Instrument panel carrier and motor vehicle

Abstract

The invention relates to an instrument panel carrier (1) of a motor vehicle with a three-dimensionally printed support structure (2) which includes a receptacle for an air conditioning unit (4). To improve the functionality of the instrument panel carrier (1), the three-dimensionally printed support structure (2) of the instrument panel carrier (1) with the mount for the air conditioning unit (4) is load-force optimized and printed from a metallic material.

Description

[0001] The invention relates to an instrument panel carrier according to the preamble of claim 1. The invention further relates to a motor vehicle with such an instrument panel carrier.

[0002] The generic German patent application DE 10 2020 100 338 A1 discloses a structural dashboard element for a vehicle dashboard assembly, wherein the structural dashboard element comprises: a crossmember bracket with a first surface, a first side, and a second side, and wherein the crossmember bracket is attached to a crossmember of the vehicle; a steering column support extending from the first side of the crossmember bracket; and a first air conditioning duct, HVAC duct, with a first end and a second end, and wherein the first HVAC duct is located adjacent to the second side of the crossmember bracket, wherein the structural dashboard element can be manufactured by a 3D or additive printing process using a metal alloy, such as an aluminum alloy. The American patent application US 2023 0 072 338 A1 discloses a structural element,forming a dashboard body of a motor vehicle, intended to be installed in a transverse mounting position within a passenger compartment of a vehicle, wherein the structural element has a one-piece perforated structure produced by three-dimensional printing, and wherein the perforated structure defines the following: a first inner channel that completely penetrates the structural element and extends transversely in the installation position of the structural element, wherein the first channel is shaped to receive a cross member, in particular one bent with a constant radius of curvature, and has at least two fastening elements intended for attachment to the cross member; a second inner passage that connects the first passage to a side of the structural element facing the rear of the vehicle in the installation position of the structural element, wherein the second passage has at least one fastening element.which serves to attach the bracket for the steering column mounting. U.S. patent application US 2019 O 210 464 A1 discloses a self-supporting support structure for an instrument panel in a vehicle, comprising: a network of a plurality of hollow beam elements and solid beam elements arranged according to a load path analysis, wherein the hollow support elements form at least one distributor used as an air duct and include at least one air inlet for introducing air into the hollow support elements and at least one air outlet for directing the air into a passenger compartment of the vehicle, wherein the support structure forms at least one mechanical connection section for connecting the support structure to adjacent structural elements of the vehicle, and wherein the support structure forms at least one steering column bearing section for supporting a steering column on the support structure.wherein the support structure forms at least one airbag mounting section for attaching an airbag to the support structure, wherein the support structure forms at least one duct for a vehicle airbag. U.S. patent application US 2022 0 009 557 A1 discloses an instrument panel body, wherein the body is manufactured as a single piece by three-dimensional printing, and wherein the instrument panel body has a gap structure defining at least one fluid circulation channel with at least one opening, wherein the gap structure defines a plurality of fluid circulation channels, at least some of which are fluidically interconnected, wherein an accessory comprises a fluid circuit that is connected via an opening therein to at least one fluid circulation channel of the body, wherein at least the accessory is selected from a ventilation device.a heating unit and an air conditioning unit. The Chinese utility model CN ​​2 07 311 620 U discloses a one-piece dashboard support forming a continuous shell with a retaining element. The German publications DE 11 2011 103 825 T5, DE 10 2004 042 287 A1 and DE 103 34 500 A1 each disclose a housing for a heating, ventilation and air conditioning unit.

[0003] The object of the invention is to functionally improve an instrument panel carrier according to the preamble of claim 1.

