Dashboard support

Abstract

The invention relates to a dashboard support for a motor vehicle, comprising a support structure (2) which extends between two motor-vehicle attachment points, wherein the support structure (2) is in the form of an open half-shell structure having two walls (8), (9) which follow the longitudinal extent of the support structure, are mutually spaced by a connecting piece (10), and are connected to each other by the connecting piece, by means of which connecting piece (10) a longitudinal side edge of the one wall (8) is connected to the same-side longitudinal side edge of the other wall (9), the mutually spaced walls (8), (9) providing an open side, and wherein the cross-sectional design of the support structure (2) is different in individual support structure portions a - h, characterized in that the opening direction of the open side of the support structure (2) in the form of a half-shell structure points downward in the spatial orientation of the installation of the support structure and in that, in each end portion of the support structure (2), an attachment element (3, 4) for connecting the support structure (2) to the motor-vehicle attachment points is inserted, as an add-on component, into the open side of the support structure (2).

Description

[0001] Instrument panel carrier

[0002] The invention relates to an instrument panel carrier for a motor vehicle with a support structure extending between two vehicle-side attachment points, wherein the support structure is designed as an open half-shell structure with two walls following its longitudinal extension, spaced apart from each other by a web and connected to each other by this web, by which web a longitudinal side edge of one wall is connected to the same side longitudinal edge of the other wall and an open side is provided by the spaced-apart walls, and the cross-sectional design of the support structure is different in individual support structure sections.

[0003] Instrument panel supports are used to mount components such as instruments, devices, and the steering column in a vehicle. Such an instrument panel support is installed between two pillars of the vehicle body, typically the A-pillars. To connect to the A-pillars, the instrument panel support has appropriately designed mechanical connectors at both ends. A key component of such an instrument panel support is a support structure extending between the connection points. Struts or supports, such as tunnel supports, can be attached to this support structure to brace it against the chassis between the two end connection points.

[0004] DE 197 35 089 A1, DE 296 15 364 U1 and DE 101 01 927 A1 each disclose a support structure for an instrument panel carrier designed as a closed hollow profile. While in the subject matter of DE 197 35 089 A1 the hollow profile is an extruded profile, in the other two aforementioned documents it is formed by two interconnected shells. These are welded together to form the hollow profile. JP 2003 182472 A discloses a reinforcing element for insertion into the support structure of an instrument panel carrier; the reinforcing element is a profile open on one side with respect to its longitudinal extent. This serves to accommodate cable bundles.

[0005] The requirements for such an instrument panel support are manifold. It is designed to meet the mechanical demands placed upon it, ensuring optimal load distribution in the event of a frontal or side impact. Furthermore, the instrument panel support serves to prevent intrusions into the passenger compartment. It must also possess sufficiently high rigidity, as other components are attached to it and must be held not only mechanically but also vibration-free. Finally, this assembly should not adversely affect audible or perceptible vibrations in the vehicle and thus exhibit favorable NVH (Noise, Vibration, Harshness) characteristics. The requirements for such an instrument panel support include...Components connected to its support structure include, among others, the instrument panel trim, the steering column, the heating and air conditioning unit, and displays such as the head-up display or a directly readable display, such as a central display.

[0006] A single-shell instrument panel support is known from EP 1 544 086 A1. Unlike double-shell support structures, this instrument panel support has only a single joint, following its longitudinal extent. This reduces the joining effort. However, a disadvantage is that, to manufacture such a single-shell instrument panel support, the sheet metal blank must be formed to create the hollow profile in such a way as to generate the joining flanges provided in the area of ​​an edge formation, resulting in a uniform deflection curve extending over the entire longitudinal extent of the instrument panel support. This limits the design freedom with regard to the design of such an instrument panel support or its support structure. Instrument panel supports with a support structure in an open-shell construction are also known. Such a support is known, for example, from EP 1 350 71 1 A1.To meet the required strength and stiffness specifications, reinforcing plastic structures are injected into these components. A disadvantage of such an instrument panel carrier design is the increased manufacturing effort due to the various process steps required. Furthermore, components with a material mix – metal and plastic – are undesirable due to the additional effort required to separate these materials for recycling.

[0007] An improvement in the properties of the instrument panel supports described above is achieved by the instrument panel support described in DE 10 2022 120 872 B3. This instrument panel support has a support structure in the form of an open half-shell structure. The open side of the support structure faces away from the passenger compartment in the longitudinal direction of the vehicle (x-direction). To meet the mechanical requirements of an instrument panel support, the support structure is designed differently in individual support structure sections, in order to meet the requirements profile of the respective support structure section. This prior art presents various possibilities for achieving this. These can include the web height or the width of the walls formed on the web, as well as profiles, bends, or the like.To provide connections for attaching the support structure to the vehicle-side mounting points, the web height is increased accordingly to achieve the required spacing of the bolting points. This has the disadvantage that a separate support structure must be provided for vehicles with different bolting geometries.

