Abstract:
A mounting structure for mounting a cockpit module onto a vehicle body on a side facing a vehicle compartment is provided with a mount member mounting a cockpit module onto a vehicle body, a resilient member disposed between the vehicle body and the cockpit module, and a guide mechanism guiding the cockpit module along a given transfer path when the cockpit module is transferred to a mount position of the vehicle body. The guide mechanism guides the cockpit module in a way to allow the cockpit module to move downward of the vehicle body in an oblique direction through at least a partial segment of the given transfer path such that an own weight of the cockpit module is allowed to apply on the resilient member to press the resilient member between the vehicle body and the cockpit module.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a mount structure for a cockpit module and a related method and, more particularly, to a mount structure for a cockpit module, equipped with an instrument panel and the like while unitizing such components, and its related method. 
   Japanese Patent Application Lai-Open Publication No. 2000-313248 discloses a mounting structure for a cockpit module, which is mounted from a side facing a vehicle compartment toward a vehicle body front, wherein a pin is provided on the vehicle body, while a channel is provided in the cockpit module, to allow the pin to be guided along the channel such that the cockpit module is moved to a given mount position along a profile of the channel. 
   SUMMARY OF THE INVENTION 
   However, upon studies conducted by the present inventors, it has been a general practice for a vehicle body panel, onto which the cockpit module is mounted in abutting engagement, that is, a dash panel by which the vehicle compartment and an engine room are defined, to be provided with a through-hole in order to pass pipes, of an air conditioning unit, which extend from the cockpit module to a vehicle body front, that is, toward the engine room. 
   Since the through-hole provides fluid communication between the engine room and the vehicle compartment, a gap formed around the pipes in the through-hole needs to be preferably filled in with a seal member for the purpose of enhancing water-tightness and sound insulating properties. To this end, a seal member, with a given thickness and serving as a resilient member, may be provided on peripheries of the pipes whereby when the cockpit module is mounted onto the vehicle body panel, the seal member is collapsed and expanded by means of the cockpit module to fill in the gap. 
   However, since the seal member is formed of resilient member, it is conceived for a demanded force to increase by a component corresponding to a reaction force of the seal member, when the cockpit module is transferred to the mount position, to force a worker to bear the burden. 
   The present invention has been completed upon such studies conducted by the present inventors and has an object to provide a mounting structure for a cockpit module and its related method which reliably enable reduction in a pressing force needed for assembling work. 
   To achieve the above object, one aspect of the present invention provides a mounting structure for mounting a cockpit module onto a vehicle body on a side facing a vehicle compartment, comprising: a mount member mounting a cockpit module onto a vehicle body; a resilient member disposed between the vehicle body and the cockpit module; and a guide mechanism guiding the cockpit module along a given transfer path when the cockpit module is transferred to a mount position of the vehicle body, the guide mechanism guiding the cockpit module in a way to allow the cockpit module to move downward of the vehicle body in an oblique direction through at least a partial segment of the given transfer path such that an own weight of the cockpit module is allowed to apply on the resilient member to press the resilient member between the vehicle body and the cockpit module. 
   In other words, another aspect of the present invention provides a mounting structure for mounting a cockpit module onto a vehicle body on a side facing a vehicle compartment, comprising: mounting means for mounting a cockpit module onto a vehicle body; dimensionally changing means for changing a shape dimensionally and resiliently, the dimensionally changing means being disposed between the vehicle body and the cockpit module; and guiding means for guiding the cockpit module along a given transfer path when the cockpit module is transferred to a mount position of the vehicle body, the guiding means guiding the cockpit module in a way to allow the cockpit module to move downward of the vehicle body in an oblique direction through at least a partial segment of the given transfer path such that an own weight of the cockpit module is allowed to apply on the dimensionally changing means to press the dimensionally changing means between the vehicle body and the cockpit module. 