[0004] The problem is solved by an instrument panel support with the features of claim 1. The motor vehicle is preferably a passenger car. In the motor vehicle, the instrument panel support advantageously serves to support a lower and an upper instrument panel section. The three-dimensionally printed support structure is manufactured using a three-dimensional printing process. This three-dimensional printing process includes all known printing methods, in particular additive manufacturing processes, with which the claimed support structure can be manufactured in an integrated manner from a metallic material. The integrated manufacturing of the instrument panel support significantly simplifies its production. The number of individual parts required for the manufacture of the motor vehicle can be particularly advantageously reduced by using the claimed instrument panel support.Furthermore, the load-optimized design of the three-dimensionally printed support structure made of metallic material effectively improves the vehicle's stability in a side-impact collision. The three-dimensionally printed and load-optimized support structure of the instrument panel carrier features a crossmember with two attachment points for connecting the crossmember to the vehicle's A-pillars. Within this three-dimensionally printed and load-optimized support structure, the crossmember represents at least one load path for a side impact. The longitudinal direction of the vehicle is also referred to as the x-direction. The transverse direction of the vehicle is also referred to as the y-direction. The vertical direction of the vehicle is also referred to as the z-direction. In a side impact, forces are transferred into the instrument panel carrier via one of the A-pillars.The load path within the crossmember allows forces from a side impact to be absorbed in a desired manner and / or transferred to a specific location where they can be dissipated using suitable side impact elements. The three-dimensionally printed and load-optimized support structure of the instrument panel carrier features a closed frame integrated into the side impact load path to accommodate the air conditioning unit. This further improves the stability of the vehicle, particularly in the event of a side impact, and enhances the load-bearing capacity of the instrument panel carrier. Furthermore, the closed frame for the air conditioning unit prevents or at least reduces unwanted damage to the unit.The frame for mounting the air conditioning unit constitutes a load-bearing housing structure integrated into the side-impact load path, encompassing at least part of the air conditioning unit's housing. This allows for a particularly advantageous improvement in the stability of the instrument panel support, especially in the event of a side impact. The air conditioning unit's housing structure is bonded to the three-dimensionally printed support structure of the instrument panel support in a material-bonded and / or integral manner through the three-dimensional printing process. The air conditioning unit's modular design is advantageous. For example, individual modules can be easily inserted into the air conditioning unit's housing with its load-bearing housing structure during installation. The load-bearing housing structure integrated into the side-impact load path features at least one flap mounting surface. This simplifies the manufacturing of the air conditioning unit.In particular, the number of individual parts required to represent the air conditioning unit or to integrate the air conditioning unit into the instrument panel carrier can be reduced.

[0005] The problem is also solved by an instrument panel support with the features of claim 2. The motor vehicle is preferably a passenger car. In the motor vehicle, the instrument panel support advantageously serves to support a lower and an upper instrument panel section. The three-dimensionally printed support structure is manufactured using a three-dimensional printing process. This three-dimensional printing process includes all known printing methods, in particular additive manufacturing processes, with which the claimed support structure can be manufactured in an integrated manner from a metallic material. The integrated manufacturing of the instrument panel support significantly simplifies its production. The number of individual parts required for the manufacture of the motor vehicle can be particularly advantageously reduced by using the claimed instrument panel support.Furthermore, the load-optimized design of the three-dimensionally printed support structure made of metallic material effectively improves the vehicle's stability in a side-impact collision. The three-dimensionally printed and load-optimized support structure of the instrument panel carrier features a crossmember with two attachment points for connecting the crossmember to the vehicle's A-pillars. Within this three-dimensionally printed and load-optimized support structure, the crossmember represents at least one load path for a side impact. The longitudinal direction of the vehicle is also referred to as the x-direction. The transverse direction of the vehicle is also referred to as the y-direction. The vertical direction of the vehicle is also referred to as the z-direction. In a side impact, forces are transferred into the instrument panel carrier via one of the A-pillars.The load path within the crossmember allows forces from a side impact to be absorbed in a desired manner and / or transferred to a specific location where they can be dissipated using suitable side impact elements. The three-dimensionally printed and load-optimized support structure of the instrument panel carrier features a closed frame integrated into the side impact load path to accommodate the air conditioning unit. This further improves the stability of the vehicle, particularly in the event of a side impact, and enhances the load-bearing capacity of the instrument panel carrier. Furthermore, the closed frame for the air conditioning unit prevents or at least reduces unwanted damage to the unit.The frame for mounting the air conditioning unit constitutes a load-bearing housing structure integrated into the side-impact load path, which includes at least part of the air conditioning unit housing. This allows the air conditioning unit housing to be effectively improved, particularly to increase the stability of the instrument panel support, especially in the event of a side impact. The air conditioning unit housing structure is bonded to the three-dimensionally printed support structure of the instrument panel support in a material-bonded and / or integral manner through the three-dimensional printing process. The air conditioning unit is advantageously modular in design. For example, individual modules of the air conditioning unit can be easily inserted into the air conditioning unit housing with the load-bearing housing structure during installation. The load-bearing housing structure integrated into the side-impact load path has at least one axle mounting point.This further simplifies the manufacturing of the air conditioning unit, because an axle required in the air conditioning unit, preferably designed as a plug-in axle, can simply be inserted into the axle receptacle on the instrument panel carrier. The plug-in axle belongs, for example, to an actuator motor integrated into the air conditioning unit.

