Plastic modular construction instrument panel

Abstract

Embodiments of the present disclosure relate to a plastic modular structural instrument panel. In some examples, a method of manufacturing an integrated vehicle body structure includes forming a unitary molded plastic panel that defines a vehicle barrier extending across at least a portion of a vehicle cabin width. The unitary molded plastic panel integrates an instrument panel structure and a cowl structure for a vehicle. The method includes attaching components to the panel and installing it into a vehicle. The panel can incorporate HVAC ducting, pre-assembled NVH panels on the wet and dry sides, connection points for vehicle systems, reinforcement ribs, embedded glass fiber, and molded datum pins. The vehicle body structure includes the unitary molded plastic panel that, when installed into a vehicle, provides an integrated instrument panel and cowl structure that forms a barrier between the passenger cabin and external elements. The structure can include pre-assembled NVH panels across the vehicle cabin width, integrated connection points for vehicle systems, and channels for perimeter seals.

Description

Technical Field

[0001] This disclosure generally relates to vehicle body structures, and more specifically to integral plastic structural assemblies for defining a barrier between a passenger compartment and external elements within a vehicle. Some examples include integral molded plastic panels that integrate an instrument panel and a front bulkhead into a unified structure for the vehicle. Some more specific examples also integrate thermal management, noise reduction, and one or more component mounting features into the structural assembly, which may define a barrier across and along at least a portion of the width of the vehicle compartment. Background Technology

[0002] In automotive design, the body structure sometimes serves as a barrier between the passenger compartment and external components. Traditional manufacturing methods rely on complex metal components requiring extensive welding, sealing, and multi-step assembly processes. The assembly process for traditional body structures can present several manufacturing challenges. For example, a typical metal dashboard structure might require over 100 spot welds and extensive application of body putty to assemble more than 50 individual parts. The manufacturing sequence may necessitate precise securing and alignment steps to ensure proper component positioning. Traditional dashboard structure components may also require numerous parts and a significant number of joining operations.

[0003] Further integration of components such as thermal management parts, noise reduction materials, and other parts of subsystems typically requires multiple discrete assembly steps during overall assembly. Traditional designs, which combine separate brackets and mounting components for vehicle systems, result in an increased number of parts and assembly complexity. The conventional multi-stage process from component manufacturing to system integration can introduce several inefficiencies in production planning and execution. Summary of the Invention

[0004] Some embodiments of this disclosure provide an integrated vehicle body structure including a monolithic molded plastic panel that, when assembled into a vehicle, extends along at least a portion of the width of the vehicle compartment to define a barrier between the passenger compartment and other external elements. This approach attempts to address some limitations of conventional metal components by integrating multiple components or vehicle features into a single structure, thereby facilitating the integration of various vehicle systems and subsystems in some examples. In some examples, the monolithic molded plastic panel helps define different spaces within the vehicle by forming a barrier between the passenger compartment and separate cavities. These cavities can accommodate vehicle systems and components while remaining isolated from passenger space.

[0005] Examples of vehicle body structures include plastic materials with embedded glass fibers, chosen for their structural characteristics. The glass fiber embedding process creates a reinforced composite structure that maintains rigidity while enabling sophisticated molding features. In some examples, these materials enable the integration of reinforcing ribs directly molded into the component, providing structural support without the need for separate reinforcing members. In some examples, these materials also allow for the direct molding of reference pins for part-to-part alignment. In some examples, the plastic material of the monolithic molded plastic panel also enables the integration of threaded fasteners through a thermal embedding process and may include integrated windshield polyurethane paths or channels directly molded into the monolithic molded plastic panel. In some examples, the monolithic design also allows for the integration of pipes, gaskets, seals, and absorbers that would otherwise require separate assembly steps.

[0006] Some examples enable pre-assembly capabilities, where noise, vibration, and harshness (NVH) panels and heating (HVAC) ducting can be pre-assembled into the structure using an integral mounting location before installation into the vehicle. This can result in reduced assembly efficiency and time, assembly line size, and assembly line length. In some examples, integrated HVAC ducting provides thermal management through channels directly molded into an integral molded plastic panel. The HVAC ducting includes pre-assembled flexible hose pass-throughs that enable efficient wiring of the thermal management system while maintaining airflow characteristics for cabin climate control. Some examples also provide thermal management through integrated HVAC ducting and improved NVH characteristics through pre-assembled components. The structure includes wet-side and dry-side NVH panels extending along at least a portion of the vehicle cabin width.

[0007] Some examples include wet-side NVH panels and dry-side NVH panels that extend along at least a portion of the width of the vehicle compartment. These panels are pre-assembled into mounting locations directly molded into monolithic molded plastic panels, thereby providing comprehensive noise reduction capabilities while maintaining structural integrity.

