Abstract:
A tubular instrument panel support structure is provided. The structure includes a plurality of support tubes aligned substantially end-to-end and extending laterally to span the width of a vehicle body for the support of various instruments and devices within the panel. A plurality of brackets and braces are welded or attached to the support tubes and extend radially outward therefrom to define various areas within the instrument panel such as a driver-side, console-side, and passenger-side. The lateral support tubes are connected to and separated into segments by a plate or plates, and each tube segment having a different configuration or gauge thickness suitable to the unique forces born by each segment. The lateral support tubes are operatively connected to a vehicle hinge pillar to thereby provide substantially rigid lateral support to the instrument panel.

Description:
TECHNICAL FIELD 
     The present invention relates to a vehicular instrument panel support structure having a plurality of support tubes spanning the width of a vehicle body. 
     BACKGROUND OF THE INVENTION 
     Instrument panels, alternately referred to as dashboards, are situated within a passenger compartment of a vehicle and positioned facing the vehicle occupants, primarily a driver/operator, for easy readability and accessibility of the various instruments housed within the instrument panel. Common instrumentation found in a vehicle passenger compartment includes, for example, speedometers, odometers, tachometers, fuel gauges, and indicator lamps. An instrument panel may also house such other non-metering devices as air bags, glove compartments or boxes, radios, CD/DVD/cassette players, navigation screens, clocks, ashtrays, speakers, climate controls, and air vents. Instrument panels are typically formed with protective padding and other external trim material which is contoured and styled to provide a fully-assembled instrument panel with an aesthetically-pleasing appearance. Instrument gauges and meters are typically faced with a transparent material for protection from damage, dirt, and/or tampering. 
     Since the aforementioned instruments and devices may contribute a substantial amount of combined weight and mass to the vehicle, the instrument panel is therefore supported by a substantially rigid substructure positioned behind and beneath the visible portions of the panel. Instrument panel support structures are often constructed from stamped and welded steel sheet metal assemblies and may include a plurality of supporting brackets or braces having a sufficient amount of surface area to allow the support structure to be attached to the vehicle and the instruments and other devices to be securely fastened within the panel. 
     SUMMARY OF THE INVENTION 
     Accordingly, a tubular instrument panel support structure is provided for use within a vehicle, wherein two lateral support tubes each having a plurality of support brackets are aligned substantially end-to-end and operatively connected to a mid-plate to span the width of a vehicle body, thereby providing adequate support for an adjoining instrument panel. 
     In accordance with one aspect of the invention, each section of lateral support tubing may be specially configured to provide an appropriate level of support for the unique forces born by that section. 
     In accordance with another aspect of the invention, two steel plates are used to divide the instrument panel support structure into three tube segments, wherein the space formed between the two plates defines a separate instrumentation console area. 
     In accordance with another aspect of the invention, a vehicle body assembly has a pair of hinge pillar assemblies and an instrument panel support structure operatively connected on either end to the respective hinge pillar assemblies, the structure further having a plurality of lateral support tubes aligned substantially end-to-end with at least one plate operatively connected between the lateral support tubes, wherein the support tubes each have support brackets extending radially therefrom. 
     The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective illustration of an instrument panel support structure according to the present invention; 
         FIG. 2  is a perspective illustration of an instrument panel support structure mounted to a body structure lower assembly; and 
         FIG. 3  is a perspective illustration of a second embodiment having two welded plates and a lateral support tube with three segments. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings wherein like reference numbers correspond to like or similar components throughout the several figures, there is shown in  FIG. 1  a tubular instrument panel support structure  10   a  according to the invention. Support structure  10   a  includes a driver-side  31   a  and passenger-side  37   a . Driver-side  31   a  has a driver-side pipe or tube  16   a . Passenger-side  37   a  has a passenger-side pipe or tube  25   a , with tubes  16   a ,  25   a  being separated by and attached to a rigid mid-plate  11   a , preferably constructed of a weldable stamped steel plate. In the preferred embodiment, the cross-sectional areas of tubes  16   a ,  25   a  are circular, although tubes with rectangular, triangular, or other suitable shapes may be also used depending on the application. 
