endpoint.

[0041] As used herein, the terms “substantially,” “basically,” and variations thereof are intended to indicate that the described feature is equal to or approximately equal to the value or description. For example, a “substantially planar” surface is intended to indicate a planar or approximately planar surface. Furthermore, “substantially” is intended to indicate that two values ​​are equal or approximately equal. In some embodiments, “substantially” may indicate that the values ​​are within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0042] Unless explicitly indicated otherwise, as used herein, the terms “the,” “an,” or “a” mean “at least one” and should not be limited to “only one.” Thus, for example, unless the context clearly indicates otherwise, references to “component” include embodiments having two or more such components.

[0043] refer to Figure 1 The motor vehicle 1 may include a body structure 2 having an interior space 3, the interior space including a driver's space 4. A steering wheel 5, a display screen 6, and an instrument panel 7 may be positioned in the interior space 3, adjacent to or in front of the driver's space 4. As discussed in more detail below, the instrument panel assembly 7 may include a near-field communication (NFC) module 10 mounted to an intermediate structure 12 behind an outer cover 14. The NFC module 10 may be positioned between the steering wheel 5 and the display screen 6. The NFC module 10 may include a known device configured to allow a user to enter and / or operate the motor vehicle 1 without using a conventional key. NFC modules are well known in the art. Therefore, a more detailed description of the functionality of the NFC module is not considered necessary.

[0044] Further reference Figure 2 During assembly, the front surface 17 of the NFC module 10 may be spaced apart from the rear surface 18 of the cover plate 14 to form a gap 16. The front surface 17 of the NFC module 10 is preferably spaced apart from the front surface or outer surface 19 of the cover plate 14 by a distance “D”. The distance D is preferably no more than about 10 mm. However, the distance D may be greater than 10 mm. At least a portion of the outer surface 19 of the cover plate 14 may include a Class A surface, which may include in-mold particle lamination (IMGL) or plastic-encapsulated components. The NFC module 10 may include components with a socket 13 ( Figure 3 The cable 11, the socket of which operatively connects the NFC module 10 to the dashboard wiring harness 15.

[0045] Further reference Figures 3 to 5 The NFC module 10 is held in or aligned with an opening 22 in an intermediate structure 12 via multiple connectors 20A and 20B, which may include barbed connectors. As discussed below, the intermediate structure 12 may include compression ribs 28 that engage the NFC module 10 to prevent movement of the NFC module 10 in the direction of arrow "V". Connectors 20A and 20B may include barbed snap-fit ​​structures in the form of flexible pillar structures having tapered distal surfaces 24A and 24B, respectively. Figure 2AConnectors 20A and 20B also include retaining surfaces 25A and 25B, respectively, which extend laterally from inner edges 26A and 26B. As discussed in more detail below, during the mounting of the NFC module 10 to the intermediate structure 12, the NFC module 10 initially engages (e.g., contacts) the tapered surfaces 24A and 24B and bends the column structures 20A and 20B, after which the column structures snap back to their unbent shape, wherein retaining surfaces 26A and 26B engage the rear surface 27 of the NFC module 10 at edge portions 27A and 27B, respectively. Figure 2 The intermediate structure 12 may include a molded polymer material, and the connectors 20A and 20B are preferably integrally formed with the intermediate structure 12.