[0008] To achieve sufficient stiffness in individual sections of the support structure, such as in the area of ​​the steering column connection, the walls extending in the x-direction are correspondingly long. When designing such a support structure, the available installation space in the x-direction must be taken into account. This space is generally very limited, which is why the desired mechanical properties sometimes cannot be achieved solely through the appropriate design of the support structure.To attach components that cannot be inserted with their end section into the forward-facing open support structure (as is the case, for example, with tunnel supports or other brackets that are intended to extend from the support structure in a different direction), cutouts or similar features are required to allow the end section of the respective component to be inserted into and joined within the half-shell structure, as disclosed, for example, in DE 10 2022 120 875 A1. Without additional measures, this results in a weakening of the support structure.

[0009] Based on this discussed prior art, the invention therefore aims to further develop an instrument panel carrier of the type discussed above in such a way that not only is a variability in the design of individual carrier structure sections possible, as described in DE 10 2022 120 872 B3, but also a more variable connection to the connection points of a motor vehicle is possible, as well as its application in installation conditions that are confined in the x-direction, in which certain measures, such as increasing the width of the walls to meet the requirements profile placed on this carrier section, cannot be implemented.

[0010] This problem is solved according to the invention by an instrument panel carrier of the aforementioned type, in which the opening direction of the open side of the carrier structure designed as a half-shell structure points downwards in the spatial position of its installation (in the z-direction) and in which a connecting element for connecting the carrier structure to the vehicle-side connection points is inserted into the open side of the carrier structure in each end section of the carrier structure as an attachment component.

[0011] The directional terms used in this description are the standard directional terms for a motor vehicle. The x-direction corresponds to the vehicle's longitudinal extent, the y-direction to its transverse extent (vehicle width), and the z-direction is the vertical direction. This instrument panel support cleverly combines the advantages of an instrument panel support according to DE 10 2022 120 872 B3, while avoiding the disadvantages of this prior art as outlined above. The support structure consists of two spaced-apart walls that follow the longitudinal extent and are connected by a web, which can also be referred to as the back. This web connects the longitudinal edges of the two walls that point in the same direction.This support structure has no further components extending along its entire longitudinal extent, at least none that can be structurally considered parts of a support structure. The design of the support structure as a half-shell structure with the open side facing downwards (z-direction) in its installed position represents a departure from the usual design of vehicle crossmembers, particularly instrument panel supports or their supporting structures. These are typically, when designed wholly or partially as half-shells, arranged with their open side facing in the x-direction in these sections, and thus in or against the direction of travel. This arrangement is chosen because, according to prevailing doctrine, it exhibits a uniform deformation behavior across its height in the event of a crash.Therefore, it was necessary to overcome this prevailing doctrine in order to arrive at the concept of the instrument panel support according to the invention. The open side of the support structure, designed in the manner of a half-shell structure, facing downwards and thus towards the floor of the passenger compartment, allows for a significantly greater variation in wall height and / or positioning (extension in the z-direction) than would be possible in the x-direction with the prior art, especially in confined installation conditions. Interestingly, it has been shown that the deformation behavior of such a support structure is comparable to that of one whose open side faces in the direction of travel.Furthermore, this design of the support structure allows for the formation of ends for connection to the vehicle-side mounting points without requiring modifications to the support structure itself for different connection geometries. The open end sections of the support structure are cleverly utilized for this purpose. In this instrument panel support, a mounting element is inserted into each end section of the support structure as an attachment component, with a section of this element extending into the open side of the support structure and connected to it. This allows one and the same support structure to be used for installation in vehicles with different mounting geometries, i.e., different distances between the mounting points in the z-direction and the connection to the support structure.In the case of different connection geometries, the corresponding connecting element is simply inserted into the downward-facing open side of the respective end section of the support structure and connected to it, typically by welding.

[0012] Since the support structure is designed as an open half-shell structure, it can be manufactured cost-effectively. Furthermore, the coating reliability of the support structure is increased across its entire surface because the support structure does not have enclosed cavities, as is the case with a hollow profile or hollow chamber profile. Typically, the support structure has a U- or C-shaped cross-section, whereby in the case of a U-shaped design, the walls can be bent away from each other at their ends, forming flanges.