[0008] Some examples provide methods for manufacturing body structures that begin with the formation of a monolithic molded plastic panel. The forming process allows for the direct integration of components and features, including NVH components, during the molding process. NVH components can be incorporated into the structure during its formation, rather than added later. Some examples include a sealing process where peripheral seals are applied to the monolithic molded plastic panel before the sealing structure is attached to the vehicle. Attached Figure Description

[0009] Throughout the accompanying drawings, reference numerals may be used repeatedly to indicate the correspondence between the referenced elements. The drawings are provided to illustrate the subjects described herein, not to limit their scope.

[0010] Figure 1The illustration shows a conventionally stamped and split dashboard and front bulkhead structure used in an exemplary prior art vehicle design, including multiple joining metal pieces pre-assembled to the body structure.

[0011] Figure 2A This is a perspective view showing an exemplary integrated body structure, including pre-assembled wet-side noise, vibration, and harshness (NVH) panels and peripheral seals, according to some examples.

[0012] Figure 2B This shows installations in vehicles according to some examples. Figure 2A A perspective view of the vehicle body structure.

[0013] Figure 3 This is an exploded perspective view showing the assembly sequence for an integrated vehicle body structure, based on some examples.

[0014] Figure 4 This is a perspective view showing integrated heating, ventilation, and air conditioning (HVAC) ductwork, mounting features, dashboard structure, and front bulkhead structure within a monolithic molded plastic panel, according to some examples.

[0015] Figure 5 This is a perspective view showing, according to some examples, the molded reinforcing ribs, molded connection points, fasteners, and mounting locations integrated into a monolithic molded plastic panel.

[0016] Figure 6A This is a perspective view showing a wet-side NVH panel according to some examples, which is configured for pre-assembly to an integral molded plastic panel at the installation location.

[0017] Figure 6B This is a perspective view showing, according to some examples, a dry-side NVH panel configured for pre-assembly onto an integral molded plastic panel.

[0018] Figure 7A This is a perspective view illustrating, based on some examples, a peripheral seal configured for application to an integral molded plastic panel.

[0019] Figure 7B This is an assembly view showing the integration of a wet-side NVH panel with an integral molded plastic panel, according to some examples.

[0020] Figure 7C This illustrates the application of peripheral seals to, based on some examples. Figure 7B Assembly diagram of integrated components.

[0021] Figure 7D This is a perspective view showing a vehicle configured to receive a body structure, based on some examples.

[0022] Figure 7EThis is a perspective view showing the body structure integrated into a vehicle according to some examples.

[0023] Figure 8 This is a flowchart illustrating example operations for assembling a vehicle body structure, based on some examples. Detailed Implementation

[0024] Figure 1 A conventional stamped dashboard and front bulkhead structure 100, used in conventional vehicle design, is shown. Here, the dashboard and front bulkhead structure are formed as separate components. The structure includes multiple metal parts that must be pre-assembled onto the body structure. As further described above, the assembly process involves numerous joining operations, including extensive spot welding and extensive application of body putty to hold the components together.

[0025] Some components require installation or assembly in a specific order, including, for example, dashboard components, reinforcements, controller brackets, front bulkhead components, wiper brackets, front bulkhead screen brackets, VIN plate mounts, instrument panel locator brackets, and various studs and nuts for component attachment. The center dashboard assembly, dashboard assembly, lower front bulkhead assembly, and upper front bulkhead assembly may each require their own spot welds, studs, nuts, and body putty application. These sub-assemblies must then be joined together before integration with the front underbody contents.

[0026] Traditional metal structures require welding or attachment of individual mounting brackets to support various vehicle systems. Additional brackets and mounting components are needed for thermal management components and noise reduction materials, which may require individual installation during the overall assembly process. In internal combustion engine vehicles, such metal dashboard and front bulkhead structures serve as fire barriers and need to be directly assembled to the body structure before installing other components.

[0027] Paint shop methods for traditional structures require the application of paint shop sealants, foam materials, and liquid sound insulation materials. Traditional designs also require separate NVH absorbers, including dashboard insulators and absorbers for both dry and wet sides, as well as mounting clips. HVAC integration requires separate inlet components that must be assembled after the main structure is completed.

[0028] In a broader sense, in the various examples described herein, the vehicle body structure includes a unified component that integrates traditionally separate structural elements. This unified component includes a dashboard structure and a front bulkhead structure formed as a single piece, which can extend across at least a portion of the width of the vehicle compartment to define a lateral vehicle barrier.

[0029] In some examples, such as the dashboard structure used herein, the dashboard structure refers to a structural barrier component positioned between the engine compartment and the passenger compartment of a vehicle. As mentioned above, in conventional internal combustion engine vehicles, the dashboard structure is typically formed from a single piece of metal to provide fire protection between the engine compartment and the passenger compartment. However, in electric vehicles, where such fire protection requirements can be reduced, the dashboard structure can be formed from alternative materials such as fiberglass-embedded plastic. In some examples, the dashboard structure forms a cavity separate from the passenger compartment, where the cavity may be the engine compartment or other mechanical space or storage volume. In some examples, the cavity is at least partially defined by an integrally molded plastic panel that serves as a barrier between the passenger compartment and the separate cavity space.

