Ultra-lightweight and recyclable dashboard

Abstract

The invention relates to a dashboard (01) comprising at least one main part (02, 03, 04) made of PPE, said dashboard (01) being recyclable, ultra-lightweight, acoustically and thermally insulating, easy to assemble and disassemble, designed to operate with thermal expansions, said dashboard including crash protection elements and integrating numerous features directly molded into the shape of the parts, in particular air circulation circuits.

Description

[0001] P4286PC00 spec dpt

[0002] Ultra-light and recyclable dashboard

[0003] CORRESPONDING REQUEST

[0004] This application claims priority from earlier application No. PCT / IB2024 / 059873, filed on October 9, 2024 on behalf of SOFTCAR SA, the content of that earlier application being incorporated by reference in its entirety into this application.

[0005] TECHNICAL FIELD

[0006] The present invention relates to an ultra-light and 100% recyclable vehicle dashboard made up of a small number of parts, made with a single material, and integrating a large number of functionalities.

[0007] PREVIOUS TECHNIQUE

[0008] Vehicles, particularly four-wheeled vehicles such as cars, vans, trucks, camper vans, motorhomes, and others, have a dashboard located in front of the driver. This dashboard has several functions: integrating the human-machine interface, providing information to users (speed, alarm, fuel gauge, energy gauge, navigation, etc.), integrating buttons or controls (hazard lights, ventilation, audio settings, etc.), directing ventilation air to regulate the cabin temperature, directing warm air to demist and defrost the windshield, providing storage for users' belongings, having a pleasant appearance and feel, resisting heat and UV radiation under the windshield, serving as a safety feature, soundproofing the cabin from the elements at the front of the vehicle, etc.Temperature variations under the windshield (from -45°C to 80°C) cause extreme thermal expansion of the dashboard, which must be taken into account to prevent breakage and rattling. Aside from driving elements such as the steering wheel, controls, and pedals, it is the primary aesthetic and ergonomic interface between users and the vehicle, making it a key component. It also plays a crucial role in passenger protection in the event of a crash.

[0009] Modern dashboards, to fulfill all their functions, are made up of a multitude of parts; some are technical, such as soundproofing components, ventilation ducts, buttons, the steering column, or the pedal assembly, for example, while others are aesthetic, designed to cover the driver's area and conceal technical components that often have an unattractive appearance. These parts are manufactured by injection molding, thermoforming, thermofoaming, and extrusion, using a wide variety of materials such as thermoplastics, metals, and fabrics, and generally include a significant amount of non-recyclable thermosetting materials such as polyurethane, for example, to obtain flexible foamed covers widely used in current vehicle ranges. All these parts are generally clipped or screwed together. Other parts are overmolded and therefore cannot be disassembled for recycling. P4286PC00 spec dpt

[0010] The large number of parts and materials used (several hundred different materials, some weighing less than two grams) makes assembling and disassembling the dashboard a lengthy and expensive process. The wide variety of materials used makes sorting them tedious, recycling the entire assembly difficult, and material recovery very low. The extensive use of materials such as thermosets renders a significant portion of the dashboard's volume unrecyclable. Treatments applied to certain parts (galvanizing, stitching, welding, varnishing) further complicate sorting and recycling. Consequently, at the end of their life, dashboards are generally not recycled but rather incinerated.

[0011] The manufacturing cost of these dashboards is significant, requiring extensive tooling and therefore representing a high capital expenditure (CAPEX). They are designed for 5,000 hours of operation. They weigh several tens of kilograms and fall outside the scope of any sustainable development or circular economy approach.

[0012] SUMMARY OF THE INVENTION AND METHODS OF ITS EXECUTION

[0013] The present invention overcomes all the aforementioned drawbacks by proposing a dashboard made up of a small number of parts, all made from a single recyclable material and forming the main body of the dashboard. P4286PC00 spec dpt

[0014] To this end, the invention proposes, in a given embodiment by way of non-limiting example, a dashboard made of three stacked pieces made of EPP (Expanded Polypropylene). Due to their thickness, these expanded pieces are rigid enough to accommodate various accessories. They are fixed to the structural elements of the vehicle's chassis and allow them to be concealed. These pieces also allow other functional elements, such as the steering column or the pedal assembly, to be concealed.

