METHOD FOR MANUFACTURING AN INSTRUMENT PANEL FOR AN ARMORED VARIANT OF A MOTOR VEHICLE

Abstract

The invention relates to a method for manufacturing an instrument panel (10) for an armored version of a motor vehicle, comprising the steps of: providing a standard carrier upper part (16) for a standard instrument panel for an unarmored standard version of the motor vehicle; specifying at least one cutting line (18) on the standard carrier upper part (16) along which it is to be shortened; specifying a safety distance to the cutting line (18); providing a decorative material (12) with at least one folded seam (20) which, when the decorative material (12) is arranged as intended on the standard carrier upper part (16), has the safety distance to the cutting line (18);The decorative material (12) is arranged on the standard carrier upper part (16), and a first part (22) of the decorative material (12) is folded away along the folding seam (20) from the cutting line (18). A second part (24) of the decorative material (12) abutting the standard carrier upper part (16) is then press-laminated using a press-laminating tool designed for the unarmored standard version of the motor vehicle, and the standard carrier upper part (16) is then shortened to the intended nominal dimension along the cutting line (18). The first part (22) of the decorative material (12) is then folded back and subsequently laminated.

Description

Technical field

[0001] The present invention relates to a method for manufacturing an instrument panel for an armored variant of a motor vehicle. State of the art

[0002] It is generally known that armored vehicles, such as armored limousines, are manufactured based on conventional versions of the vehicles in question. Such armored vehicles, also known as special protection vehicles, are used, among others, by politicians to ensure their reliable protection, particularly during public appearances.

[0003] Protective materials such as armored steel, aramid fabric, and ceramics can be used on the outer skin. The vehicle floor, for example, can be made of a special aluminum alloy, while the windows are often made of special glass with a shatter-resistant polycarbonate layer. As a result, the windows are often significantly thicker compared to conventional vehicle windows.

[0004] The armor plating, particularly the armored windshield and A-pillar, typically results in less interior space in the front of the vehicle compared to the corresponding standard version. Longitudinally, the thicker windshield can reduce the space by up to 10 cm. Furthermore, the armor plating can make the A-pillar comparatively thicker, which can further restrict space laterally.

[0005] This presents, among other things, the challenge that a standard instrument panel does not fit sufficiently in such an armored vehicle. This, in turn, can make the production of instrument panels for an armored version of a vehicle considerably more complex and expensive compared to the conventional version of the same vehicle.

[0006] Document WO 2012 / 177 256 A1 discloses a method for manufacturing an instrument panel. This involves providing a carrier plate and a defined cutting line. Additionally, a decorative material with at least one seam is provided. The decorative material and carrier plate are heat-laminated and then cut to a predetermined nominal dimension. Description of the invention

[0007] The object of the invention is to provide an instrument panel for an armored variant of a motor vehicle in a particularly simple manner.

[0008] This problem is solved by the subject matter of the independent claim. Further possible embodiments of the invention are disclosed in the dependent claims, the description, and the figures.

[0009] The inventive method for manufacturing an instrument panel for an armored variant of a motor vehicle involves the following steps: - Providing a standard carrier upper part for a standard instrument panel for an unarmored standard version of the motor vehicle; - Specifying at least one cutting line on the standard carrier upper part along which it is to be shortened in order to achieve a target dimension suitable for the instrument panel carrier of the armored vehicle; - Specifying a safety distance to the cutting line; - Providing a decorative material with at least one fold seam which, when the decorative material is arranged as intended on the series carrier upper part, has the safety distance to the cutting line; - Arranging the decorative material on the standard carrier upper part and folding away a first part of the decorative material along the folding seam from the cutting line, after which a second part of the decorative material lying against the standard carrier upper part is press-laminated using a press-laminating tool designed for the unarmored standard version of the motor vehicle and then the standard carrier upper part is cut to the intended nominal dimension along the cutting line; - Folding back the first part of the decorative material onto the standard carrier top, which has been shortened to the required dimensions, or onto another component, after which the first part of the decorative material is laminated onto the standard carrier top, which has been shortened to the required dimensions, or onto the other component.

[0010] The standard instrument panel carrier for the unarmored version of the vehicle serves to hold decorative material on its upper surface. Due to the thicker windshield compared to the unarmored version, among other things, it is necessary to shorten the standard carrier carrier accordingly. For this purpose, at least one cutting line is provided on the standard carrier carrier, along which the carrier carrier must be shortened to achieve the required dimensions for the instrument panel carrier of the armored vehicle. With regard to the intended installation position, the cutting line can, for example, run transversely across the vehicle. However, other directions are also possible and depend on how much the available space in the armored version of the vehicle differs from the unarmored version.Different cutting lines can also be specified, depending on how the standard carrier top is to be shortened and thus trimmed.