[0030] In some examples, such as those used herein, the front bulkhead structure refers to a structural component positioned between the vehicle's hood and windshield area. As also stated above, the front bulkhead structure conventionally comprises multiple separately assembled metal components that interface with both the front bulkhead structure and the exterior body panels. These metal interface components provide structural connection points between the dashboard structure and the body panels while maintaining proper alignment and sealing.

[0031] In some examples of this disclosure, the integral molded plastic panel integrates the front bulkhead and dashboard features directly into the molded structure, eliminating the need for separate metal components while maintaining the structural connection between the dashboard and front bulkhead structure and the external body panels. In some examples, the front bulkhead structure establishes a wet and dry barrier for the vehicle at the windshield interface, where windshield polyurethane and seals are applied directly to the front bulkhead structure.

[0032] In some of the described examples, these traditionally separate structures are integrated into a unified glass fiber-embedded plastic component that defines a barrier between the passenger compartment and external elements. When these structures are separate metal components, this integration eliminates the need for the multiple assembly steps and joining operations previously required.

[0033] Unified components can incorporate a variety of additional features, including but not limited to thermal management elements, noise / vibration / roughness (NVH) components, mounting locations, and integrated piping and channels. The integration of the dashboard and front bulkhead structure provides the basis for incorporating these additional features while reducing the overall number of parts and assembly complexity.

[0034] In some examples, unified components replace many separate metal parts that would traditionally be required, including separate dashboard and front bulkhead components, multiple reinforcements, and various mounting brackets. The integrated structure maintains structural integrity while providing improved assembly efficiency through parts consolidation.

[0035] See the attached diagram for this point again. Figure 2AA current example of a body structure 202 with a pre-assembled wet-side NVH panel 602 and peripheral seals 702 is shown. The body structure 202 includes a monolithic molded plastic panel 502 that integrates the instrument panel structure 204 and the front bulkhead structure 206. The monolithic molded plastic panel 502 forms the core structure, combining the instrument panel structure 204 and the front bulkhead structure 206 into a single molded part. Fiberglass inlays are incorporated into the instrument panel structure 204 and the front bulkhead structure 206 within the body structure 202. In some examples, the figures illustrate how these structures are integrated to create a barrier between the passenger compartment and external components.

[0036] As in Figure 6A As can be seen more clearly, the wet-side NVH panel 602 is mounted to the integral molded plastic panel 502 using mounting position 208, as shown in... Figure 5 This is more clearly visible in the image. In some examples, the mounting location allows the NVH panel to span the entire width of the vehicle cabin to provide noise reduction coverage. For example, in... Figure 7A As can be seen more clearly, the peripheral seal 702 follows the edge contour of the structure where it interfaces with the vehicle. In other examples, the mounting location allows the NVH panel to extend a portion of the vehicle cabin width.

[0037] In some examples, mounting locations 208 are positioned across the integral molded plastic panel 502 to enable direct attachment of the component. In the body structure 202, these mounting locations are molded directly into the structure during forming to provide a robust attachment point for the wet-side NVH panel 602.

[0038] Figure 2B This is a perspective view showing a body structure 202 installed in a vehicle 210 according to some examples. In some examples, the figure shows a complete assembly positioned and secured within the body structure. In some examples, the mounting location 208 spans the width of the vehicle 210 compartment to ensure proper positioning and support of the wet-side NVH panel 602, which may extend together with the body structure 202 for noise reduction purposes.

[0039] The installation configuration demonstrates the positioning of the body structure 202 within the vehicle 210, which extends along at least a portion of the width of the vehicle 210 compartment to create a barrier between the passenger compartment and external components.

[0040] Figure 3 This is an exploded perspective view showing the assembly sequence for the integrated body structure 202 according to some examples. Figure 3 The integral molded plastic panel 502, wet-side NVH panel 602, dry-side NVH panel 604, and peripheral seal 702 are shown.

[0041] In some examples, the structure demonstrates the integration of multiple systems within a single molded plastic panel 502. HVAC ductwork 402 is formed directly within the single molded plastic panel 502 during the molding process. In some examples, connection points 504 are positioned to accommodate vehicle systems such as wipers, instrument panels, and vehicle computers, as well as other systems that interface with the structure.

[0042] The wet-side NVH panel 602 and the dry-side NVH panel 604 are mounted to predetermined positions molded into the integral molded plastic panel 502. In some examples, these panels extend along at least a portion of the width of the vehicle 210 compartment, coexisting with the integral molded plastic panel 502, and engage with integrated absorbers and pads molded during component formation.

[0043] The peripheral seal 702 follows the edge contour of the body structure 202, thereby forming an environmental barrier between the integral molded plastic panel 502 and the vehicle 210. In some examples, the peripheral seal 702 interfaces with mounting location 208 for securing and positioning the seal along the edge contour of the body structure 202.