[0015] PPE parts also integrate other vehicle components such as an electronic vehicle control unit, a central information and control tablet, heating, ventilation, and air conditioning elements for the passenger compartment, a motorized ventilation flap, electrical harnesses, a GPS, LTE, and Bluetooth antenna, ambient lighting elements, other interior masking elements, defrosting grilles, a smartphone holder, etc.

[0016] In the PPE parts, ducts are molded in, guiding air from the ventilation unit to the various outlets (passenger compartment and windshield) without the need for additional hoses. Since the materials are the same for all dashboard components, thermal expansion does not affect the air ducts, which are molded directly into the parts. The ducts remain airtight regardless of temperature. Storage compartments and other cavities are also molded directly into these parts, reducing the number of individual parts to be manufactured and the number of assembly steps.

[0017] The use of PPE allows for an ultra-lightweight, structurally sound dashboard with an attractive appearance. It can be textured or grained directly without the need for additional components, is pleasant to the touch with a degree of flexibility, and is 100% recyclable. It can be formed partially or entirely from recycled material(s), thus complying with European directives. PPE also provides acoustic and thermal insulation, and energy absorption in the event of a crash.

[0018] The dashboard's simple construction (no glued or welded components) makes it easy to install, easy to replace for vehicle refurbishment, and easy to recycle as a single unit, as the number of materials to separate is small. It also allows for conversion from a left-hand drive to a right-hand drive vehicle with minimal parts changes and therefore few tools required (ideally only one).

[0019] The dashboard mounting on the vehicle chassis is designed to compensate for significant differences in expansion, with substantial clearances between parts made of different materials, and a limited number of fasteners, some of which allow the parts room to expand. P4286PC00 spec dpt

[0020] In embodiments, the invention relates to a vehicle dashboard comprising at least one main part made of a single material.

[0021] In some execution modes, the instrument panel comprises at least one to six main parts made of a single material.

[0022] In embodiments, the material constituting the main part or parts is fully and / or partially recyclable and / or made from recycled materials.

[0023] In some embodiments, the material constituting the main part or parts is PPE (Expanded Polypropylene). Other equivalent materials are possible.

[0024] In some embodiments, the instrument panel includes air circuits for ventilation, demisting and defrosting, said air circuits being part of the main part or parts thereof, without any added part.

[0025] In some embodiments, the instrument panel includes a ventilation flap that directs the majority of the air from said circuits either towards the windshield or into the passenger compartment, said ventilation flap being located directly within the air circuits. P4286PC00 spec dpt

[0026] In some embodiments, at least two of the main parts are fixed to each other only by clips.

[0027] In dashboard execution modes, the intermediate TBDB and upper TBDB (the term "TBDB" being the contraction of "TaBleau De Bord") are fixed to each other only by clips, allowing the upper TBDB to be changed very quickly without touching any other element(s) of the dashboard.

[0028] In some execution modes, the dashboard includes a small number of fixings, said fixings being simple and quick to implement, allowing simple and quick assembly and disassembly of the whole, for production, for renovation, and / or for recycling.

[0029] In some embodiments, the instrument panel includes at least one crash energy absorber forming part of at least one of said main parts, and not having a metallic reinforcement insert, providing crash protection.

[0030] In some execution modes, the main parts have a texture or graining applied during manufacturing, allowing for parts with a specific appearance.

[0031] In embodiments, the material constituting said main parts and the geometry of said main parts achieve good P4286PC00 spec dpt thermal insulation, good acoustic insulation and / or good vibration absorption.

[0032] In some execution modes, the panel mechanically supports an electronic control unit, and / or ventilation elements, and / or heating elements, and / or air conditioning elements, and / or a smartphone holder and / or ambient lighting.

[0033] In some execution modes, the instrument panel includes at least one storage element, such as a storage compartment, forming part of at least one of said main parts.