   Besides, another aspect of the present invention provides a method of mounting a cockpit module onto a vehicle body on a side facing a vehicle compartment, comprising: providing a resilient member between a vehicle body and a cockpit module; guiding the cockpit module along a given transfer path when the cockpit module is transferred to a mount position of the vehicle body to allow the cockpit module to move downward of the vehicle body in an oblique direction through at least a partial segment of the given transfer path; causing an own weight of the cockpit module to act on the resilient member to press the resilient member between the vehicle body and the cockpit module; and mounting the cockpit module onto the vehicle body. 
   Other and further features, advantages, and benefits of the present invention will become more apparent from the following description taken in conjunction with the following drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view showing a state in which a cockpit module and a dash panel are viewed toward a vehicle body front-side from a vehicle body backside in the presently filed embodiment according to the present invention; 
       FIG. 2  is a perspective view showing an abutment side, associated with the vehicle body, of the cockpit module as viewed toward the vehicle body backside from the vehicle body front-side in the presently filed embodiment; 
       FIG. 3  is a perspective view showing a framework member of the cockpit module in the presently filed embodiment; 
       FIG. 4  is a partially exploded perspective view showing a flange member located on a left end of the framework member of the cockpit module and a left side front pillar to which the flange member is mounted in the presently filed embodiment; 
       FIG. 5  is a partially exploded perspective view showing a flange member located on a right end of the framework member of the cockpit module and a right side front pillar to which the flange member is mounted in the presently filed embodiment; 
       FIG. 6  is a perspective view showing a right side surface of the flange member shown in  FIG. 5 ; 
       FIG. 7  is a schematic side view of the flange member as viewed along an X-direction shown in  FIG. 4 ; 
       FIG. 8A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between a bracket (flange member), a post bracket and the dash panel in a state in which a guide pin is placed in a vicinity of an inlet of a channel during mounting work for the cockpit module in the presently filed embodiment; 
       FIG. 8B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between a pipe of a vehicle equipment and the dash panel in the same state of  FIG. 8A ; 
       FIG. 8C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between a locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 8A ; 
       FIG. 9A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between the bracket, the post bracket and the dash panel in a state in which the guide pin is disposed in a lower end portion of the channel during the mounting work for the cockpit module in the presently filed embodiment; 
       FIG. 9B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the pipe of the vehicle equipment and the dash panel in the same state of  FIG. 9A ; 
       FIG. 9C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 9A ; 
       FIG. 10A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between the bracket, the post bracket and the dash panel in a state in which the guide pin is placed in a mount position during the mounting work for the cockpit module in the presently filed embodiment; 
       FIG. 10B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the pipe of the vehicle equipment and the dash panel in the same state of  FIG. 10A ; 
       FIG. 10C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 10A   
       FIG. 11 , which corresponds to  FIG. 1 , is an exploded perspective view showing a state in which a cockpit module and a dash panel are viewed toward a vehicle body front-side from a vehicle body backside in another example of the presently filed embodiment according to the present invention; and 
       FIG. 12 , which corresponds to  FIG. 4 , is a partially exploded perspective view showing a flange member located on a left end of a framework member of the cockpit module and a left side front pillar to which the flange member is mounted in another example. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Hereinafter, a mounting structure of a cockpit module and its related method of an embodiment according to the present invention are described below in detail with reference to  FIG. 1  to  FIG. 10C . Incidentally, in the drawing figures, an arrow “FR” indicates a front direction of a vehicle body, an arrow “R” a right direction of the vehicle body and an arrow “UPR” an upper direction of the vehicle body with the arrow “FR”, the arrow “R” and the arrow “UPR” forming a three-axis rectangular coordinate system. Hereunder, descriptions as to various directions in the presently filed embodiment conform to such a coordinate system. 