[0044] Figure 4 The diagram illustrates an integrated HVAC conduit 402, hose pass-through 404, stud 406, and mounting location 208 within a monolithic molded plastic panel 502, according to some examples. The monolithic molded plastic panel 502 integrates the HVAC conduit 402 during the molding process to provide thermal management capabilities. The HVAC conduit 402 and hose pass-through 404 are pre-assembled to the monolithic molded plastic panel 502 during molding.

[0045] In some examples, the HVAC duct 402 includes an integrated flexible hose pass-through 404, which enables the thermal management system to be routed efficiently while maintaining the required airflow characteristics. The flexible hose pass-through 404 is pre-assembled to the integral molded plastic panel 502 during the forming process, thereby allowing direct integration of the thermal management system.

[0046] In some examples, the studs 406 are molded directly into the integral molded plastic panel 502 during forming. These molded studs 406 and threaded fasteners serve as connection points within the integral molded plastic panel 502, providing robust mounting capability.

[0047] In some examples, the stud 406 is heat-embedded into a predetermined position. The heat-embedding process maintains the integrity of the threads while securing the fastener within the integral molded plastic panel 502 for threaded engagement to attach the component.

[0048] Mounting positions 208 are strategically positioned within the overall monolithic molded plastic panel 502 structure to accommodate a variety of vehicle systems and components. In some examples, these mounting positions 208 are formed directly into the monolithic molded plastic panel 502 during the molding process for efficient assembly and secure attachment of system components.

[0049] Figure 5 This is a perspective view showing molded reinforcing ribs 506, molded connection points 504, and fasteners 508 integrated within a monolithic molded plastic panel 502, according to some examples. During the formation of the structural supports distributed throughout the monolithic molded plastic panel 502, the reinforcing ribs 506 are molded directly into the monolithic molded plastic panel 502. A glass fiber embedded structure allows these ribs to be positioned to maintain structural integrity.

[0050] In some examples, molded connection point 504 provides a mounting location for vehicle systems such as wipers, dashboards, and vehicle computers.

[0051] In some examples, connection point 504 allows for direct attachment of components without the need for a separate bracket.

[0052] In some examples, connection point 504 is strategically positioned throughout the structure to facilitate efficient assembly.

[0053] In some examples, connection points 504 maintain precise spatial relationships between mounted components. Connection points 504 are positioned according to the specific spatial and functional requirements of the vehicle system they support to ensure proper alignment and interface with the components. In some examples, connection points 504 incorporate specific geometric features directly molded into the structure to facilitate proper component orientation and attachment. These features may include alignment surfaces, retaining features, or other mounting interfaces specific to the supported vehicle system.

[0054] In some examples, the molded connection point 504 is integrated into the body structure 202 during forming to accommodate the vehicle system. Integration can occur simultaneously with the molding of the integral molded plastic panel 502.

[0055] In some examples, the reference pin 510 and the alignment feature are molded into the integral molded plastic panel 502. The reference pin 510 may be molded into the integral molded plastic panel 502 simultaneously with the alignment feature. The reference pin 510 can allow for repeatable part-to-part positioning.

[0056] Fastener 508 is integrated at specific predetermined locations within the structure via a precise thermal embedding process. This process maintains thread integrity while securing the fastener within the integral molded plastic panel 502. In some examples, thermally embedded fasteners enable the provision of threaded metal elements at locations requiring mechanical fastening while simultaneously achieving a robust attachment of the vehicle system.

[0057] In some examples, the glass fiber embedded construction allows for direct integration of the mounting positions 208 during the molding process. In other examples, the mounting positions 208 are designed to adapt to specific load requirements based on the components they support.

[0058] Figure 6A This is a perspective view showing a wet-side NVH panel 602 according to some examples, configured for pre-assembly to an integral molded plastic panel 502. In some examples, the wet-side NVH panel 602 extends substantially along at least a portion of the width of the vehicle compartment, co-existing with the integral molded plastic panel 502. The panel is integrated with a specific mounting location 208 in the integral molded plastic panel 502.

[0059] In some examples, the wet-side NVH panel 602 engages an integrated absorber and pad, which are pre-assembled into mounting positions 208 directly molded into the integral molded plastic panel 502.

[0060] In some examples, mounting location 208 is positioned throughout the structure to optimize noise reduction capabilities. In some examples, mounting location 208 incorporates specific features to ensure proper positioning of the wet-side NVH panel 602. In some examples, mounting location 208 incorporates specific features to ensure secure attachment of the wet-side NVH panel 602.

[0061] In some examples, mounting location 208 is designed to maintain a precise spatial relationship between the wet-side NVH panel 602 and adjacent components within the assembly.

[0062] In some examples, the wet-side NVH panel 602 works in conjunction with integrated thermal management features molded into the integral molded plastic panel 502 to provide thermal management capabilities.

[0063] In some examples, mounting position 208 allows the wet-side NVH panel 602 to be pre-assembled to the body structure 202 before installation on vehicle 210.