[0034] In some execution modes, the dashboard includes at least one TBDB foot having better shock resistance than said main parts.

[0035] In some execution modes, the dashboard includes said TBDB foot which is fixed to said dashboard only by simple means such as clips or screws allowing said TBDB foot to be changed quickly.

[0036] In some embodiments, the TBDB foot is made of a material of the same family as the main parts, allowing them to be recycled in the same recycling stream. P4286PC00 spec dpt

[0037] In execution modes, only the said TBDB base changes between a dashboard with left-hand drive and a dashboard with right-hand drive.

[0038] In embodiments, the invention relates to a vehicle equipped with a dashboard as described in this application.

[0039] In some execution modes, the dashboard is placed and / or screwed onto a floor and / or a stand.

[0040] In some embodiments, the fixings between the dashboard and other vehicle components allow a degree of freedom in the transverse direction, to allow the various parts to expand thermally without causing breakage or unpleasant friction or squeaking noises.

[0041] In some embodiments, the main part or parts have transverse play relative to the other vehicle elements, in order to allow it / them to expand thermally without causing breakage or unpleasant friction or squeaking noise.

[0042] SUMMARY DESCRIPTION OF THE DRAWINGS

[0043] The present invention and its advantages will become more apparent from the description below of an embodiment given by way of non-limiting example, with reference to the accompanying drawings in which: P4286PC00 spec dpt

[0044] - Figure 1 represents a perspective view of the 3 main parts of the dashboard;

[0045] - Figure 2 shows an exploded view of the 3 main parts of the dashboard;

[0046] - Figure 3 shows a view of the open dashboard with the ventilation circuits visible;

[0047] - Figure 4A represents a perspective view of the dashboard mounted on a chassis structure, passenger compartment side;

[0048] - Figure 4B represents a perspective view of the dashboard mounted on a chassis structure, external side;

[0049] - Figure 5A represents an exploded view of the dashboard from the passenger compartment side;

[0050] - Figure 5B shows an exploded view of the dashboard from the outside;

[0051] - Figure 6A shows a cross-sectional view of the dashboard with the flap positioned for defrosting;

[0052] - Figure 6B shows a cross-sectional view of the dashboard with the flap positioned for passenger compartment ventilation;