[0046] like Figure 4 and Figure 6 As shown, the opening 22 through the intermediate structure 12 may have a generally rectangular shape, having an upper edge 22A, a lower edge 22B, and end edges 22C and 22D. The NFC module 10 has a generally rectangular peripheral shape, having an upper surface segment 10A, a lower surface segment 10B, and end surface segments 10C and 10D. Surface segments 10A to 10D extend between the front surface 17 and the rear surface 27 of the NFC module 10. The intermediate structure 12 may include a plurality of positioning structures, such as compression ribs 28, which engage surfaces 10A and 10B of the NFC module 10 to vertically position the NFC module 10 within the opening 22 of the intermediate structure 12. The compression ribs 28 may be configured to provide an interference fit with surfaces 10A and 10B of the NFC module 10 to prevent the NFC module 10 from being positioned within the opening 22 in the shape of arrow "V" (…). Figure 2 The NFC module 10 is moved in the direction of the opening 22 of the intermediate structure 12, thereby being securely positioned within the opening 22. The edge 22C of the opening 22 may include a stop surface 29. Figure 4 The stop surface engages the end surface 10C of the NFC module 10, thereby horizontally positioning the NFC module 10 in the opening 22 and preventing movement of the NFC module 10 in the direction of arrow "H". The NFC module 10 may have a known design including flanges 31A and 31B with openings 30A and 30B respectively, to provide mounting of the NFC module 10 using threaded fasteners. However, given the connectors 20A and 20B and the positioning structure, threaded fasteners are not required, so that, according to one aspect of this disclosure, threaded fasteners and mounting openings 30A and 30B are generally not utilized. However, threaded fasteners (not shown) may be used in openings 30A and / or 30B. Figure 4As shown, the intermediate structure 12 may include an opening 32 adjacent to the connector 20B. When the NFC module 10 is installed, the front surface 17 of the NFC module 10 is preferably substantially coplanar with the front surface 21 of the intermediate structure 12 in the area surrounding the opening 22 of the intermediate structure 12.

[0047] refer to Figure 4 and Figure 5 The intermediate structure 12 includes a plurality of upright surface portions 35A to 35E on its front side 36. Openings 37A to 37E are respectively located on the upright surface portions 35A to 35E. Surfaces 35A to 35E may be flat. The intermediate structure 12 also includes a pin opening 38.

[0048] refer to Figure 4 When the instrument panel 7 is fully assembled, the first portion 21A of the surface 21 of the intermediate structure 12 can be positioned behind the cover 14. During assembly, the end edge 14A of the cover 14 can abut the upright end plate 12A of the intermediate structure 12, thereby exposing the surface 21B of the intermediate structure 12. Surface 21B is preferably a Class A surface, and surface 21A is preferably a non-Class A surface. For example, surface 21B may optionally include IMGL to match the outer surface 19 of the cover 14.

[0049] refer to Figure 5 During assembly, the posts 40A to 40E of the cover plate 14 are inserted into the openings 37A to 37E of the intermediate structure 12, and the locating pins 44A and 44B of the cover plate 14 are respectively positioned in the pin openings 38A and 38B. Pins 44A and 44B can be tightly received in the pin openings 38A and 38B, respectively, thereby accurately positioning the cover plate 14 relative to the intermediate structure 12 in a plane transverse to the axes of pins 44A and 44B. (Reference) Figure 5A When assembling the intermediate structure 12 and the cover plate 14, the end surface 42 of the rib 41 contacts the surface 35 of the adjacent opening 37 of the intermediate structure 12, and the end surface 46 of the rib 45 of the pin 44 contacts the surface 39 of the adjacent pin opening 38 of the intermediate structure 12, thereby positioning the cover plate 14 relative to the intermediate structure 12 in the front-rear direction. It should be understood that, for clarity, the area between surfaces 35 and 42 is shown (…). Figure 5A ) and between surfaces 39 and 46 ( Figure 5B Small gaps exist between the intermediate structure 12 and the cover plate 14, but these gaps are preferably absent when the intermediate structure 12 and the cover plate 14 are fully assembled. After the intermediate structure 12 and the cover plate 14 are positioned relative to each other, the ends of the column 40 are melted (thermally melted) to form deformable retaining portions 43, thereby firmly interconnecting the intermediate structure 12 and the cover plate 14.

[0050] refer to Figure 3 and Figure 7The intermediate structure 12 includes a plurality of upright surfaces 50 and an attachment surface 49 protruding from the upright surfaces 50. The attachment structure 49 includes upright sidewalls 59 and horizontal walls 58 extending between the upright sidewalls 59. The upright sidewalls 59 include a positioning surface 60 and an end portion 59A.