[0013] In this instrument panel support structure, the supporting structure is the continuous structural component extending across the distance between the vehicle-side mounting points, forming an open half-shell structure. This supporting structure is responsible for absorbing the forces acting upon it in a side impact, thus stiffening the passenger compartment between the vehicle-side mounting points against lateral indentation. The open side of the supporting structure can be closed in sections by attachment components and / or reinforcement components, so that in such a section, the otherwise spaced walls are connected by such a component. Typically, these components do not penetrate the half-shell structure over its entire depth, resulting in a hollow profile section within such a support structure segment.Since such a support structure section has only a relatively short length in relation to the entire longitudinal extent of the support structure, no losses are to be accepted with regard to any surface coating that may be required.

[0014] The support structure is typically manufactured from a ferrous metal blank using a forming process. This forming process includes press hardening of the entire component or individual support structure sections. The support structure can have a straight path between the A-pillar-side attachment points. However, the support structure will generally have a non-linear path, at least in the x-direction, for example, due to the offset of individual support structure sections in the x-direction. The support structure itself can be composed of one or more interconnected support structure sections. This includes the possibility of using a blank for the forming process that is composed of different blank sections. These sections can differ, for example, in their material thickness, material properties, or composition.

[0015] The downward-facing open side of the support structure in this instrument panel carrier offers the further advantage that this open side can be used to anchor or attach various add-on components to the support structure. Add-on components can be made of the same material or a different material, such as a different metal. In this respect, the design of the instrument panel carrier is considerably less restricted by space constraints than in the x-direction. This allows for the connection of, for example, tunnel supports or other brackets, whereby, unlike instrument panel carriers according to the prior art, no separate cutouts are required to insert the end sections into the interior of the half-shell structure.Rather, the supporting structure remains unaffected in the area where attachments are connected, with their end sections inserted into the open side of the supporting structure. The downwardly open (in the z-direction) supporting structure readily allows for the connection of attachments that extend along a certain section of the structure. These can be profile sections, which may be designed as closed profiles or as half-shell structures. These typically engage with the open side of the supporting structure at one end. In the case of a half-shell structure, the web connecting the walls would be inserted into the open side of the supporting structure. The stiffness and vibration behavior of this section of the supporting structure can be influenced by the width of this insertion. Such an attachment is therefore a reinforcing profile.According to one embodiment, such a reinforcing profile is a C-profile whose open side also faces downwards. This type of additional reinforcement of the support structure is advantageous for sections of the support structure subjected to higher loads, such as the section to which the steering column module is attached. It is understood that the attachment components inserted into the open side of the support structure with their end sections also contribute to a local reinforcement or stiffening of the support structure. This is typically taken into account during the design of the support structure, which can then be dimensioned accordingly smaller in these sections. This also leads to an improvement in vibration behavior.

[0016] Preferably, the end section(s) of an attachment component extend into the open side of the support structure up to the web of the same or at least up to the transition of the side walls into the web and are then joined to the support structure on the inside.

[0017] The cross-sectional design of the individual support structure sections typically differs by

[0018] • the bridge height,

[0019] • the web profiling,

[0020] • the wall width of at least one wall,

[0021] • the wall profiling of at least one wall,

[0022] • the spatial arrangement of the walls in relation to each other, • the geometric design of the transition between the walkway and the wall and / or

[0023] • the material thickness and / or the material properties.

[0024] Given the previously described background that the different cross-sectional design of the support structure occurs in the z-direction, variation in the x-direction is nevertheless possible, even under confined installation conditions in this direction. Such variation is reflected, for example, in the width of the web. Due to the measures described, a variation in the width of the web to design the support structure according to the requirements of its individual sections is not necessary or only necessary to a limited extent. Therefore, in a preferred embodiment, the width of the web in individual support structure sections is reduced by no more than 50%, and in particular by no more than 30%, from its maximum width along the entire longitudinal extent of the support structure.

[0025] A reinforcing profile inserted into the open side of the support structure can also be designed with an angled leg extending away from the support structure. This leg can serve as the connection for a strut or a bracket. In another embodiment, an angled leg is formed onto such a reinforcing profile, extending to the connecting element located at one end. The connecting element then connects one end of the support structure to the end of the angled leg of the reinforcing profile on this side.

[0026] The web located in the xy direction can, for example to improve buckling behavior in an offset section in the event of a side impact, have a rib following the extension of the support structure. This rib can be designed as a positive or negative structure. Typically, such a rib is designed as a negative structure that projects into the half-shell structure. This ensures that the outer surface of the web remains uniform across its width for supporting, for example, an instrument panel, so that such a component experiences two-point support in such a section. An offset section is typically a section in the support structure where its extension between the two connecting elements is offset in the x-direction. Such a stiffening rib preferably extends not only over the offset section but also into the support structure sections adjacent to the offset section.