[0053] NUMERICAL REFERENCES OF THE ELEMENTS

[0054] - 01: dashboard

[0055] - 02: TBDB low

[0056] - 02a: Pocket tray

[0057] - 02b: Crash energy absorber

[0058] - 03: Intermediate TBDB

[0059] - 03a: Clip TBDB P4286PC00 spec dpt

[0060] - 03b: Intermediate air circuit

[0061] - 03c: Lower defrosting circuit

[0062] - 03d: Clip flap

[0063] - 03rd: Lower passenger compartment circuit

[0064] - 04: TBDB high

[0065] - 04a: TBDB clipping cavities

[0066] - 04b: Upper defrosting circuit

[0067] - 04c: Upper passenger compartment circuit

[0068] - 05: Ventilation column

[0069] - 05a: Upper cavity

[0070] - 21: Foot TBDB

[0071] - 22: Electronic control unit

[0072] - 23: Smartphone holder

[0073] - 31: TBDB screw

[0074] - 32: Ventilation flap

[0075] - 33: Valve motor

[0076] - 41: Defrosting grilles

[0077] - 42: Rain sensor

[0078] - 43: Ambient lighting

[0079] - 51: Heating and ventilation unit

[0080] - 52: Air conditioning evaporator

[0081] - 53: Cabin air filter

[0082] - 54: Condensate funnel

[0083] - 60: Chassis

[0084] - 61: Floor

[0085] 62: Easel P4286PC00 spec dpt

[0086] 63: Trestle beam

[0087] - 64: Easel upright

[0088] - 65: Steering column

[0089] - 66: Steering wheel

[0090] - 67: Crankset

[0091] - 68: Electrical harness

[0092] - 69: Upper trestle screw

[0093] - 70: Rear trestle screw

[0094] - 71: Door or hood release handle

[0095] - 72: Interior lighting

[0096] - 73: TBDB foot screw

[0097] DETAILED DESCRIPTION OF EXECUTION METHODS OF THE INVENTION

[0098] The invention is not limited to the embodiments or methods of execution described, but is capable of being modified by using means equivalent to those described. The invention and its principle therefore relate to a vehicle dashboard 01 consisting of three main parts: the lower dashboard 02, the intermediate dashboard 03, and the upper dashboard 04 (the term "dashboard" being an abbreviation of "TaBleau De Bord"). These main parts 02, 03, and 04 are favorably manufactured by heating and expanding a polymer in a mold, preferably recyclable thermoplastic Expanded Polypropylene (EPP). These main parts 02, 03, and 04 can be manufactured entirely from virgin material, entirely from recycled materials, or a mixture of both.The use of recycled materials is in line with the new European laws, which increasingly encourage and require the automotive industry to use second-life materials.

[0099] The instrument panel 01 according to the invention is not limited to three main parts, but may comprise from one to six parts, for example. According to Figures 4A to 6B, the instrument panel 01 includes another part, the ventilation column 05, which contains a heating / ventilation unit 51, an air conditioning evaporator 52, and a cabin air filter 53. The ventilation column 05 has the same material, process, assembly, and other properties as the main parts 02, 03, and 04. However, it is not part of the overall structure of the instrument panel 01, and it is much less visible in the passenger compartment than the other main parts. Thus, in the remainder of this description, the term "main part" will be used to refer only to the parts numbered 02, 03, and 04 in the figures, although the invention is not limited to these three parts.The term "PPE parts" will be used to characterize the parts numbered 02, 03, 04, and 05 in the figures, although said part 05 is not part of said main parts 02, 03 and 04, and the invention is not limited to the use of PPE to produce said parts 02, 03, 04 and 05, other equivalent materials being possible and covered by this application.

[0100] The main parts 02, 03, and 04 are assembled by simple and detachable means, facilitating recycling. For example, as shown in the figures of this application, which are given by way of non-limiting example, the intermediate TBDB 03 is fixed to the lower TBDB 02 with TBDB P4286PC00 spec dpt screws.

[0101] 31. The upper TBDB 04 is attached to the intermediate TBDB 03 by clipping. The intermediate TBDB 03 has TBDB 03a clips for this purpose, and the upper TBDB 04 has TBDB 04a clipping cavities. The TBDB 03a clips are formed during the manufacturing process of the intermediate TBDB 03. They are geometries of the intermediate TBDB 03, made of the same material as the rest of the part. The TBDB 43a clipping cavities are formed during the manufacturing process of the upper TBDB 04. They are geometries of the upper TBDB 04, made of the same material as the rest of the part.

[0102] The main components 02, 03, and 04 are stacked one on top of the other and held in place by simple and quick-to-install and remove fasteners. There is no gluing, welding, or other such fastening. This simplifies the assembly process of the dashboard 01, its refurbishment if, for example, worn or damaged parts need replacing, and its recycling, as the components are easy to separate.

[0103] Since the intermediate dashboard 03 and upper dashboard 04 are held together only by clips, the upper dashboard 04 can be changed very quickly without touching any other part of the dashboard (01). Simply pull it to unclip it, then press a new one against the intermediate dashboard 03. A new upper dashboard 04 of the same style can thus be installed, or one of a different style, depending on preferences and circumstances. P4286PC00 spec dpt

[0104] According to one embodiment, the PPE parts 02, 03, 04, and 05 are fitted with inserts, for example, made of PP (Polypropylene), into which the TBDB 31 screws or other screws of the system are screwed. These inserts improve the screw retention and thus the fastening. Since the inserts are preferably made of PP, they can be recycled in the same process as the rest of the PPE parts 02, 03, 04, and 05 without having to separate the PPE parts from the compact PP inserts, as the materials belong to the same family.