[0051] refer to Figure 7 The intermediate structure 12 is secured to the main instrument panel base 55 by inserting the end portion 59A of the attachment structure 49 of the intermediate structure 12 into the opening 52 of the main instrument panel base 55. During assembly, the clip 62 engages the horizontal wall 58 of the attachment structure 49 to securely attach the intermediate structure 12 to the main instrument panel base 55. The clip 62 may include a conventional medium-holding-force polymer clip. During installation, the end surface 60 of the upright sidewall 59 of the attachment structure 49 engages the front surface 61 of the main instrument panel base 55. Figure 7 The intermediate structure 12 is positioned relative to the base plate 55 in the front-rear direction. The end portion 59A of the attachment structure 49 can be tightly received in the opening 52 in the main instrument panel base plate 55, thereby positioning the intermediate structure 12 relative to the main instrument panel base plate 55. During assembly, the rear side (e.g., surface 2) of the intermediate structure 12 faces the main instrument panel base plate 55, and the front side (e.g., surface 21) of the intermediate structure 12 faces away from the main instrument panel base plate 55. The main instrument panel base plate 55 can be fixed to the vehicle body structure 2, thereby fixing the intermediate structure 12 and the cover plate 14 relative to the vehicle body structure 2.

[0052] The intermediate structure 12, cover plate 14, and main instrument panel substrate 55 may comprise a monolithically molded polymer structure. During assembly, the intermediate structure 12 and cover plate 14 may be interconnected, and the pillar 40 may be heat-fused as described above. The NFC module 10 can then be snapped into place in the opening 22 of the intermediate structure 12. For example, the NFC module 10 may be positioned adjacent to the rear side 48 of the intermediate structure 12, and the NFC module 10 may be displaced into the opening 22, whereby connectors 20A and 20B of the intermediate structure 12 engage the NFC module 10, and the NFC module 10 is then snapped into place in the opening 22, thereby securing the NFC module 10 to the intermediate structure 12. The cable 11 of the NFC module 10 can then be connected to the wiring harness 15 using a suitable connector (such as a socket 13). Figure 3 Then, the intermediate structure 12 can be fixed to the main instrument panel base plate 55 by inserting the attachment structure 49 of the intermediate structure 12 into the opening 52 of the main instrument panel base plate 55. Then, the assembly (NFC module 10, intermediate structure 12, cover plate 14 and main instrument panel base plate 55) can be fixed to the body structure 2.

[0053] Because the intermediate structure 12 includes connectors 20A and 20B that allow the NFC module 10 to be secured to the intermediate structure 12 without the use of threaded fasteners, the intermediate structure 12 eliminates the need for separate brackets, threaded fasteners and other such connection features.

[0054] It should be understood that changes and modifications may be made to the foregoing structure without departing from the concept of the invention, and it should also be understood that such concept is intended to be covered by the appended claims unless the language of those claims expressly specifies otherwise.

[0055] According to the present invention, an instrument panel assembly for a motor vehicle is provided, the instrument panel assembly comprising: a main instrument panel base plate configured to be fixed to a vehicle body structure adjacent to a driver's space; an intermediate structure fixed to the main instrument panel base plate, wherein a rear side of the intermediate structure faces the main instrument panel base plate and a front side of the intermediate structure faces away from the main instrument panel base plate, the intermediate structure including an opening therethrough and a plurality of barbed connectors extending from the rear side of the intermediate structure around the opening; a near field communication (NFC) module positioned aligned with the opening of the intermediate structure, wherein the NFC module is held by the barbed connectors; and an outer panel fixed to the intermediate structure and extending over at least a portion of the intermediate structure including the opening and over the NFC module, the outer panel having an inner surface facing the NFC module and an outer surface facing away from the NFC module, wherein at least a portion of the outer surface includes a decorative Class A surface.

[0056] According to an embodiment, the decorative Class A surface of the outer panel includes in-mold particles.

[0057] According to an embodiment, the dashboard assembly includes a molded polymer structure; and the barbed connector includes a barbed snap-fit ​​connector integrally formed with the polymer material of the intermediate structure.