[0064] Figure 6B This is a perspective view showing a dry-side NVH panel 604 configured for pre-assembly to an integral molded plastic panel 502, according to some examples. The dry-side NVH panel 604 is mounted to a molded location within the structure, extending along at least a portion of the width of the vehicle 210 compartment.

[0065] In some examples, the dry-side NVH panel 604 interfaces with absorbers and pads that are molded into the integral molded plastic panel 502 during its formation process.

[0066] In some examples, mounting location 208 for the dry-side NVH panel 604 is positioned to optimize noise reduction capabilities.

[0067] In some examples, the dry-side NVH panel 604 extends along at least a portion of the width of the vehicle 210 cabin, together with the body structure 202, to provide comprehensive acoustic management.

[0068] In some examples, the dry-side NVH panel 604 is pre-assembled to the body structure 202 before installation.

[0069] In some examples, the installation location is positioned across the width of the vehicle compartment to ensure proper positioning and support of the dry-side NVH panel 604.

[0070] In some examples, the dry-side NVH panel 604 interfaces with absorbers and pads molded into the integral molded plastic panel 502 during its formation process, enabling direct integration of noise reduction features.

[0071] Figure 7A This is a perspective view illustrating a peripheral seal 702 configured, according to some examples, for application to an integral molded plastic panel 502. The peripheral seal 702 follows the edge contour of the structure, creating an environmental barrier between the body structure 202 and the vehicle 210.

[0072] In some examples, the peripheral seal 702 interfaces with the mounting location 208 for securing and positioning the seal along the edge contour of the vehicle body structure 202.

[0073] In some examples, the peripheral seal 702 provides environmental protection through a single interface.

[0074] In some examples, the peripheral seal 702 follows a contour designed to interface with the molding features of the integral molded plastic panel 502.

[0075] In some examples, peripheral seals 702 are applied to the integral molded plastic panel 502 before the sealing structure is attached to vehicle 210. The pre-application of peripheral seals 702 allows for the pre-assembly of environmental barriers.

[0076] In some examples, the peripheral seal 702 is integrated with the mounting surface along the edge contour of the vehicle body structure 202 to provide environmental protection through a uniform sealing approach.

[0077] Figure 7BThis is an assembly diagram showing the integration of the wet-side NVH panel 602 with the integral molded plastic panel 502. The wet-side NVH panel 602 is mounted to a predetermined position molded into the integral molded plastic panel 502.

[0078] In some examples, the wet-side NVH panel 602 interfaces with an integrated absorber and pad pre-assembled into mounting location 208 directly molded into the monolithic molded plastic panel 502.

[0079] In some examples, mounting location 208 is positioned throughout the structure to optimize noise reduction capabilities.

[0080] In some examples, mounting location 208 incorporates specific geometric features to facilitate the proper orientation of the wet-side NVH panel 602. These specific geometric features allow for a secure attachment of the wet-side NVH panel 602.

[0081] In some examples, mounting location 208 is designed to maintain a precise spatial relationship between the wet-side NVH panel 602 and adjacent components within the assembly.

[0082] In some examples, mounting position 208 allows the wet-side NVH panel 602 to be pre-assembled onto the structure before installation on vehicle 210.

[0083] In some examples, the mounting location 208 spans the width of the vehicle 210 compartment to ensure proper positioning and support of the wet-side NVH panel 602.

[0084] Figure 7C This is an assembly drawing showing the application of a peripheral seal 702 to the overall assembly of the vehicle body structure 202. The seal interfaces with a mounting surface along the edge contour of the vehicle body structure 202. The peripheral seal 702 provides environmental protection through a single interface.

[0085] In some examples, the peripheral seal 702 is integrated with the mounting location 208 along the edge contour of the vehicle body structure 202 to provide environmental protection through a uniform sealing approach.

[0086] In some examples, mounting position 208 is specifically designed to maintain proper positioning of the peripheral seal 702 during and after assembly.

[0087] In some examples, mounting location 208 incorporates features that ensure consistent compression and retention of the peripheral seal 702 at the interface between the body structure 202 and the vehicle 210.

[0088] In some examples, the integrated mounting location 208 allows the peripheral seal 702 to maintain its environmental protection capabilities while adapting to manufacturing tolerances.

[0089] In some examples, the mounting surface is positioned to optimize the interface between the peripheral seal 702 and the vehicle body structure 202.

[0090] Figure 7D This is a perspective view showing a vehicle 210 configured to receive a body structure 202. In some examples, the vehicle 210 includes a mounting interface corresponding to a molded reference pin 510 and alignment features integrated into an integral molded plastic panel 502.

[0091] Figure 7E This is a perspective view showing the positioning and attachment of the body structure 202 to the vehicle 210. The installation utilizes molded reference pins 510 for alignment and integrated connection points 504 for secure attachment. The body structure 202 is fitted with thermally inserted threaded fasteners 508 at predetermined locations to maintain a secure attachment.