[0105] To be approved, a vehicle must have means of demisting and defrosting the windshield. For this purpose, the heating and ventilation unit 51 draws air from the vehicle's passenger compartment, via the passenger compartment filter 53, and heats it. At the outlet of the heating and ventilation unit 51, the hot air is pushed into an upper cavity 05a of the ventilation column, then into an intermediate air circuit 03b, then into a cavity formed by a lower defrosting circuit 03c and an upper defrosting circuit 04b, and finally through defrosting grilles 41 to be directed onto the windshield.

[0106] The upper cavity 05a is formed during the manufacturing process of the ventilation column 05. It is a part of the ventilation column 05, made of the same material as the rest of the part. The intermediate air circuits 03b and the lower defrost circuit 03c are formed during the manufacturing process of the intermediate TBDB 03. They are parts of the intermediate TBDB 03, made of the same material as the rest of the part. The upper defrost circuit 04b is formed during the manufacturing process of the upper TBDB 04. It is a geometry of the upper TBDB 04, made of the same material as the rest of the part.

[0107] Between said intermediate air circuit 03b and said defrosting circuits 03c and 04b, a ventilation damper 32 is mounted with a damper motor 33. Said ventilation damper 32 and damper motor 33 are clipped into damper clips 03d of said intermediate TBDB. The damper clips 03d are formed during the manufacturing process of said intermediate TBDB 03. They are parts of said intermediate TBDB 03, made of the same material as the rest of the part.

[0108] When the ventilation flap 32 is in the raised position, as shown in Figure 6A, warm air flows to the windshield, as described previously, with all other circuits closed. When the ventilation flap 32 is in the lowered position, as shown in Figure 6B, the circuit to the windshield is closed. Warm air then flows between the lower passenger compartment circuits 03e and the upper passenger compartment circuits 04c, towards the passenger compartment and the occupants to warm them.

[0109] The circuits described above as closed may, however, allow some air to pass through, as automotive construction standards require that 80% of the airflow be maintained in one circuit and 20% in the other. Thus, when the ventilation flap 32 is in the raised position, approximately 80% of the air from the heating and ventilation unit 51 is directed towards the windshield, with the remaining 20% ​​directed towards the passenger compartment. Conversely, when the ventilation flap 32 is in the lowered position, approximately 80% of the air from the heating and ventilation unit 51 is directed towards the passenger compartment, with the remaining 20% ​​directed towards the windshield.

[0110] The lower passenger compartment circuits 03e are formed during the manufacturing process of the intermediate TBDB 03. They are parts of the intermediate TBDB 03, made of the same material as the rest of the part. The upper passenger compartment circuits 04c are formed during the manufacturing process of the upper TBDB 04. They are parts of the upper TBDB 04, made of the same material as the rest of the part.

[0111] The air circulating in cavities 04a and 05a and in circuits 03b, 03c, 03e, 04b, and 04c can also be cold. For this purpose, the air passes around the air conditioning evaporator 52, which is cooled by a refrigeration system. When the air then passes into the heating and ventilation unit 51, the internal heating circuit is deactivated, so that the air is cooled and dried by contact with the walls of the air conditioning evaporator 52, but is not heated in the heating and ventilation unit 51.

[0112] The air circulating in said cavities 04a and 05a and in said circuits 03b, 03c, 03e, 04b and 04c can also be hot and dry. For this purpose, the air passes around said air conditioning evaporator 52, which is cooled by a refrigeration system. When the air then passes into said heating and ventilation unit 51, the internal heating circuit is activated, so that the air is cooled and dried by contact with the walls of said air conditioning evaporator 52, and then heated in said heating and ventilation unit 51.

[0113] The aforementioned PPE parts 02, 03, 04 and 05 are pressed together using clips, such as clips 03a, and screws, such as screws 31, and the adjustments between the parts. This pressure slightly compresses the contact surfaces between the parts, thus ensuring a seal between cavities 04a and 05a and circuits 03b, 03c, 03e, 04b and 04c.

[0114] Since the aforementioned PPE parts 02, 03, 04 and 05 are made of the same material, they will have identical thermal expansions. Thus, when hot or cold air is blown, the aforementioned PPE parts 02, 03, 04 and 05 expand or contract in the same way, so that the aforementioned cavities 04a and 05a and the aforementioned circuits 03b, 03c, 03e, 04b and 04c remain aligned regardless of the temperature, guaranteeing the airtightness of the air circuit under all circumstances.