[0058] According to an embodiment, the barbed snap-fit ​​connector includes a flexible post structure having a tapered distal surface and a retaining surface. The retaining surface extends laterally from the inner edge of the tapered distal surface, whereby during installation of the NFC module, the NFC module initially engages the tapered distal surface and bends the post structure, subsequently snapping the post structure back to an unbent shape, wherein the retaining surface engages the surface of the NFC module, thereby holding the NFC module in the opening to the intermediate structure.

[0059] According to an embodiment, the NFC module has an elongated rectangular shape formed by a peripheral surface extending between the front and rear surfaces of the NFC module, the peripheral surface including end segments extending between opposite side segments; and the intermediate structure includes at least two barbed snap-fit ​​connectors adjacent to each side segment of the peripheral surface of the NFC module.

[0060] According to an embodiment, the retaining surface of the hook-type snap-fit ​​connector contacts the rear surface of the NFC module.

[0061] According to an embodiment, the front side of the intermediate structure includes a surface surrounding the opening in the intermediate structure, the surface being coplanar with the front surface of the NFC module; the intermediate structure includes an upright end panel having a Class A surface not covered by the outer panel.

[0062] According to an embodiment, the surface of the intermediate structure surrounding the opening is set at an acute angle relative to a vertical plane; the opening through the intermediate structure is rectangular and includes an upper edge and a lower edge adjacent to the upper and lower edges of the NFC module, respectively; and the intermediate structure includes a plurality of upper barb-type snap-fit ​​connectors and a plurality of lower barb-type snap-fit ​​connectors adjacent to the upper and lower edges of the opening through the intermediate structure, respectively, wherein the flexible column structure of the upper barb-type snap-fit ​​connector and the lower barb-type snap-fit ​​connector each defines a cross-sectional length and width, and wherein the width of the lower barb-type snap-fit ​​connector is greater than the width of the upper barb-type snap-fit ​​connector.

[0063] According to an embodiment, the main instrument panel base plate includes a plurality of openings and at least one retaining clip structure adjacent to each opening; and the intermediate structure includes a plurality of tapered protrusions projecting from the rear side of the intermediate structure, wherein the tapered protrusions are disposed in the openings of the main instrument panel base plate and engage the retaining clip structure to secure the intermediate structure to the main instrument panel base plate.

[0064] According to an embodiment, the intermediate structure includes a plurality of upright wall sections having attachment openings therethrough; and the outer panel includes a plurality of connecting structures projecting from the inner surface of the outer panel, wherein the connecting structures are received in the attachment openings of the intermediate structure.

[0065] According to an embodiment, the outer panel includes a positioning surface adjacent to the connecting structure, wherein the positioning surface engages the upright wall section of the intermediate structure to position the outer panel relative to the intermediate structure at least in the front-back horizontal direction; the outer panel includes a plurality of positioning posts received in positioning openings in the intermediate structure to position the outer panel at least vertically relative to the intermediate structure; and the connecting structure includes polymer hot-melt pillars that are melt-formed to secure the outer panel to the intermediate structure.

[0066] According to the present invention, a method of manufacturing an instrument panel structure for a motor vehicle includes: forming a main instrument panel substrate; forming an intermediate structure having an opening therethrough and a plurality of connectors adjacent to the opening; forming an outer panel having an outer surface including a decorative Class A surface; securing an NFC module to the intermediate structure by moving the NFC module to engage with the connectors; attaching the intermediate structure to the outer panel; and attaching the intermediate structure to the main instrument panel substrate.

[0067] In one aspect of the invention, the intermediate structure is attached to the outer panel using a hot-melt process, thereby bringing the intermediate structure and the outer panel into contact, and then melting at least a portion of the intermediate structure and / or the outer panel.

[0068] In one aspect of the invention, after the intermediate structure is attached to the outer panel, the NFC module is fixed to the intermediate structure.

[0069] In one aspect of the invention, the method includes: electrically connecting the NFC module to a wiring harness of the dashboard.