     FIG. 1  is an exploded perspective view showing a state in which a cockpit module and a dash panel are viewed toward a vehicle body front-side from a vehicle body backside in the presently filed embodiment;  FIG. 2  is a perspective view showing an abutment side, associated with the vehicle body, of the cockpit module as viewed toward the vehicle body backside from the vehicle body front-side in the presently filed embodiment;  FIG. 3  is a perspective view showing a framework member of the cockpit module in the presently filed embodiment;  FIG. 4  is a partially exploded perspective view showing a flange member located on a left end of the framework member of the cockpit module and a left side front pillar to which the flange member is mounted in the presently filed embodiment;  FIG. 5  is a partially exploded perspective view showing a flange member located on a right end of the framework member of the cockpit module and a right side front pillar to which the flange member is mounted in the presently filed embodiment;  FIG. 6  is a perspective view showing a right side surface of the flange member shown in  FIG. 5 ;  FIG. 7  is a schematic side view of the flange member as viewed along an X-direction shown in  FIG. 4 ;  FIG. 8A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between a bracket (flange member), a post bracket and the dash panel in a state in which a guide pin is placed in a vicinity of an inlet of a channel during mounting work for the cockpit module in the presently filed embodiment;  FIG. 8B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between a pipe of a vehicle equipment and the dash panel in the same state of  FIG. 8A ;  FIG. 8C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between a locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 8A ;  FIG. 9A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between the bracket, the post bracket and the dash panel in a state in which the guide pin is disposed in a lower end portion of the channel during the mounting work for the cockpit module in the presently filed embodiment;  FIG. 9B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the pipe of the vehicle equipment and the dash panel in the same state of  FIG. 9A ;  FIG. 9C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 9A ;  FIG. 10A  is a partially cross-sectional and schematic side structural view, as viewed in the same direction as that of  FIG. 7 , showing a relative positional relationship between the bracket, the post bracket and the dash panel in a state in which the guide pin is placed in a mount position during the mounting work for the cockpit module in the presently filed embodiment;  FIG. 10B  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the pipe of the vehicle equipment and the dash panel in the same state of  FIG. 10A ; and  FIG. 10C  is a partially cross-sectional and schematic side structural view showing a relative positional relationship between the locate hole, formed in the cockpit module, and the dash panel in the same state of  FIG. 10A . 
   As shown in  FIGS. 1 to 3 , the cockpit module  1  is provided with a support member  2 , extending in a lateral direction of the vehicle body and serving as a framework member, to which an instrument panel  3  and a steering mechanism  4  are integrally mounted into a module structure. 
   The cockpit module  1  is mounted to a dash panel  5  and front pillars  6  on side facing a vehicle compartment C from a vehicle body backside. In particular, first, the cockpit module  1  is transferred from the vehicle body backside to a given position (mount position) and temporarily held in the mount position by means of locate pins  7  provided on the dash panel  5  and guide pins  8 A to  8 D provided on the front pillars  6 . With the cockpit module  1  temporarily kept in such a position intact, the cockpit module  1  is fixedly secured to the vehicle body, such as the dash panel  5 , by means of bolts that are not shown. 
   As shown in  FIGS. 4 and 5 , a guide mechanism  9  is provided for the purpose of permitting the cockpit module  1  to be more easily and reliably transferred to the mount position. More particularly, the guide mechanism  9  is comprised of channels  12 A to  12 D formed in brackets (flange members)  10 ,  11  located on both sides of the cockpit module  1  and formed of plate-like members, respectively, and guide pins  8 A to  8 D protruding from inner surfaces on both sides of the dash panel  5  toward an inside of the vehicle compartment in a horizontal direction in correspondence to the respective channels  12 A to  12 D. 
   More particularly, as shown in  FIG. 7 , the channel  12 A provided in the bracket  10  at the left end of the support member  2  is formed so as to extend from a front edge of the bracket  10  toward the vehicle body backside in a horizontally mounting attitude (an attitude in which the cockpit module  1  is mounted in the vehicle body set in horizontal) and has a segment  12   a  extending downward from an inlet  12   i  in an oblique direction and a segment  12   b  folding back at a bottom of the segment  12   a  and extending upward in an oblique direction. With the channel  12 A, the segment  12   a  extends in the obliquely downward direction at an inclination angle α, with respect to a horizontal direction  13 , which is smaller than an inclination angle β, with respect to a horizontal direction  13 , at which the segment  12   b  extends in the obliquely upward direction, with the inlet  12   i  and an innermost position (mount position)  12   j  being set at the substantially same height. 