[0027] Another way to influence the mechanical properties of the support structure as a whole or in individual sections is to design one or both walls with a longitudinally angled leg. The width of the legs can vary along the length of the support structure or even within a single section. Typically, the angle is directed away from the other wall of the support structure. If both walls have such a longitudinally angled leg, the support structure develops a hat-shaped cross-sectional profile in the section with the longitudinally angled legs.

[0028] The invention is described below with reference to an exemplary embodiment and the accompanying figures. These show:

[0029] Fig 1 : a rear view of an instrument panel support with a support structure designed as an open half-shell structure, the open side of which points downwards,

[0030] Fig. 2a - 2d: each a cross-section through the support structure of the instrument panel carrier of figure 1 along the section line AA (Fig. 2a), along the section line BB (Fig. 2b), along the section line CC (Fig. 2c) and along the section line DD (Fig. 2d),

[0031] Fig. 3: a top view of the instrument panel support of Figure 1, Fig. 4: an enlarged view of the left, driver's side end section of the instrument panel support of Figure 1 and

[0032] Fig. 5: a sectional view along line EE of Figure 4.

[0033] An instrument panel carrier 1 comprises a support structure 2. The support structure 2 extends between the A-pillars of a motor vehicle (not shown). The support structure 2 is designed as an open half-shell structure, with its open side facing downwards (z-direction). Several attachment components are connected to the support structure 2. Two connecting elements 3, 4 are inserted into the open sides of the end sections of the support structure as attachment components, one of each being inserted into an end section of the support structure 2 and joined to it on the inside. In the illustrated embodiment, a tunnel support 5 and a reinforcing profile 6 with connecting parts 7, 7.1 for attaching a steering column module (not shown in the figures) are also connected to the support structure 2 as attachment components.

[0034] The cross-sectional shape of the support structure 2 varies along its longitudinal extent. Based on this cross-sectional shape, the support structure 2 can be divided into different support structure sections. These are identified in Figures 1 and 3 by the reference symbols a - h.

[0035] The support structure 2 is fundamentally C-shaped and has two opposing walls 8, 9, spaced apart in the x-direction and extending in the y-direction, as well as a web 10 connecting these walls 8, 9 (see also Figure 2a). The height of the walls 8, 9 extends in the z-direction. The individual support structure sections a - h differ in the height of the walls 8, 9, the width of the web 10, the profile of the web 10, and / or in that the free ends of the walls 8, 9 have externally angled legs 11, 11.1 (see Figure 2b), giving these support structure sections d - h a hat profile. Figure 2a shows a cross-section of the support structure 2 in its support structure section c. The C-shaped cross-sectional design extends over the support structure sections a - c.The support structure sections d–h adjacent to support structure section c have the previously mentioned legs 11, 11.1 (see cross-sectional view in Figures 2b–2d). In support structure section 2c, the height of the walls 8, 9 is reduced compared to adjacent support structure sections d, f, while leg 11.1 is longer. Additionally, the web 10 is profiled by a groove 12 introduced as a negative structure (see sectional view in Figure 2c). In support structure sections f–h, the support structure 2 again has walls 8, 9 that are higher than the wall height in support structure section e, and whose height also exceeds the height of the walls 8, 9 in support structure sections c, d. The top view of the instrument panel support 1 in Figure 3 illustrates the variation in the width of the web 10 of its support structure 2.The width of web 10 is narrowest in support structure sections a, g, h and greatest in support structure section e. Support structure section e is an offset section that bridges an offset in the x-direction between the adjacent support structure section f and the support structure section d on the other side. The groove 12 is located in this offset of the support structure 2 within support structure section e. From the top view of web 10 in Figure 3, it is clear that the groove follows the extension of the support structure 2 and continues into the adjacent support structure sections d and f.

[0036] The reinforcing profile 6, as an attachment component with its connecting parts 7, 7.1, is shown again enlarged in Figure 4. In the illustrated embodiment, the reinforcing profile 6 is also C-shaped with its open side facing downwards. The web 13 of the reinforcing profile 6 is inserted into the open side of the support structure 2, such that the web 13 is located between the walls 8, 9. In this way, the otherwise downwardly open support structure 2 is formed as a closed profile along the longitudinal extent of the reinforcing profile 6 (see also Figure 5). The reinforcing profile has a leg 14 that is angled downwards relative to the course of the support structure 2 and extends to the lower end section of the connecting element 3. This element is thus located between the end section of the support structure 2 on this side and the end section of the angled leg 14 of the reinforcing profile 6 on this side.The invention has been described with reference to exemplary embodiments. Without departing from the scope of protection described by the applicable claims, numerous further embodiments of the inventive concept would be apparent to a person skilled in the art, without these needing to be explained in more detail within the scope of these explanations.