[0070] In one aspect of the invention, after the NFC module is fixed to the intermediate structure, the intermediate structure is attached to the main instrument panel substrate.

[0071] In one aspect of the invention, the intermediate structure comprises a molded polymer, and the connector comprises an integrally molded barbed connector projecting from the rear side of the intermediate structure.

[0072] In one aspect of the invention, the NFC module is secured in the opening of the intermediate structure by causing the NFC module to slidably contact the barbed connector to bend the barbed connector, thereby snapping the NFC module into place, wherein the barbs of the barbed connector engage the surface of the NFC module, thereby holding the NFC module in place on the intermediate structure.

[0073] According to the present invention, a motor vehicle is provided, comprising: a body structure having an interior space including a driver's compartment; an instrument panel assembly disposed in the interior space in front of the driver's compartment, the instrument panel assembly including: a main instrument panel base plate fixed to the body; an intermediate structure fixed to the main instrument panel base plate, the intermediate structure having an opening therethrough and at least one resilient snap-fit ​​connector disposed adjacent to the opening; an NFC module fixed to the intermediate structure via the at least one resilient snap-fit ​​connector adjacent to the opening; and an outer panel fixed to the intermediate structure and extending above the opening in the intermediate structure and above the NFC module, the outer panel having an inner surface facing the NFC module and an outer surface facing away from the NFC module, wherein at least a portion of the outer surface includes a decorative Class A surface.

[0074] According to an embodiment, the NFC module has a rectangular perimeter; the opening is rectangular, and the NFC module is tightly received in the opening; the intermediate structure comprises a polymer, and the at least one resilient snap connector comprises a plurality of cantilevered barbed connectors, the plurality of cantilevered barbed connectors extending from the rear side of the intermediate structure adjacent to at least two opposite side edges of the rectangular opening; and the NFC module is connected to the dashboard wiring harness via a wire extending from the NFC module to the dashboard wiring harness.

Claims

1. An instrument panel assembly for a motor vehicle, the instrument panel assembly comprising: A main instrument panel base plate, the main instrument panel base plate being configured to be fixed to a vehicle body structure adjacent to the driver's space; An intermediate structure is fixed to the main instrument panel base plate, wherein the rear side of the intermediate structure faces the main instrument panel base plate and the front side of the intermediate structure faces away from the main instrument panel base plate. The intermediate structure includes an opening therethrough and a plurality of barbed connectors extending from the rear side of the intermediate structure around the opening. A near field communication (NFC) module, the NFC module being positioned aligned with the opening of the intermediate structure, wherein the NFC module is held by the barbed connector; as well as An outer panel is fixed to the intermediate structure and extends over at least a portion of the opening in the intermediate structure and over the NFC module, the outer panel having an inner surface facing the NFC module and an outer surface facing away from the NFC module, wherein at least a portion of the outer surface includes a decorative Class A surface.

2. The instrument panel assembly as claimed in claim 1, wherein: The decorative Class A surface of the outer panel includes in-mold particles.

3. The instrument panel assembly as claimed in claim 1 or claim 2, wherein: The dashboard assembly includes a molded polymer structure; and The barbed connector includes a barbed snap-fit ​​connector, which is integrally formed with the polymer material of the intermediate structure.

4. The instrument panel assembly as claimed in any one of claims 1 to 3, wherein: The hook-and-loop fastener connector includes a flexible post structure having a tapered distal surface and a retaining surface. The retaining surface extends laterally from the inner edge of the tapered distal surface, whereby during installation of the NFC module, the NFC module initially engages the tapered distal surface and bends the post structure, after which the post structure snaps back to its unbent shape, wherein the retaining surface engages the surface of the NFC module, thereby holding the NFC module in the opening to the intermediate structure.

5. The instrument panel assembly as claimed in any one of claims 1 to 4, wherein: The NFC module has an elongated rectangular shape formed by a peripheral surface extending between the front and rear surfaces of the NFC module, the peripheral surface including end segments extending between opposite side segments; and The intermediate structure includes at least two barbed snap-fit ​​connectors for each side segment of the peripheral surface adjacent to the NFC module.