[0006] A preferred embodiment of the instrument panel support is characterized in that the frame for receiving the air conditioning unit has the shape of a rectangle. This simplifies the installation of the air conditioning unit in the instrument panel support.

[0007] Another preferred embodiment of the instrument panel support is characterized in that the three-dimensionally printed and load-optimized support structure of the instrument panel support has a support leg for supporting the air conditioning unit in a vehicle height direction. The vehicle height direction is also referred to as the z-direction. The support leg advantageously reduces undesirable vibrations during vehicle operation, which are unavoidable, for example, due to the weight of the air conditioning unit. The support leg is advantageously supported at one free end by a floor structure of the vehicle.

[0008] Another preferred embodiment of the instrument panel support is characterized in that the three-dimensionally printed and load-optimized support structure of the instrument panel support has at least one air bag recess, at least one mixing chamber, and / or at least one channel structure. The channel structure is, for example, provided with a plastic foam that serves to represent an air duct on the existing channel structure. This significantly simplifies the manufacturing process for representing air ducts connected to the air conditioning unit.

[0009] The invention further relates to a motor vehicle with two A-pillars to which a previously described instrument panel support is attached. The instrument panel support is attached to the A-pillars, for example, by means of screw connections.

[0010] Further advantages, embodiments, and details of the invention will become apparent from the following description, in which various exemplary embodiments are described in detail with reference to the drawings. The drawings show: Fig. 1, Fig. 2 to Fig. 3 perspective views of an instrument panel support with a three-dimensionally printed and load-optimized support structure that includes a mount for an air conditioning unit; Fig. 4 a perspective view of the instrument panel support from the Fig. 1, Fig. 2 to Fig. 3 without the air conditioner; and Fig. 5 the instrument panel carrier Fig. 4 according to a further embodiment with an integrated supporting housing structure.

[0011] In the Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. Figure 5 shows an instrument panel support 1 in various perspectives and embodiments. The instrument panel support 1 comprises a three-dimensionally printed support structure 2. The three-dimensionally printed support structure 2 includes a receptacle 3 for an air conditioning unit 4.

[0012] The three-dimensionally printed support structure 2 of the instrument panel carrier 1 includes, in addition to the mounting 3 for the climate control unit 4, a cross member 5. The cross member 5 extends in a transverse direction of the vehicle, which is also referred to as the y-direction.

[0013] At its opposite ends, the crossmember 5 has two attachment points 6, 7 for connecting the instrument panel carrier 1 to the crossmember 5 and the A-pillars of a motor vehicle. The attachment points 6, 7 are designed, for example, as screw attachment points. Thus, the instrument panel carrier 1 and the crossmember 5 can be easily and securely fastened to the A-pillars of the motor vehicle using screws at the attachment points 6, 7.

[0014] In Fig. Figure 4 indicates further attachment points 8 and 9 on the instrument panel support 1, indicated by circles. Attachment points 8 are advantageously used to connect an upper instrument panel section to the instrument panel support 1. Attachment points 9 are advantageously used to connect a lower instrument panel section to the instrument panel support 1. Further attachment points on the instrument panel support 1 serve, for example, to attach a center console to the instrument panel support 1.

[0015] The mounting 3 for the air conditioning unit 4 comprises a closed frame 10. In the Fig. 1, Fig. 2 to Fig. Figure 3 shows how the air conditioning unit 4 is installed in the frame 10 of the instrument panel carrier 1.

[0016] The instrument panel support 1 comprises, in addition to the mounting 3 with the frame 10 and the cross member 5, a support leg 15. The support leg 15 extends downwards from the cross member 5 with the frame 10 essentially in a vehicle z-direction or vehicle height direction. The support leg 15 allows the weight of the air conditioning unit 4 to be easily supported against a floor structure of the vehicle when the instrument panel support 1 is installed.