[0115] The system described above thus makes it possible to achieve the demisting and defrosting of the windshield, the heating and cooling of the passenger compartment, with air circulating directly in the said main parts 02, 03, 04 and 05, without the use of hoses or added pipes.

[0116] According to one embodiment, as shown in Figures 4a and 4b, said dashboard 01 is placed on the floor 61 of a vehicle chassis 60, and on the trestle 62 of said chassis 60. To compensate for the differences in thermal expansion between said chassis 60 and said dashboard 01, particularly in the transverse direction where the parts have the greatest dimension, clearance is left between the side walls of said main parts 02, 03, and 04, and said trestle supports 64. This clearance prevents friction that could occur between said main parts 02, 03, and 04 and said trestle supports 64, such friction being amplified in the event of high heat, with greater expansion of said polymer main parts 02, 03, and 04, compared to said trestle supports, which being part of the chassis structure, are favorably made of metal.These frictions cause unpleasant grinding and squeaking noises for the user, which must therefore be eliminated. Beyond the friction noises, insufficient clearance could restrict the thermal expansion of the main parts 02, 03, and 04, significantly increasing internal stresses and potentially leading to their failure.

[0117] The attachment of said parts PPE 02, 03, 04, and 05 to said chassis 60 is achieved with a small number of components, and only with easily removable components such as screws or clips. No adhesives such as glue or welding are used, in order to allow for easy mounting and dismounting of said dashboard 01 from the vehicle. By way of non-limiting example, said dashboard 01, as shown in the figures, is fixed with four upper bracket screws 69 between said intermediate dashboard 03 and said bracket beam 63, and two rear bracket screws 70 between said lower dashboard 02 and said bracket beam 63. Clearances are also provided at the P4286PC00 spec dpt of the fasteners to allow for expansion of the parts, particularly transversely.

[0118] Thus assembled, the dashboard 01 conceals the less aesthetically pleasing technical elements of the vehicle, such as the chassis components 61, 62, 63, and 64, the heating and ventilation unit 51, the air conditioning evaporator 52, the steering column 65, the steering wheel 66, the pedal assembly components 67, etc. The PPE parts 02, 03, 04, and 05 are also technical parts, but have a surface texture, ideally a graining applied directly in the manufacturing mold, which gives them an aesthetic appearance. Their graining, texture, and flexibility also provide a pleasant feel for the user, eliminating the need for additional parts, fabrics, or treatments. According to a non-limiting embodiment, parts may nevertheless be added to conceal gaps, such as the TBDB feet 21.

[0119] The aforementioned TBDB 21 feet allow for the integration of elements such as door or hood release handles 71, or interior lighting 72, without complicating the geometries and therefore the manufacturing of the aforementioned main parts 02, 03, and 04, said elements 71 and 72 being given by way of non-limiting example. The aforementioned TBDB 21 feet also provide protection against impacts, particularly kicks, which can frequently occur in this area near the door through which users enter the vehicle's passenger compartment. The said TBDB 21 feet are favorably made of PP to absorb shocks, P4286PC00 spec dpt and to be able to be recycled with the said PPE parts 02, 03, 04 and 05. Just like the other elements of the said dashboard 01, the said TBDB 21 feet are fixed by simple and quick elements to put in place and remove, such as TBDB 73 foot screws.There is no gluing, welding, or other such fastening. This allows for easy removal of a used TBDB 21 foot and replacement with a new one, for the purpose of refurbishing the 01 dashboard.