     Because tubes  16   a,    25   a  are separate components, the configurations, i.e. the respective diameters and gauge thicknesses, of tubes  16   a,    25   a  may be customized to match their respective load requirements simply by selecting and welding appropriately-sized and positioned tubes  16   a,    25   a  to either side of mid-plate  11   a . This customizable feature provides flexibility in instrument panel design and affords an opportunity to reduce unnecessary vehicle weight. For example, the driver-side  31   a  of support structure  10   a  may require a relatively large diameter driver-side tube  16   a  in order to support a steering column (not shown) and additional steering column-related brackets to further absorb or dampen road vibrations transmitted toward the driver through the column, while a typical passenger-side  37   a  may function properly with a reduced passenger-side tube  25   a , making the extension or expanse of a single, uniform tube  16   a  unnecessary. 
     Driver-side tube  16   a  and passenger-side tube  25   a  abut opposite sides of mid-plate  11   a  and are aligned end-to-end to laterally span the width of the vehicle body for substantially rigid axial support. Driver-side tube  16   a  has a plate-end  13  which is welded, fused, otherwise attached to or integrally formed with mid-plate  11   a , and a bracket-end  15  which is supported by a driver-side end bracket  14   a . Likewise, passenger-side tube  25   a  has a plate-end  23  which is welded, fused, or otherwise attached to or integrally formed with mid-plate  11   a , and a bracket-end  27  which is supported by a passenger-side end bracket  12   a . At least one plenum bracket  24   a  extends radially forward from each of tubes  16   a ,  25   a  toward a plenum upper  44  (see  FIG. 2 ) portion of a vehicle body, the brackets  24   a  being bolted or otherwise attached to the plenum upper for bracing support. At least one of a plurality of instrument panel attachment brackets  17  is positioned at each end of support structure  10   a  and extends radially forward from its respective end bracket  12   a ,  14   a  to attach to an instrument panel retainer (not shown), the retainer being preferably constructed of molded plastic suitable for attachment and housing of the various instruments, gauges, and trim material comprising the final instrument panel. 
     As stated previously herewithin, a mid-plate  11   a  divides support structure  10   a  into a driver-side  31   a  and a passenger-side  37   a . Driver-side  31   a  is herein depicted in a typical left-hand drive configuration common to North America, although by reversing the configuration a right-hand drive arrangement may be readily accomplished. Driver-side  31   a  includes a plurality of steering column-related instrument panel supports such as a bolster plate  20  and energy absorbing (E/A) support brackets  22  welded to and extending radially from driver-side tube  16   a . Mid-plate  11   a  of  FIG. 1  is preferably an arrow-shape plate as shown to allow a plurality of weldable plate surfaces  45  having various non-orthogonal angles. However, those skilled in the art will recognize that a variety of plate shapes and sizes can be used depending on the specific application. Bracket-end  15  of driver-side tube  16   a  is inserted into and held captive by a driver-side bracket  14   a  as shown in  FIG. 1 . A lift bracket  18  is shown attached to driver-side bracket  14   a  to provide a lifting point to facilitate lifting and inserting of a complete support structure  10   a  into the vehicle cabin (not shown). 
     Passenger-side  37   a  includes passenger side tube  25   a , to which is welded, fused, or otherwise attached a left-hand H-brace  30 , right-hand H-brace  28 , and center H-brace  26 , the three H-braces together defining a center console or section  29 . As with bracket-end  15  and end bracket  14   a , bracket-end  27  of passenger-side tube  25   a  is inserted into and supported by a passenger-side end bracket  12   a . Lift bracket  18  is shown attached to a passenger-side end bracket  12   a  and, in conjunction with lift bracket  18  positioned on the driver-side and attached to a driver-side end bracket  14   a , provides a lifting point for lifting and inserting a complete support structure  10   a  into the vehicle cabin (not shown). Passenger-side tube  25   a  has a plate end  23  which is welded, fused, or otherwise attached to or integrally formed with mid-plate  11   a  opposite of plate-end  13  of tube  16   a . Depending on the weight supported by center section  29 , H-braces  26 ,  28 ,  30  may be further supported by a brace or gusset  33 . In the preferred mode, a passenger-side section  39  is framed by left- and right-hand straps  34 ,  36 , respectively, which are welded or otherwise attached above or at one end to a passenger-side tube  25   a , and below or at its other end to a lateral lower tie strap  32 . Tie strap  32  extends laterally between and attaches to a right-hand H-brace  28  and the passenger-side end bracket  12   a . However, those in the art will recognize that various passenger-side arrangements can easily be formed by varying combinations and configurations of support straps and braces. 