[0092] In some examples, vehicle 210 includes a mounting location 208 corresponding to the molded reference pin 510. In some examples, vehicle 210 includes alignment features integrated into an integral molded plastic panel 502.

[0093] In some examples, connection point 504 is positioned according to specific spatial requirements to ensure proper alignment between body structure 202 and vehicle 210.

[0094] In some examples, the mounting interface allows the vehicle body structure 202 to be precisely positioned within the vehicle 210 while maintaining an appropriate spatial relationship with adjacent vehicle systems.

[0095] In some examples, integrated connection point 504 provides a secure connection point between body structure 202 and vehicle 210.

[0096] In some examples, the thermally embedded threaded fastener 508 maintains a secure attachment between the vehicle body structure 202 and the vehicle 210 through a predetermined installation position.

[0097] In some examples, the mounting configuration of the body structure 202 extends along at least a portion of the width of the vehicle 210 compartment to create a barrier between the passenger compartment and external components.

[0098] Figure 8 This is a process flow diagram illustrating example operations during the assembly of a vehicle body structure 202 according to some examples.

[0099] At operation 802, in some examples, the process begins with forming an integral molded plastic panel 502 extending along at least a portion of the width of the vehicle 210 compartment. The forming process incorporates embedded glass fiber material. In some examples, the glass fiber embedding creates a reinforced composite structure that remains rigid while allowing molding features to be incorporated during forming.

[0100] In operation 804, the forming process integrates multiple components into the integral molded plastic panel 502 during its creation. In some examples, the forming process integrates the instrument panel structure 204 and the front bulkhead structure 206 together. The instrument panel structure 204 and the front bulkhead structure 206 are merged into a single component. Merging them into a single component creates a continuous barrier between the passenger compartment and external elements. This integration allows for the direct combination of structural and functional features during the initial forming process.

[0101] In operation 806, the connection point 504 and the reinforcing rib 506 are directly molded into the component structure. In some examples, this includes forming the molded connection point 504 for a vehicle system and creating the reinforcing rib 506 that provides structural support without requiring separate parts. The connection point 504 can be positioned to accommodate the installation of vehicle systems including wipers, instrument panels, and vehicle computers.

[0102] In operation 808, reference pins 510 and alignment components are formed in an integrally molded plastic panel 502 for part-to-part positioning. Part-to-part positioning can be repeated during assembly operations. Reference pins 510 can engage with connection points 504 to maintain proper spatial relationships between components.

[0103] In operation 810, the threaded fastener 508 is thermally embedded into a predetermined position within the integral molded plastic panel 502. The thermally embedded threaded fastener 508 enables a secure connection of the vehicle system while providing metal threaded fasteners 508 where mechanical fastening is required.

[0104] In operation 812, the wet-side NVH panel 602 and the dry-side NVH panel 604, as well as the HVAC duct 402 component, are pre-assembled into the molded mounting position 208.

[0105] In operation 814, a peripheral seal 702 is applied to the integral molded plastic panel 502. In some examples, the peripheral seal 702 follows an edge profile to form an environmental barrier between the body structure 202 and the vehicle 210. In some examples, the peripheral seal 702 interfaces with a mounting location 208 for fixing and positioning. In some examples, the mounting location 208 incorporates features that ensure consistent compression of the peripheral seal 702. In some examples, the installation of the peripheral seal 702 accommodates manufacturing tolerances while maintaining environmental protection.

[0106] In operation 816, the molded reference pin 510 is used to position the body structure 202 and attach it to the vehicle 210.

[0107] The operations of the method may be performed in whole or in part, may be performed in combination with some or all of the operations of other methods, and may be performed by any number of different systems. Any process description, element, or block in the flowcharts described herein should be understood as potentially representing a module, segment, or portion of code comprising executable instructions for implementing a particular logical function or element in the process. Alternative implementations are included within the scope of the examples described herein, wherein elements or functions may be removed from the order shown or discussed, depending on the functionality involved, including substantially simultaneously or in reverse order, depending on the understanding of a person skilled in the art.

[0108] In some examples, the body structure can be implemented in various vehicle configurations, each with a specific fit for an integral molded plastic panel 502.

[0109] In some examples, the body structure 202 can be scaled to accommodate a larger vehicle 210 cabin width. Additional reinforcing ribs 506 provide increased structural support, while enlarged HVAC ductwork 402 capacity allows for modifications to the internal passageways.

[0110] In some examples, the vehicle body structure 202 can accommodate specialized sensors or computing devices via molded connection points 504, such as Figure 4 As shown. An additional computer mounting location 208 is integrated, and the HVAC duct 402 can be modified to provide cooling for electronic components.

[0111] In some examples, integration of the body structure 202 with other vehicle systems is facilitated by a reinforced plastic design. This integration can be maintained with precise positioning via molded reference pins 510.

[0112] Example

[0113] Therefore, some examples of this disclosure may include one or more of the following aspects.