[0120] The aforementioned dashboard 01 allows for the integration and mechanical support of numerous components.As shown in the various figures, it supports said feet TBDB 21, an electronic control unit 22 and a smartphone holder 23 which are screwed onto said lower TBDB 02, said ventilation flaps 32 and flap motor 33 which are clipped into said flap clips 03d of said intermediate TBDB 03, said defrosting grilles 41 which are screwed onto said upper TBDB 04, a rain sensor 42 which is wedged between said upper TBDB 04 and the windshield, ambient lighting 43 inserted into said upper TBDB 40, said heating / ventilation unit 51 which is inserted into said ventilation column 05 and blocked by said lower TBDB 02, said air conditioning evaporator 52, said cabin air filter 53 and a condensate funnel 54 which are screwed into said ventilation column 05, and electrical bundles 68 which are inserted into the geometries of said parts PPE 02, 03, 04 and 05, and fixed by clips.All these elements are of course given by way of non-limiting example, the scope of the invention extending beyond this enumeration. P4286PC00 spec dpt.

[0121] Therefore, there are few components mounted on the aforementioned dashboard 01, with simple fixings that are easy to install and remove. This facilitates assembly during production, component replacement for refurbishment, and the separation of different materials for recycling.

[0122] Cavities can be formed during the manufacturing process of the main parts 02, 03, 04, creating geometries made of the same material as the rest of the part. In this way, for example, storage compartments 02a or crash energy absorbers 02b can be manufactured without adding any extra parts, always with the aim of simplifying assembly and disassembly.

[0123] Since the aforementioned PPE parts 02, 03, 04, and 05 are made of PPE, the dashboard 01 can be manufactured with very significant thicknesses. These significant thicknesses, the addition of crash energy absorbers 02b, and the material's properties ensure that the aforementioned PPE parts 02, 03, 04, and 05 provide effective protection in front of users, particularly in the event of a crash. The fact that the dashboard 01 does not have a metal reinforcement insert also prevents it from causing injury to users in a crash. On the contrary, it will absorb potential impacts.

[0124] According to one embodiment, cavity 02a is not used as a storage compartment, but serves to house a passenger airbag. In this embodiment, the airbag is fixed to the trestle beam 63, and the airbag cover P4286PC00 spec dpt is flush with the lower TBDB 02, and made of the same material as the latter.

[0125] Since the aforementioned PPE parts 02, 03, 04, and 05 are made of PPE, the dashboard 01 can be manufactured with a solid and robust appearance for the user, while maintaining an ultra-low mass. The significant thickness and properties of the material mean that the aforementioned PPE parts 02, 03, 04, and 05 provide good acoustic and thermal insulation, which is a significant advantage for insulating users from external temperatures, road noise, and noise and heat that could be generated by a possible engine installed at the front of the dashboard 01. The geometries and properties of the material also allow for vibration absorption.

[0126] According to one embodiment of the invention, said intermediate TBDB 03 and upper TBDB 04 are symmetrical along a mid-plane separating the left part from the right part of said dashboard 1. Thus, only said lower TBDB 02 needs to be modified and have an additional production mold to produce vehicles with left-hand drive and vehicles with right-hand drive.

[0127] The instrument panel 01 is located directly under the windshield and is therefore exposed to sunlight. According to one embodiment, to resist UV radiation from the sun, the grade of PPE used to manufacture the PPE parts 02, 03, 04, and 05 in general, and the upper instrument panel 04 in particular, is a grade with good UV resistance properties. P4286PC00 spec dpt

[0128] The embodiments have been described to provide a comprehensive understanding of the principles, function, manufacture, and use of the systems and processes described in this application. One or more of these embodiments are illustrated in the accompanying drawings. The systems and processes specifically described in this application and illustrated in the accompanying drawings are non-limiting embodiments of the scope of the present invention. The features illustrated or described in relation to one embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. A number of problems with conventional processes and systems are noted herein, and the processes and systems described herein may solve one or more of these problems.Furthermore, while this invention has been described in conjunction with a number of embodiments, the alternatives, modifications, equivalents and variants which are in the spirit and scope of the present invention are also covered by this application.

Claims

P4286PC00 spec dpt DEMANDS 1. Vehicle dashboard (01) comprising at least one main part (02, 03, 04) made of a single material.

2. Vehicle dashboard (01) according to the preceding claim, said dashboard comprising at least one to six main parts (02,03,04) made of a single material.

3. Vehicle dashboard (01) according to any one of the preceding claims, the material constituting said main parts (02, 03, 04) being wholly or partially recyclable and / or made from recycled materials.