[0037] Reference symbol list

[0038] 1 Instrument panel carrier

[0039] 2 Support structure

[0040] 3 Connecting element

[0041] 4 Connecting element

[0042] 5 Tunnel support

[0043] 6 Reinforcement profile

[0044] 7, 7.1 Connection part

[0045] 8 Wall

[0046] 9 Wall

[0047] 10 Bridge, 1 1.1 Leg

[0048] 12 groove

[0049] 13 Bridge

[0050] 14 legs ah support structure section

Claims

Patent claims 1. Instrument panel carrier for a motor vehicle with a support structure (2) extending between two motor vehicle-side attachment points, wherein - the supporting structure (2) is designed as an open half-shell structure with two walls (8, 9) following its longitudinal extension, spaced apart from each other by a web (10) and connected to each other by this web, by which web (10) a longitudinal side edge of one wall (8) is connected to the equilateral longitudinal side edge of the other wall (9) and an open side is provided by the spaced-apart walls (8, 9), and - the cross-sectional design of the support structure (2) differs in individual support structure sections (a - h), characterized in that the opening direction of the open side of the support structure (2) designed as a half-shell structure points downwards in the spatial position of its installation and that a connecting element (3, 4) for connecting the support structure (2) to the vehicle-side connection points is inserted into the open side of the support structure (2) in each end section of the support structure (2) as an attachment component.

2. Instrument panel support according to claim 1, characterized in that the cross-sectional design of the individual support structure sections (a - h) is defined by • their bridge height, • their web profile, • their wall width of at least one wall, • their wall profiling of at least one wall, • their spatial position of the walls in relation to each other, • their geometric design of the transition between the bridge and the wall and / or • differs in their material thickness and / or material properties.

3. Instrument panel carrier according to claim 2, characterized in that the width of the web (10) in individual carrier structure sections (a - h) is reduced by no more than 50% from its maximum width within the longitudinal extent of the carrier structure (2).

4. Instrument panel carrier according to one of claims 1 to 3, characterized in that the instrument panel carrier (1 ) has in at least one carrier structure section (c) a reinforcing profile (6) which is inserted into the open side of the carrier structure (2) with at least one section and connected to it.

5. Instrument panel support according to claim 4, characterized in that the reinforcement profile (6) has an open half-shell structure, wherein the open side also points downwards.

6. Instrument panel carrier according to claim 4 or 5, characterized in that the reinforcement profile (6) has a leg (14) angled relative to the longitudinal direction of the carrier structure (2) in the direction of a connecting element (3, 4) and the end section of the angled leg (14) is connected to the connecting element (3, 4).

7. Instrument panel carrier according to one of claims 1 to 6, characterized in that at least one holder, a support, a strut or the like is inserted into the open side of the carrier structure (2) as a further attachment component with an end section and is connected to the carrier structure (2).

8. Instrument panel carrier according to claim 7, characterized in that the end section of the attachment component engages in the open side of the carrier structure (2) extending to its web (10) or to the transition of one or both walls (8, 9) into the web (10).

9. Instrument panel carrier according to one of claims 1 to 8, characterized in that a groove (12) designed as a negative structure and following the extension of the carrier structure (2) is incorporated into the web (10) of the carrier structure (2).

10. Instrument panel support according to claim 9, characterized in that the support structure (2) has an offset section (support structure section e) in which it is offset in its longitudinal extension in the x-direction, and the groove (12) in the web (10) extends over the offset section (support structure section e).

11. Instrument panel carrier according to claim 10, characterized in that the groove (12) extends into the carrier structure sections (d, f) bordering the offset section (carrier structure section e).

12. Instrument panel support according to one of claims 1 to 11, characterized in that at least one wall (8, 9) of the support structure (2) has a longitudinally angled leg (1 1 , 1 1.1 ).

13. Instrument panel support according to claim 12, characterized in that the angled leg (1 1 , 1 1.1 ) is angled away from the other wall (9, 8) of the support structure (2).

14. Instrument panel support according to claim 7, characterized in that both walls (8, 9) have at least section by section over the longitudinal extent of the support structure (2) a longitudinal leg (1 1 , 11.1 ) angled from the wall surface, whereby this support structure section (d - h) is profiled in a hat shape.

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