6. The instrument panel assembly as claimed in any one of claims 1 to 5, wherein: The retaining surface of the hook-type snap-fit ​​connector contacts the rear surface of the NFC module.

7. The instrument panel assembly as claimed in any one of claims 1 to 6, wherein: The front side of the intermediate structure includes a surface surrounding the opening in the intermediate structure, the surface being coplanar with the front surface of the NFC module; The intermediate structure includes an upright end panel having a Class A surface not covered by the outer panel.

8. The instrument panel assembly as claimed in any one of claims 1 to 7, wherein: The surface of the intermediate structure surrounding the opening is set at an acute angle relative to the vertical plane; The opening through the intermediate structure is rectangular and includes an upper edge and a lower edge adjacent to the upper and lower edges of the NFC module, respectively; and The intermediate structure includes a plurality of upper barb-type snap-fit ​​connectors and a plurality of lower barb-type snap-fit ​​connectors adjacent to the upper edge and the lower edge of the opening passing through the intermediate structure, respectively. The flexible column structure of the upper barb-type snap-fit ​​connectors and the lower barb-type snap-fit ​​connectors each defines a cross-sectional length and width, and the width of the lower barb-type snap-fit ​​connectors is greater than the width of the upper barb-type snap-fit ​​connectors.

9. The instrument panel assembly as claimed in any one of claims 1 to 8, wherein: The main instrument panel base plate includes multiple openings and at least one retaining clip structure adjacent to each opening; and The intermediate structure includes a plurality of tapered protrusions projecting from the rear side of the intermediate structure, wherein the tapered protrusions are disposed in the opening of the main instrument panel substrate and engage the retaining clip structure to secure the intermediate structure to the main instrument panel substrate.

10. The instrument panel assembly as claimed in any one of claims 1 to 9, wherein: The intermediate structure includes multiple upright wall sections, each having an attachment opening passing through it; and The outer panel includes a plurality of connecting structures projecting from the inner surface of the outer panel, wherein the connecting structures are received in the attachment opening of the intermediate structure.

11. The instrument panel assembly as claimed in any one of claims 1 to 10, wherein: The outer panel includes a positioning surface adjacent to the connecting structure, wherein the positioning surface engages the upright wall section of the intermediate structure to position the outer panel relative to the intermediate structure at least in the front-back horizontal direction; The outer panel includes a plurality of positioning posts, which are received in positioning openings in the intermediate structure to position the outer panel at least vertically relative to the intermediate structure; and The connection structure includes a polymer hot-melt column, which is melted and shaped to secure the outer panel to the intermediate structure.

12. A method for manufacturing an instrument panel structure for a motor vehicle, the method comprising: Forming the main instrument panel substrate; An intermediate structure is formed having an opening therethrough and a plurality of connectors adjacent to the opening; An outer panel is formed, the outer panel having an outer surface including a decorative Class A surface; The NFC module is secured to the intermediate structure by moving it to engage with the connector; Attach the intermediate structure to the outer panel; as well as The intermediate structure is attached to the main instrument panel base plate.

13. The method of claim 12, wherein: The intermediate structure is attached to the outer panel using a hot-melt process, thereby bringing the intermediate structure and the outer panel into contact, and then at least a portion of the intermediate structure and / or the outer panel is melted.

14. The method of any one of claims 12 and 13, wherein: After the intermediate structure is attached to the outer panel, the NFC module is fixed to the intermediate structure.

15. The method according to any one of claims 12 to 14, wherein: After the NFC module is fixed to the intermediate structure, the intermediate structure is attached to the main instrument panel substrate; The NFC module is secured in the opening of the intermediate structure by causing the NFC module to slide into the barbed connector, thereby bending the barbed connector and snapping the NFC module into place. The barbs of the barbed connector engage the surface of the NFC module, thus holding the NFC module in place on the intermediate structure.

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