[0114] Example 1 includes a method of manufacturing an integrated body structure for a vehicle, the method comprising: forming an integral molded plastic panel to define a transverse vehicle barrier extending across at least a portion of the width of a vehicle compartment, the integral molded plastic panel defining an integrated dashboard and front bulkhead structure for the vehicle; attaching one or more components to the integral molded plastic panel; and mounting the integral molded plastic panel into the vehicle to define the transverse vehicle barrier.

[0115] Example 2: According to the method of Example 1, the integrated dashboard and front bulkhead structure of the installed monolithic plastic panel includes structural components positioned between the vehicle's hood and windshield area to define the vehicle's wet / dry barrier.

[0116] Example 3: According to the method of Example 2, the integrated dashboard and front bulkhead structure of the installed monolithic plastic panel also includes a structural barrier component positioned between the engine compartment and the passenger compartment of the vehicle.

[0117] Example 4: According to one or more of the methods in Examples 1-3, one or more heating, ventilation, and air conditioning (HVAC) ducts are integrated into the integral molded plastic panel before the integral molded plastic panel is installed into the vehicle.

[0118] Example 5: According to one or more of the methods in Examples 1-4, the method further includes pre-assembling a wet-side noise, vibration, and harshness (NVH) sub-panel and a dry-side NVH sub-panel into an integrated body structure, wherein the wet-side NVH sub-panel is located on a first side of the integral molded plastic panel and the dry-side NVH sub-panel is located on a second side of the integral molded plastic panel.

[0119] Example 6: According to one or more of the methods in Examples 1-5, it further includes integrating one or more connection points for vehicle systems or electrical wiring harnesses into the integral molded plastic panel during the formation of the integral molded plastic panel.

[0120] Example 7: According to one or more of the methods in Examples 1-6, the method further includes integrating channels for peripheral sealing into the integral molded plastic panel during the formation of the integral molded plastic panel.

[0121] Example 8: The method of Example 7 further includes introducing sealing or sealant material into the channel before installing the integral molded plastic panel into the vehicle.

[0122] Example 9: According to one or more of the methods in Examples 1-8, it further includes molding one or more reinforcing ribs or embedded glass fibers into the integral molded plastic panel during the formation of the integral molded plastic panel.

[0123] Example 10: According to one or more of the methods in Examples 1-9, it further includes thermally embedding one or more threaded fasteners into an integral molded plastic panel.

[0124] Example 11: A vehicle body structure including a monolithic molded plastic panel for defining a lateral vehicle barrier that extends across at least a portion of the width of the vehicle compartment, the monolithic molded plastic panel providing an integrated dashboard and front bulkhead structure for the vehicle when mounted to the vehicle.

[0125] Example 12: According to the vehicle body structure of Example 11, the integrated dashboard and front bulkhead structure includes: a structural component positioned between the vehicle's hood and windshield area to define a wet / dry barrier for the vehicle; and a structural barrier component positioned between the vehicle's engine compartment and passenger compartment.

[0126] Example 13: According to one or more of the body structures in Examples 11-12, a wet-side noise, vibration, and harshness (NVH) sub-panel is also included on a first side of the integral molded plastic panel; a dry-side NVH sub-panel is also included on a second side of the integral molded plastic panel; wherein when the body structure is mounted to the vehicle, the wet-side NVH sub-panel and the dry-side NV sub-panel each extend substantially together with the integral molded plastic panel across the width of the vehicle cabin.

[0127] Example 14: Based on the body structure of Example 13, the dry-side NVH sub-panel and the wet-side NVH sub-panel are pre-assembled into one or more mounting locations molded into an integral molded plastic panel.

[0128] Example 15: Based on one or more of the vehicle body structures in Examples 11-14, one or more integrated connection points are also included, which are configured to connect to the vehicle's system or electrical wiring harness.

[0129] Example 16: According to the vehicle body structure of Example 15, one or more integrated connection points include physical or electrical connection points for any one or more of the following: wiper blades, wiper motors, instrument panels, instrument panel components, vehicle braking systems, vehicle lighting systems, vehicle guidance systems, vehicle sensors, and vehicle processors.

[0130] Example 17: A body structure according to one or more of Examples 11-16, wherein the integral molded plastic panel includes one or more molded reinforcing ribs.

[0131] Example 18: A vehicle body structure according to one or more of Examples 11-17, wherein the integral molded plastic panel includes embedded glass fiber.

[0132] Example 19: A body structure according to one or more of Examples 11-18, wherein the integral molded plastic panel includes one or more molding references or part alignment pins.

[0133] Example 20: According to one or more of the vehicle body structures in Examples 11-19, a channel for receiving sealant material or peripheral seals is also included.

[0134] Unless otherwise specified, conditional language, such as “can,” “able,” “may,” or “may,” is understood in context to generally express that some examples include, while others do not, certain features, elements, and / or steps. Therefore, such conditional language is not generally intended to imply that features, elements, and / or steps must be included for logic used to determine whether such features, elements, and / or steps are included in any particular example or to be performed in any particular example, with or without user input or prompts.

