Abstract:
Disclosed herein is an interior structural assembly for a vehicle. The assembly includes a defrost panel forming at least a portion of a defrost duct, the defrost panel has first and second panel extensions laterally extending at opposite ends of a defrost base and an instrument panel overlaying the defrost panel, the instrument panel having at least one defrost aperture and first and second ends generally horizontally extending across the interior width of the vehicle, wherein the first and second panel extensions extend to the first and second ends of the instrument panel, respectively.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally pertains to an interior structural assembly for a vehicle and more specifically, a defrost panel structure for mounting a speaker. 
       BACKGROUND 
       [0002]    Some vehicles include speakers that are located at end portions of an instrument panel and adjacent to a windshield. Some of these speakers are mounted on an inner surface of the instrument panel. Conventionally, for example, the speakers are mounted to the inner surface by having an attachment mechanism molded into the instrument panel. In another instance, for example, the speakers are attached to the inner surface via brackets/clips during vehicle assembly. By having to account for these attachment mechanisms in the design of the instrument panel, valuable and limited vehicle space is utilized. 
         [0003]    Furthermore, rear portions of many instrument panels slope downward toward the windshield. Speakers are sometimes mounted such that they are angled rearward with respect to the plane of the windshield so that vehicle occupants can hear the sound produced thereby. These factors can contribute to an increased amount of space needed at the bottom of the instrument panel slope to accommodate the speakers as well as any attachment mechanisms associated with them, which can limit styling freedom. 
       SUMMARY 
       [0004]    Embodiments of an interior structural assembly for a vehicle are disclosed herein. In one such embodiment, the assembly includes a defrost panel forming at least a portion of a defrost duct. The defrost panel has first and second panel extensions laterally extending at opposite ends of a defrost base. The assembly also includes an instrument panel overlaying the defrost panel. The instrument panel has at least one defrost aperture and first and second ends generally horizontally extending across substantially the interior width of the vehicle. 
         [0005]    Embodiments of a speaker assembly for a vehicle are also disclosed herein. In one such embodiment, the assembly includes a speaker, a defrost panel and an instrument panel. The defrost panel has at least one panel extension laterally extending at an end of the defrost panel. The speaker is mounted in an aperture of the at least one panel extension. The instrument panel overlays the defrost panel and has first and second ends generally horizontally extending across the interior width of the vehicle. 
         [0006]    Other embodiments of the invention are described in additional detail hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
           [0008]      FIG. 1  is a perspective view of a passenger compartment having an interior structural assembly according to one embodiment of the present invention; 
           [0009]      FIG. 2  is a top plan view of an instrument panel and a defrost panel of the interior structural assembly of  FIG. 1 ; 
           [0010]      FIG. 3  is an enlarged partial perspective view of the instrument panel and the defrost panel of  FIG. 2 ; 
           [0011]      FIG. 4  is an enlarged partial bottom perspective view of the instrument panel and the defrost panel of  FIG. 2 ; 
           [0012]      FIG. 5  is a perspective view of the defrost panel of  FIG. 3 ; and 
           [0013]      FIG. 6  is a cross-section of the instrument panel and the defrost panel taken along line  6 - 6  of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Defrost panels can accommodate windshield defroster ducts below the instrument panel that run laterally adjacent to the windshield. Conventionally, some windshield defroster ducts only occupy a fraction of the overall length of the instrument panel. Embodiments of the present invention include a defrost panel having structural components capable of accommodating mounting locations for one or more speakers. Accordingly, rather than attaching the speakers directly to, for example, the inner surface of the instrument panel as described previously, the speakers can be mounted to the aforementioned structural components of the defrost panel. The speakers can be, for example, attached at approximately the same location as they conventionally might otherwise be attached directly to the instrument panel. 
         [0015]    Referring to  FIGS. 1-6 , a passenger vehicle  10  includes an interior structural assembly  12  according to one embodiment of the present invention. As shown in  FIG. 1 , vehicle  10  contains a driver compartment  14 , a passenger compartment  16 , a windshield  18 , A-pillars  20 , and front-side windows  23 . A-pillars  20  separate windshield  18  from front-side windows  23 . Although a passenger vehicle is shown, embodiments of the present invention may be used with any other type of vehicle having any other interior/exterior design or configuration such as a truck, boat, bus, etc. 
         [0016]    Interior structural assembly  12  includes an instrument panel  22  overlaying a defrost panel  24 . The defrost panel  24  includes a portion of a defrost duct  25  (shown in  FIG. 5 ). As shown, the instrument panel  22  projects rearward and extends substantially the entire width of the vehicle  10  along a lower end portion of the windshield  18  and is made of a single piece of material. The instrument panel  22  gently slants rearward into both the driver compartment  14  and the passenger compartment  16 . The instrument panel  22  can be made of, for example, a synthetic resin material or any other suitable material. However, in other embodiments, the instrument panel  22  can have a different configuration than that shown in  FIG. 1 . For example, the instrument panel  22  can be made of more than one piece or does not have to substantially extend the entire width of the vehicle  10 . The instrument panel  22  also includes a defroster vent  26  with one or more defrost apertures  26   a  for supplying air from the defrost panel  24 . In the embodiment shown in  FIG. 1 , the defroster vent  26  occupies less than substantially the entire length of the instrument panel  22 . The instrument panel  22  also includes a speaker grille  28  mounted over a speaker  30  attached to the defrost panel  24 . The speaker grille  28  can connect to the instrument panel so that when it is installed, its top surface is substantially flush with the top surface of the instrument panel. Of course, other embodiments can include different structures of instrument panel  22  and are not limited to those shown in the Figures. 