       FIG. 2  shows support structure  10   a  after it has been inserted into a vehicle cabin (not shown) and bolted or otherwise attached to a vehicle body structure lower  38 . For clarity, trim and instrumentation are omitted from  FIG. 2 . In the preferred mode, a support structure  10   a  with accompanying retainer, instrumentation, and trim (not shown), is fully assembled outside of the vehicle cabin. The complete support structure  10   a  then is lifted at lift brackets  18  and inserted into the vehicle, preferably through an open doorway, then bolted or fastened into place on the vehicle body structure lower  38 . Alternatively, instruments and other devices, as well as trim material, may be installed and attached after support structure  10   a  has been installed. Driver-side end bracket  14   a  is fastened or bolted to a driver-side hinge pillar inner assembly  42  portion of a vehicle body, and passenger-side end bracket  12   a  is fastened or bolted to a passenger-side hinge pillar inner assembly  40  portion of a vehicle body. H-braces  28 ,  30  are bolted or fastened to body structure lower  38 , preferably to a plurality of floor brackets  46  welded or otherwise rigidly attached to the front of dash  55  of body structure lower  38 . Once attached, H-braces  28 ,  30  provide vertical sag support to structure  10   a . After a plurality of plenum bracket attachments  24   a  are firmly attached to a plenum upper  44 , and instrument panel attachment or support brackets  17  are attached to a panel retainer as previously described, the bolts and hinges are trimmed out in an aesthetically pleasing manner, preferably by using a valance panel and end caps constructed of material that matches and blends with the exterior top surfaces of the dashboard. 
     Turning to  FIG. 3 , which shows a second preferred embodiment, support structure  10   b  includes a driver-side  31   b  having first and second driver-side tubes  16   b,    16   c , a center console area  51  having a center console tube  56 , and a passenger-side area  37   b  having a passenger-side tube  25   b . The tubes  16   c ,  56 ,  25   b  are aligned substantially end-to-end and are separated by and attached to a plurality of rigid mid-plates  11   b ,  11   c  which are preferably formed of weldable stamped steel. One end of a driver-side tube  16   b  is inserted into and/or welded to a first end  21   a  of a steering column attachment bracket  19 , while the other end of tube  16   b  is supported by a driver-side bracket  14   b  to provide substantially rigid axial and vertical support. A second driver-side tube  16   c  is inserted into and/or welded to a second end  21   b  of the attachment bracket. At least one plenum bracket  24   b  extends radially forward from a second driver-side tube  16   c  and, along with a plurality of forward-extending instrument panel support brackets  17  (see  FIGS. 1 and 2 ), is bolted or attached to a plenum upper  44  (see  FIG. 2 ) for bracing support. Various other driver-side supports and brackets such as E/A brackets  22  are welded or otherwise attached to tubes  16   b,    16   c  respectively as required by the vehicle design. An H-brace adapter bracket  54   a  is welded to and positioned at the end of a left-hand H-brace  30 , which extends longitudinally downward from and is welded or otherwise attached to a second driver-side tube  16   c.    
     A center-console area  51  is defined by the area between mid-plates  11   b,    11   c  and may support and frame such devices as air vents or outlets, navigation screens, radios/CD/DVD players, and controls for heaters, air conditioning, defrosters, and the like. Area  51  further includes a center-console tube  56 , which is welded or attached between mid-plates  11   b ,  11   c  and to which is welded or attached a rectangular radio attachment bracket  52 . Welded to and spanning the distance between mid-plates  11   b ,  11   c  is an upper center retainer bracket  53 , which along with center H-brace  26  provides substantially rigid lateral support to center console area  51 . 
     A passenger-side  37   b  has a passenger-side tube  25   b  extending laterally from mid-plate  11   c  to passenger-side end bracket  12   b  to provide substantially rigid axial and vertical support. At least one plenum bracket  24   b  extends radially forward from passenger-side tube  25   b  and is bolted or attached to a plenum upper  44  (see  FIG. 2 ) for bracing support. At least one forward-extending instrument panel support bracket  17  (see  FIGS. 1 and 2 ) may be attached to passenger-side end bracket  12   b  to attach to an instrument panel retainer (not shown), as previously described herewithin. As in  FIG. 1 , passenger-side  37   b  may be supported by a variety of lateral and horizontal support brackets or braces, such as straps  32 ,  34 ,  36 . An H-brace adapter bracket  54   b  is welded to and disposed at the end of a left-hand H-brace  28  which extends downward from and is welded or otherwise attached to tube  25   b . Center H-brace  26  wraps around and/or is welded to H-braces  28 ,  30  to provide lateral bracing support to center-console area  51 , as well as additional weldable surface area. 
     While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.