[0135] Unless otherwise specifically stated, disjunctive language such as the phrase “at least one of X, Y, or Z” should be understood in context as generally used to refer to items, terms, etc., which can be X, Y, or Z or any combination thereof (e.g., X, Y, and / or Z). Therefore, such disjunctive language is generally not intended and should not imply that some examples require at least one of X, at least one of Y, or at least one of Z to be present individually.

[0136] It should be emphasized that many variations and modifications can be made to the above examples, and the elements of these variations and modifications should be understood as other acceptable examples. All such modifications and variations are intended to be included within the scope of this disclosure.

[0137] It should also be understood that one or more elements depicted in the accompanying drawings may also be implemented in a more discrete or integrated manner, or even removed or rendered inoperable in some cases, as may be useful for a particular application.

Claims

1. A method for manufacturing an integrated body structure for a vehicle, the method comprising: A monolithic molded plastic panel is formed to define a transverse vehicle barrier that extends across at least a portion of the width of the vehicle compartment, the monolithic molded plastic panel defining an integrated dashboard and front bulkhead structure for the vehicle. Attach one or more components to the integral molded plastic panel; as well as The integral molded plastic panel is installed into the vehicle to define the lateral vehicle barrier.

2. The method of claim 1, wherein the integrated dashboard and front bulkhead structure of the installed monolithic plastic panel includes structural components positioned between the hood and windshield area of ​​the vehicle to define a wet barrier and / or a dry barrier for the vehicle.

3. The method of claim 2, wherein the integrated dashboard and front bulkhead structure of the installed monolithic plastic panel further includes a structural barrier component positioned between the engine compartment and passenger compartment of the vehicle.

4. The method of claim 1, further comprising integrating one or more heating, ventilation, and air conditioning (HVAC) ducts into the integral molded plastic panel before installing the integral molded plastic panel into the vehicle.

5. The method of claim 1, further comprising pre-assembling a wet-side noise, vibration and roughness NVH sub-panel and a dry-side NVH sub-panel into the integrated body structure, wherein the wet-side NVH sub-panel is located on a first side of the integral molded plastic panel and the dry-side NVH sub-panel is located on a second side of the integral molded plastic panel.

6. The method of claim 1, further comprising integrating one or more connection points for a vehicle system or electrical wiring harness into the integral molded plastic panel during the formation of the integral molded plastic panel.

7. The method of claim 1, further comprising integrating channels for peripheral sealing into the integral molded plastic panel during the formation of the integral molded plastic panel.

8. The method of claim 7, further comprising introducing a sealant or sealant material into the channel prior to mounting the integral molded plastic panel into the vehicle.

9. The method of claim 1, further comprising molding one or more reinforcing ribs or embedded glass fibers into the integral molded plastic panel during the formation of the integral molded plastic panel.

10. The method of claim 1, further comprising thermally embedding one or more threaded fasteners into the integral molded plastic panel.

11. A vehicle body structure, comprising: An integral molded plastic panel for defining a transverse vehicle barrier that extends across at least a portion of the width of the vehicle compartment, the integral molded plastic panel providing an integrated dashboard and front bulkhead structure for the vehicle when mounted to the vehicle.

12. The vehicle body structure according to claim 11, wherein the instrument panel and front bulkhead structure comprises: Structural components positioned between the vehicle's hood and windshield area to define the vehicle's wet and / or dry barriers, and A structural barrier component, which is positioned between the engine compartment and the passenger compartment of the vehicle.

13. The vehicle body structure according to claim 11, further comprising: Wet-side noise, vibration, and roughness (NVH) sub-panel located on the first side of the integral molded plastic panel; Dry-side NVH sub-panel located on the second side of the integral molded plastic panel; in When the body structure is installed in the vehicle, the wet-side NVH sub-panel and the dry-side NVH sub-panel each extend substantially together with the integral molded plastic panel across the width of the vehicle cabin.

14. The vehicle body structure of claim 13, wherein the dry-side NVH sub-panel and the wet-side NVH sub-panel are pre-assembled to one or more mounting locations molded into the integral molded plastic panel.

15. The vehicle body structure of claim 11, further comprising one or more integrated connection points configured to connect to a system or electrical wiring harness of the vehicle.

16. The vehicle body structure of claim 15, wherein the one or more integrated connection points include physical or electrical connection points for any one or more of the following: wiper blades, wiper motors, instrument panels, instrument panel components, vehicle braking systems, vehicle lighting systems, vehicle guidance systems, vehicle sensors, and vehicle processors.

17. The vehicle body structure of claim 11, wherein the integral molded plastic panel includes one or more molded reinforcing ribs.

18. The vehicle body structure of claim 11, wherein the integral molded plastic panel includes embedded glass fibers.

19. The vehicle body structure of claim 11, wherein the integral molded plastic panel includes one or more molded built-in reference pins or part alignment pins.

20. The vehicle body structure of claim 11 further includes a channel for receiving sealant material or peripheral seals.

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