         [0017]    A central console portion  32  extends downward from a central portion of the instrument panel  22 . The central console portion can provide access to a user control  34  to, for example, adjust the volume of the speaker  30 . The central console portion  32  can also house various other components, such as HVAC controls, HVAC air outlets, an audio system, etc. 
         [0018]    Referring to  FIGS. 2 and 3  the defrost panel  24  includes two panel extensions  36  with each panel extension  36  having a speaker mounting structure  38 . The panel extensions extend laterally from a defrost base  41  (shown in  FIG. 5 ) and extend to ends  40  of the instrument panel  22 . Although two panel extensions are shown, in other embodiments, a defrost panel may only have one panel extension  36  extending from either end of the defrost base. In other words, if a second speaker is desired or required, it may be attached using conventional means. Since, for example, the panel extensions  36  extend to the ends of  40  of the instrument panel  22 , the overall stiffness and rigidity of the interior structural assembly  40  is increased. However, the panel extensions  36  do not necessarily have to extend to the ends  40  of the instrument panel and may extend to any length from the defrost base  41  as desired or required. 
         [0019]    Each speaker mounting structure  38  includes a speaker aperture  42  for receiving the speaker  30 . The speaker aperture  42  can be aligned with an instrument panel aperture  44  in a speaker ledge  46  in instrument panel  22 . Although each panel extension  36  is shown as having one speaker mounting structure, in other embodiments, multiple speaker mounting structures can be included that hold, for example, smaller-sized speakers. 
         [0020]    The panel extension  36  is covered by the speaker ledge  46 . The speaker mounting structure  38  of panel extension  36  includes a speaker locating projection  48  that can assist in aligning the speaker  30  to its proper position. Speaker mounting structure  38  also includes three speaker fastening structures  45  for fastening the speaker to the panel extension  36 . In this manner, the speaker can be secured in an upright position. The speaker fastening structures  45  can be molded directly into the defrost panel  24 , which permits a reduction of the number of parts and cost. In other words, embodiments of the present invention may render the use of additional attachment mechanisms (e.g. brackets or clips) to secure the speaker unnecessary. 
         [0021]    The instrument panel  22  and the defrost panel  24  can be secured together. The defrost panel  24  can be, for example, attached to the instrument panel  22  by welding, screws, clips, adhesive or any other suitable attachment mechanism. In the embodiment shown, an instrument panel fastening structure  50  such as an aperture can be included in the panel extension  36  and can be secured using a fastener (not shown) such as a clip, hook or screw that passes through the instrument panel  22  and engages the defrost panel  24 . Further, the sides of the instrument panel  22  and the defrost panel  24  can be engaged using snap-fit connections  52  (shown in  FIG. 4 ). Further, grille locating apertures  54  can receive, for example, a securing member, such as a catch to form a snap-fit engagement with the speaker grille  28 . Although two grille locating apertures  54  are shown, the instrument panel  22  can include any number of grille locating apertures  54 . 
         [0022]    Referring again to  FIG. 4 , a partial bottom perspective view of the instrument panel  22  and the defrost panel  24  is shown. Each of the three speaker fastening structures  45  corresponds with a threaded boss  58  (only two can be seen in  FIG. 4 ) vertically projecting downward from a bottom surface of the instrument panel  22 . Accordingly, for example, the speaker  30  can be engaged with the speaker fastening structure  45  by using a screw. Of course, the speaker  30  may be attached using any other mechanism (e.g., clips, adhesive, welding) and is not limited to that shown. 
         [0023]    The defrost panel  24  is separated from and can also be supported by a side window defrost duct  60  for supplying air to front side windows  23 . Mounting standoffs  62  separate the defrost panel  24  from the side window defrost duct  60 . The defrost panel  24  can be aligned with the side window defrost duct  60  using defrost panel locating structures  66  and secured using defrost panel fastening structures  64 . As shown, defrost panel fastening structure  64  is a threaded boss that can be secured to side window defrost duct  60  using a screw. However other attachment mechanisms (e.g., clips, adhesive, welding) can be used in lieu of a boss and screw combination 
         [0024]    Referring to  FIG. 5  the defrost panel  24  is illustrated without the instrument panel  22 . Each panel extension  36  includes a speaker recess  68  for accommodating the speaker mounting structure  38 . As shown in  FIG. 6 , the speaker recess  68  extends below the defrost base  41  and similarly, the speaker ledge  46  extends below a top surface of the instrument panel  22 . As discussed previously, the panel extensions  36  extend from the defrost base  41 . Defrost duct  25  is also connected to the defrost base  41  and has windshield defroster passageways  70  for providing air to windshield  18 . The defrost duct  25  can include multiple windshield defroster passageways  70  as illustrated in  FIG. 5  or alternatively can include only a single one of the windshield defroster passageways  70 . 
         [0025]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.