4. Vehicle dashboard (01) according to any one of the preceding claims, the material constituting said main parts (02, 03, 04) being PPE (Expanded Polypropylene).

5. Vehicle dashboard (01) according to any one of the preceding claims, comprising air circuits (03b, 03c, 03e, 04b, 04c) for ventilation, demisting and defrosting, said air circuits forming part of said main parts (02, 03, 04), without any added part.

6. Vehicle dashboard (01) according to the preceding claim, comprising a ventilation flap (32) for directing predominantly the air from said circuits either towards the windshield or towards P4286PC00 spec dpt the passenger compartment, said ventilation flap (32) being directly placed in the air circuits (03b, 03c, 03e, 04b, 04c).

7. Vehicle dashboard (01) according to any one of the preceding claims, wherein at least two of the main parts (02, 03, 04) are fixed to each other solely by clips.

8. Vehicle dashboard (01) according to the preceding claim, wherein said intermediate TBDB (03) and upper TBDB (04) are fixed to each other only by clips (03a), allowing said upper TBDB (04) to be changed very quickly without touching any other element of said dashboard (01).

9. Vehicle dashboard (01) according to any one of the preceding claims, characterized by a small number of fixings, said fixings being simple and quick to implement, allowing simple and quick assembly and disassembly of the whole, for production, for renovation, and / or for recycling.

10. Vehicle dashboard (01) according to any one of the preceding claims, comprising at least one crash energy absorber (02b) forming part of at least one of said main parts (02, 03, 04), and not having a metallic reinforcement insert, providing crash protection. P4286PC00 spec dpt 11. Vehicle dashboard (01) according to any one of the preceding claims, said main parts (02, 03, 04) having a texturing or graining carried out during manufacturing, allowing parts to have an appearance.

12. Vehicle dashboard (01) according to any one of the preceding claims, wherein the material constituting said main parts (02, 03, 04) and the geometry of said main parts (02, 03, 04) provide good thermal insulation, good acoustic insulation and / or good vibration absorption.

13. Vehicle dashboard (01) according to any one of the preceding claims, said dashboard mechanically supporting an electronic control unit (22), and / or ventilation elements (51), and / or heating elements (51), and / or air conditioning elements (52), and / or a smartphone holder (23) and / or ambient lighting (43).

14. Vehicle dashboard (01) according to any one of the preceding claims, comprising at least one storage element, such as a storage compartment (02a), forming part of at least one of said main parts (02, 03, 04) 15. Vehicle dashboard (01) according to any one of the preceding claims, comprising at least one TBDB foot (21) having better impact resistance than said main parts (02, 03, 04). Tl P4286PC00 spec dpt 16. Vehicle dashboard (01) according to the preceding claim, wherein said TBDB foot (21) is fixed to said dashboard (01) only by simple means such as clips or screws (73) allowing said TBDB foot (21) to be changed quickly.

17. Vehicle dashboard (01) according to any one of claims 15 or 16, wherein said TBDB foot (21) is made of a material of the same family as said main parts (02, 03, 04), allowing them to be recycled in the same recycling circuit.

18. Vehicle dashboard (01) according to any one of the preceding claims, wherein only said lower dashboard (02) changes between a dashboard with left-hand drive and a dashboard with right-hand drive.

19. Vehicle equipped with a dashboard (01) according to one of the preceding claims.

20. Vehicle according to the preceding claim, said dashboard (01) being placed and / or screwed onto a floor (61) and / or a trestle (62).

21. A vehicle according to claim 19 or 20, wherein the fixings between the dashboard (01) and the other vehicle components allow a degree of freedom in the transverse direction, in order to permit P4286PC00 spec dpt allows the different parts to expand thermally without causing breakage or unpleasant noise of friction or squeaking.

22. Vehicle according to any one of claims 19 to 21, wherein said main parts (02, 03, 04) have transverse play relative to the other elements of the vehicle, in order to allow them to expand thermally without causing breakage or unpleasant friction or squeaking noise.

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