[0011] The specified safety distance to the cutting line serves to prevent the decorative material from being soiled or damaged during the manufacturing of the instrument panel. This safety distance can be, for example, a few centimeters from the cutting line. The decorative material for the armored version of the vehicle can be, for instance, a corresponding cut piece of leather or other materials. The inclusion of a folding seam in the decorative material allows the first section of the material to be folded away along this seam. The decorative material can be made from several pieces joined together by this folding seam. Folding away means, in particular, that the first section of the decorative material attached to the standard upper support can be folded away from the upper support and thus folded over.The first part of the decorative material, after being folded over, can then lie against the second part of the decorative material. The visible sides of the parts can then lie against each other, specifically the sides facing the vehicle interior in the intended installation position. The first part of the decorative material is therefore sufficiently far removed from the specified cutting line along which at least the upper part of the standard carrier must be shortened or trimmed. The arrangement of the folding seam is chosen so that, when the decorative material is correctly positioned on the upper part of the standard carrier, it maintains the aforementioned safety distance from the cutting line.

[0012] After the decorative material has been correctly positioned on the standard carrier panel and the first part of the decorative material folded away, the second part of the decorative material, which rests against the standard carrier panel, is press-laminated using a press-lamination tool designed for the unarmored version of the vehicle. Therefore, the same press-lamination tool can be used to manufacture the instrument panel for the armored version as for the unarmored version. This allows for significant cost savings in the production of the instrument panel for the armored version of the vehicle.

[0013] After the press lamination process, the second part of the decorative material was bonded to the standard carrier top. The standard carrier top was then cut to the specified dimensions along the predefined cutting line. By folding back the first part of the decorative material, it was ensured that the decorative material would not be soiled or damaged during the cutting process. This cutting can be carried out, for example, using a milling process. After cutting, the first part of the decorative material, which had not yet been bonded to the standard carrier top, was folded back so that it now rested against the standard carrier top (cut to the specified dimensions) or another component. The folded-back first part of the decorative material was then laminated, meaning it was also fixed to the standard carrier top (cut to the specified dimensions) or the other component.The component may, for example, have been attached beforehand to the shortened series carrier top, especially in the area of ​​a cut edge that is created during shortening.

[0014] A key aspect of the invention is to use as many standard components, process steps, and tools as possible for the manufacture of the instrument panel for the armored version of the vehicle as are used for the manufacture of the instrument panel for the unarmored version. This includes, among other things, the use of the press-lamination tool that is also used for the unarmored version of the vehicle. This creates significant cost-saving potential. The method according to the invention thus makes it possible to provide an instrument panel for an armored version of a vehicle in a particularly simple and cost-effective manner.

[0015] One possible embodiment of the invention provides that, prior to the application of the decorative material to the upper part of the standard carrier, at least one groove is produced on the upper part of the standard carrier to at least partially accommodate the folded seam. For example, a groove on the upper part of the standard carrier can be produced by a milling process. The groove forms a recess on the upper part of the standard carrier so that the folded seam can be accommodated within it. This ensures a particularly flush surface finish on the finished component, i.e., the instrument panel. The groove is produced, in particular, on an upper surface of the upper part of the standard carrier that faces an underside of the decorative material when the latter has been applied as intended.

[0016] In a further possible embodiment of the invention, a marking is applied to the standard carrier upper section before the decorative material is applied. This marking serves to automatically identify the standard carrier upper section to be shortened. This makes it easy to locate the manufacturing process for the armored version of the vehicle, for example, within the same production line as the manufacturing process for the instrument panel for the unarmored version of the vehicle. By providing the marking, it is easy to automatically identify which manufacturing process is being carried out; in particular, the manufacturing process for the instrument panel for the armored version of the vehicle can thus be reliably identified.

[0017] In a further possible embodiment of the invention, a bore is produced as a marker, which is detected by a button of an adhesive spraying system. Consequently, a specific adhesive application for the manufacture of the instrument panel for the armored version of the vehicle is carried out before press lamination. The invention is based on the understanding that different adhesive applications are required for the standard version and the armored version. Specifically, during the manufacturing process for the armored version, a portion of the adhesive application must be omitted compared to the standard version. This is because, before cutting, only the aforementioned second part of the decorative material is press-laminated, while the folded-back first part of the decorative material is not yet press-laminated.The probe of the adhesive spraying system can use the bore to accurately identify that the manufacturing process is for the armored version of the vehicle, ensuring that the specific adhesive application can be carried out reliably before press lamination.