[0017] In Fig. Figure 5 indicates that the three-dimensionally printed and load-optimized support structure 2 of the instrument panel carrier 1, in addition to the cross member 5 and the support leg 15, also includes a housing structure 11, which is connected to the frame 10 by the three-dimensional printing process and, together with the frame 10, is integrated into the load path for the side impact on the motor vehicle with the instrument panel carrier 1.

[0018] The housing structure 11 is part of a housing 20 of the air conditioning unit 4. The housing structure 11 includes, for example, a pot-shaped housing body of the air conditioning unit 4. Individual modules of the air conditioning unit 4 can be easily inserted into this pot-shaped housing body during assembly.

[0019] The housing structure 11 of the housing 20 of the air conditioning unit 4 is advantageously equipped with at least one flap mounting surface 12, a shaft receptacle 13, and a mixing chamber 16. The flap mounting surface 12 provided on the housing structure 11 interacts with an air flap (not shown). The shaft receptacle 13 of the housing structure 11 serves to insert a plug-in shaft (not shown), for example, of an actuator.

[0020] In Fig. Figure 5 further shows that an airbag receptacle 14 is formed on the instrument panel carrier 1. The airbag receptacle 14 serves, for example, to accommodate a knee airbag (not shown) on the instrument panel carrier 1.

[0021] Furthermore, the instrument panel carrier 1 is advantageously equipped with a channel structure 17, which, as can be seen in Fig. 5, for example, is provided in or on the housing structure 11. This channel structure 17, in combination with a plastic foam, advantageously serves to provide air channels in or on the instrument panel support 1. This eliminates the need for complex blow-molded parts to represent the air channels. Reference sign 1 Instrument panel carrier 2 Supporting structure 3 recording 4 air conditioner 5 crossbeams 6 Connection point 7 Connection point 8 more connection points 9 more connection points 10 frames 11 Housing structure 12 flap bearing surface 13 Axle mounting 14 Airbag intake 15 legs 16 Mixing chamber 17 Channel structure 20 cases

Claims

[1] Instrument panel carrier (1) of a motor vehicle with a three-dimensionally printed support structure (2) which includes a mount for an air conditioning unit (4), characterized by, that the three-dimensionally printed support structure (2) of the instrument panel carrier (1) with the mounting for the air conditioning unit (4) is load-optimized and printed from a metallic material, wherein the three-dimensionally printed and load-optimized support structure (2) of the instrument panel carrier (1) has a cross member (5) with two connection points (6, 7) for connecting the cross member (5) to the A-pillars of the motor vehicle, wherein the cross member (5) in the three-dimensionally printed and load-optimized support structure (2) of the instrument panel carrier (1) represents at least one load path for a side impact, wherein the three-dimensionally printed and load-optimized support structure (2) of the instrument panel carrier (1) has a closed frame (10) integrated into the load path for the side impact for mounting the air conditioning unit (4),wherein the frame (10) for receiving the air conditioning unit (4) constitutes a load-bearing housing structure (11) integrated into the load path for the side impact, which comprises at least a part of a housing (20) of the air conditioning unit (4), characterized by , that the load-bearing housing structure (11) integrated into the load path for the side impact has at least one flap mounting surface (12). [2] Instrument panel carrier (1) according to the preamble of claim 1, in particular according to claim 1, characterized by , that the load-bearing housing structure (11) integrated into the load path for the side impact has at least one axle mount (13). [3] Instrument panel carrier (1) according to any one of the preceding claims, characterized by , that the frame (10) for receiving the air conditioning unit (4) has the shape of a rectangle. [4] Instrument panel carrier (1) according to any one of the preceding claims, characterized by, that the three-dimensionally printed and load-optimized support structure (2) of the instrument panel carrier (1) has a support leg (15) for supporting the air conditioning unit (4) in a vehicle height direction. [5] Instrument panel carrier (1) according to any one of the preceding claims, characterized by , that the three-dimensionally printed and load-optimized support structure (2) of the instrument panel carrier (1) has at least one air bag receptacle (14), at least one mixing chamber (16) and / or at least one channel structure (17). [6] Motor vehicle with two A-pillars to which an instrument panel carrier (1) according to one of the preceding claims is attached.

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