[0018] Another possible embodiment of the invention provides that, before the decorative material is applied to the serial carrier top, a first area of ​​the serial carrier top, corresponding to the first part of the decorative material, is covered (i.e., masked), and then a second area of ​​the serial carrier top, corresponding to the second part of the decorative material, is provided with a hot melt. Afterward, the decorative material is pre-fixed to the serial carrier top, and then the second part of the decorative material is press-laminated. The covering process reliably ensures that the first area of ​​the serial carrier top remains free of hot melt, since only the second part of the decorative material is to be press-laminated to the second area of ​​the serial carrier top. Thus, it is then possible to reliably bond only the second part of the decorative material to the serial carrier top by press lamination using the serial press-lamination system.

[0019] Another possible embodiment of the invention provides that the first part of the decorative material, which is folded away along the seam, is fixed to the upper part of the standard carrier before it is shortened, in particular by means of clamps. This ensures, especially during the shortening process, that the folded-away first part of the decorative material remains in place and is therefore not soiled or damaged by the shortening operation.

[0020] Another possible embodiment of the invention provides that, after press lamination and before trimming the standard carrier upper part, it is connected to a standard defrost assembly for the unarmored version of the vehicle and then trimmed together with it. The instrument panel for the armored version of the vehicle is thus manufactured using the standard defrost assembly. Tools used for this, such as a typically quite expensive injection mold, can therefore be used. This allows for significant cost savings in the production of the instrument panel for the armored version of the vehicle. The standard carrier upper part is thus connected to the standard defrost assembly, and then these parts are trimmed together to the required dimensions.The standard defrost assembly serves to direct airflow, particularly for warming the windshield.

[0021] Another possible embodiment of the invention provides that, after the standard carrier upper part and the standard defrost assembly have been shortened together, a defrost channel is attached to a front area of ​​the shortened standard defrost assembly, in relation to its intended arrangement in the armored vehicle, particularly by means of ultrasonic welding. The standard defrost assembly would already have a defrost channel for guiding air, but this is cut open during the shortening process, so that there is no longer a closed cross-section at this point. To remedy this, the aforementioned defrost channel is attached. Thus, it is not necessary to provide or manufacture the entire defrost assembly specifically for the armored version of the vehicle, but only the aforementioned defrost channel, which is manufactured specifically for the armored version of the vehicle and its instrument panel.The tooling for manufacturing the retrofitted defrost duct is significantly smaller and therefore less expensive than the corresponding tooling for the standard defrost assembly. This approach, in turn, allows for considerable cost and effort savings. Furthermore, the defrost duct can be designed to be manufactured as a single part for both left-hand and right-hand drive vehicles, offering further cost savings.

[0022] Another possible embodiment of the invention provides that, after trimming, at least one reinforcement structure intended for the armored version of the vehicle is attached as part of the instrument panel, particularly in the area of ​​a passenger airbag duct and / or in areas adjacent to the respective A-pillars when installed as intended. One or more such reinforcement structures may be necessary, for example, due to the significantly thicker and less flexible windshield in the armored version of the vehicle. The reinforcement structure in the area of ​​the passenger airbag duct can thus ensure that the passenger airbag deploys as intended when triggered. Furthermore, additional or alternative reinforcement structures can be provided elsewhere, which are advantageous for the armored version of the vehicle.

[0023] An instrument panel for an armored version of a motor vehicle comprises a shortened standard support bracket for a standard instrument panel from an unarmored version of the vehicle, laminated with a decorative material that features at least one folded seam. As mentioned previously, the folded seam ensures that the decorative material is not damaged during the instrument panel manufacturing process. Furthermore, the folded seam prevents visual defects, such as creases or similar imperfections, from occurring when the decorative material is folded back and forth. Finally, the folded seam can give the decorative material a high-quality appearance.

[0024] Further advantages, features, and details of the invention may become apparent from the following description of possible embodiments and from the drawings. The features and combinations of features mentioned above in the description, as well as those shown below in the figure description and / or in the figures themselves, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention. Brief character description

[0025] The drawing shows in: Fig. 1. A perspective view of an instrument panel for an armored variant of a motor vehicle; Fig. 2 a perspective view of a standard carrier upper part for a standard instrument panel for an unarmored standard version of the motor vehicle; Fig. 3 a decorative material which has several fold-over seams at various points for easy partial folding of the decorative material; Fig. 4 a schematic representation of several manufacturing steps for the manufacture of the instrument panel for the armored variant of the motor vehicle; Fig. 5 a representation of the partially completed instrument panel for the armored version of the motor vehicle; Fig. 6 a defrost duct which is part of the completed instrument panel for the armored version of the motor vehicle.

[0026] In the figures, identical or functionally equivalent elements are provided with the same reference symbols.

[0027] An instrument panel 10 for an armored variant of a motor vehicle is shown in a perspective view in Fig. Figure 1 shows the instrument panel 10, which includes a decorative material 12, for example, a leather decorative material. Furthermore, the instrument panel 10 includes a shortened defrost assembly 14. The following figures illustrate a method for manufacturing the instrument panel 10 in more detail. It is particularly important for the manufacturing process of the instrument panel 10 that as many serial production processes, serial production components, and serial production tools as possible are used in the production of an instrument panel for an unarmored version of the vehicle in question.

[0028] In Fig. Figure 2 shows a standard support bracket 16 for a standard instrument panel for an unarmored production version of the vehicle in a perspective view. At least one section line 18, indicated only schematically here, is specified on the standard support bracket 16, along which the standard support bracket 16 must be shortened to achieve a target dimension suitable for the instrument panel support bracket 12 of the armored vehicle. Due, among other things, to the comparatively thick windshield of the armored version of the vehicle, it is necessary to shorten the standard support bracket 16 accordingly in the longitudinal direction of the vehicle. Due to potentially thicker A-pillars of the armored vehicle compared to the unarmored vehicle, it may also be necessary to shorten the standard support bracket 16 on the sides, i.e., in the transverse direction of the vehicle.

[0029] In Fig. Figure 3 shows a top view of the decorative material 12. In the present case, the decorative material 12 comprises several fold-over seams 20. The fold-over seams 20 serve to allow the respective first parts 22 of the decorative material 12 to be easily folded away or over towards the second part 24.

[0030] In Fig. Figure 4 schematically depicts part of the required manufacturing steps for the instrument panel 10. A safety distance to the cutting line 18, not shown in detail, is specified. The hinge seams 20 are arranged or manufactured such that, when the decorative material 12 is arranged as intended on the standard carrier upper part 16, the hinge seams 20 have the corresponding safety distance to the cutting line 18 or to several cutting lines 18. Several seam grooves, not shown in detail here, can be provided on the standard carrier upper part 16, designed to accommodate the hinge seams 20 completely or at least partially.

[0031] Before the decorative material 12 is applied, masks 26 are attached to the standard carrier upper part 16. The masks 26 are attached where the first parts 22 of the decorative material 12 would rest if they were not folded away. Only then are the exposed areas of the standard carrier upper part 16, i.e., where there are no masks 26, coated with a hot melt adhesive. The decorative material 12 is then pre-fixed to the standard carrier upper part 16. The second part 24 of the decorative material 12, pre-fixed to the standard carrier upper part 16, is then press-laminated. For this purpose, the decorative material 12, which was previously applied to the standard carrier upper part 16, is placed into a press-laminating tool (not shown here), which is also used to manufacture instrument panels for unarmored versions of the vehicle.

[0032] A marking can be produced on the series carrier upper part 16, which serves for the automated identification of the series carrier upper part 16 to be shortened. For example, a bore can be produced as the marking, which is automatically detected by means of a button of an adhesive spraying system, as a result of which a hot melt adhesive specific to the production of the instrument panel 10 for the armored variant of the vehicle is applied before press lamination.

[0033] After the decorative material 12 has been partially press-laminated onto the standard carrier upper part 16, the resulting assembly is joined to a standard defrost assembly 28. The standard defrost assembly 28 is primarily used for the production of the unarmored standard version of the vehicle, but also serves as the basis for the production of the instrument panel 10 for the armored version. Thus, after press-lamination and before shortening the standard carrier upper part 16, it is joined to the standard defrost assembly 28 and then shortened together with it. This results, among other things, in the following: Fig. 1. Shortened defrost assembly shown. This can be achieved, for example, by milling from the rear and bottom and at all necessary points.

[0034] In Fig. Among other things, the shortened defrost assembly 14 can now be seen in Figure 5, which, due to the cutting, now partially has an open cross-section, where originally the standard defrost assembly 28 had a closed defrost channel for the standard version of the motor vehicle.

[0035] In Fig. Figure 6 shows a defrost duct 30, which was specially manufactured for the instrument panel 10 of the armored version of the vehicle. After shortening, the defrost duct 30 is attached to a front section of the shortened standard defrost assembly 14 as part of the instrument panel 10, in relation to its intended arrangement in the armored vehicle, for example by ultrasonic welding. This allows a closed cross-section to be created, through which, for example, hot air can be supplied towards the windshield for defrosting.

[0036] After shortening, at least one reinforcement structure intended for the armored version of the vehicle can be installed as part of the instrument panel 10. For example, a corresponding reinforcement structure can be installed in the area of ​​a passenger airbag duct. This may be necessary to enable the passenger airbag to deploy as intended, despite the armored windshield, and / or to prevent the structure surrounding the passenger airbag from yielding undesirably when the airbag is deployed. Reinforcement structures can also be provided in other locations, for example, near the A-pillars.

[0037] Using the described manufacturing process, it is possible to easily produce such instrument panels 10 for armored vehicle variants by employing as many standard components, tools, and processes as possible. This significantly reduces the effort required to manufacture such instrument panels 10, which also has a correspondingly positive effect on costs. REFERENCE MARK LIST 10 Instrument panel 12 Decorative material 14 shortened defrost assembly 16 series carrier top 18 Section line 20 Folded seam 22 first part of the decorative material 24 second part of the decorative material 26 masks 28 Series Defrost Assembly 30 Defrost channel

Claims

[1] Method for producing an instrument panel (10) for an armoured variant of a motor vehicle, comprising the steps: - Providing a series carrier upper part (16) for a series instrument panel for an unarmored series variant of the motor vehicle; - specifying at least one cutting line (18) on the series carrier upper part (16) along which it is to be shortened in order to achieve a desired dimension suitable for the instrument panel carrier of the armoured motor vehicle; - Specifying a safety distance from the cutting line (18); - Providing a decorative material (12) with at least one folding seam (20) which, when the decorative material (12) is arranged as intended on the series carrier upper part (16), has the safety distance from the cutting line (18); - Arranging the decorative material (12) on the series carrier upper part (16) and folding away a first part (22) of the decorative material (12) along the folding seam (20) from the cutting line (18), after which a second part (24) of the decorative material (12) lying on the series carrier upper part (16) is press-laminated by means of a press-laminating tool designed for the unarmored series variant of the motor vehicle and then the series carrier upper part (16) is shortened along the cutting line (18) to the intended nominal size; - Folding back the first part (22) of the decorative material (12) onto the series carrier upper part (16) shortened to the desired size or onto another component, after which the first part (22) of the decorative material (12) is then laminated onto the series carrier upper part (16) shortened to the desired size or onto the other component. [2] Method according to claim 1, wherein, before arranging the decorative material (12) on the series carrier upper part (16), at least one seam trench is produced on the series carrier upper part (16) for at least partially receiving the folding seam (20). [3] Method according to claim 1 or 2, wherein, before the decorative material (12) is arranged on the series carrier upper part (16), a marking is produced on the latter, which marking serves for the automated detection of the series carrier upper part (16) to be shortened. [4] Method according to claim 3, wherein a hole is produced as the marking, which is detected by means of a sensor of an adhesive spraying system, as a result of which an adhesive specific for the production of the instrument panel (10) for the armoured variant of the motor vehicle is applied before the press lamination. [5] Method according to one of the preceding claims, wherein, before arranging the decorative material (12) on the series carrier upper part (16), a first region of the series carrier upper part (16) associated with the first part (22) of the decorative material (12) is covered and then a second region of the series carrier upper part (16) associated with the second part (24) of the decorative material (12) is provided with a hotmelt, after which the decorative material (12) is pre-fixed to the series carrier upper part (16) and then the second part (24) of the decorative material (12) is press-laminated. [6] Method according to one of the preceding claims, wherein the first part (22) of the decorative material (12) folded away along the folding seam (20) is fixed to the series carrier upper part (16) before it is shortened to size, in particular by means of clamps. [7] Method according to one of the preceding claims, wherein after the press-laminating and before the shortening of the series carrier upper part (16), this is connected to a series defrost assembly (28) for the unarmored series variant of the motor vehicle and is then shortened together with this. [8] Method according to claim 7, wherein after the joint shortening of the series carrier upper part (16) and the series defrost assembly (28), a defrost channel (30) is attached to a front region of the shortened series defrost assembly (14) with respect to a proper arrangement in the armoured vehicle, in particular by means of ultrasonic welding. [9] Method according to one of the preceding claims, wherein after the trimming, at least one reinforcement structure provided for the armoured variant of the motor vehicle is attached as part of the instrument panel (10), in particular in the region of a passenger airbag channel and / or in areas adjacent to respective A-pillars in the intended installation position.

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