   As shown in  FIG. 7 , similarly, another channel  12 B provided in the bracket  10  is formed in a position under parallel translation so as to define its position dislocated from the channel  12 A in vertical (in a lower area in this example) and horizontal (in a rearward position in this example) directions to be configured in the same shape as that of the channel  12 A. Accordingly, even the channel  12 B has the segment  12   a  extending downward in the oblique direction and the segment  12   b  extending upward in the oblique direction like the channel  12 A, with the angle α selected to be smaller than the angle β while the inlet  12   i  and the mount position  12   j  being aligned on the substantially same height. 
   In the meanwhile, as shown in  FIGS. 5 and 6 , the channels  12 C and  12 D, provided in the bracket  11  at the right end of the support member  2 , are located at positions dislocated representatively from the channel  12 A under parallel translation, that is, the channels  12 A and  12 C are located at left and right symmetric positions with respect to one another while the channels  12 B and  12 D are located at left and right symmetric positions with respect to one another. Moreover, the channels  12 C and  12 D have basically identical shapes to the channel  12 A, that is, the channels  12 A,  12 B,  12 C and  12 D have basically identical shapes to one another. Therefore, to describe with a focus on the channels  12 C and  12 D, these channels are configured in the same shape and provided in positions dislocated in vertical and horizontal directions. However, in contrast to a structure wherein the channels  12 A to  12 C are formed by cutting out plate-like portions of the brackets  10 ,  11  into respective profiled shapes, the channel  12 D is formed in the bracket  11  at a lower end surface and, thus, no segment  12   a , extending downward in the oblique direction is present with only segment  12   b , extending upward in the oblique direction, being formed. That is, the channel  12 D has an edge  11   e  formed at a lower end of the bracket  11  in the same profile as an upper portion of the channel  12 C and resultantly, as upper portions of the channels  12 A and  12 B in parallel thereto, whereby the edge  11   e  is able to achieve the same functions as those of the channels  12 A to  12 C. 
   With such a structure set forth above, when mounting the cockpit module  1 , the guide pins  8 A to  8 D are inserted from the inlets  12   i  to the associated channels  12 A to  12 D and guided through the channels  12 A to  12 D to relatively move to the mount positions  12   j . Accordingly, the brackets  10 ,  11  with the channels  12 A to  12 D formed, respectively, that is, the cockpit module  1  initially move upward in the oblique direction at the inclination angle α, which is relatively less acute, in association with the segment  12   a  and, subsequently, move downward this time in the oblique direction at the inclination angle β, which is greater than the inclination angle α, in association with the segment  12   b . Incidentally, since the brackets  10 ,  11  are formed with the plural parallel channels  12 A to  12 D, inclined movement of the cockpit module  1  is restricted and the cockpit module  1  is sustained in a substantially fixed attitude (=attitude in the mount position) during a period in which the cockpit module  1  is guided by the guide mechanism  9  to move to the mount position. 
   Pipes  14 , for delivering water, air or coolant of an air conditioning unit, and harnesses penetrate thorough and protrude from a surface, with which the dash panel  5  is held in abutting engagement, of the cockpit module  1  and these pipes  14  and the like are inserted through a through-hole  15  formed in the dash panel  5 . With a view to absorbing error in mount position, error in mount positions of the pipes  14  and the like in the cockpit module  1 , and vertical displacements of the pipes  14  and the like during mounting work, the through-hole  15  is formed in a larger size than outer diameters of the pipes  14  and the like and, for this reason, a gap can be formed around the pipes  14  and the like in the through-hole  15  under a condition where the cockpit module  1  is mounted. 
   To fill in such a gap, a seal member (such as urethane rubber)  16  is mounted around the pipes  14  and the like as a resilient member. The seal member  16  is intervened between the cockpit module  1  and the dash panel  5  and compressed to expand in a radial direction when the cockpit module  1  is mounted onto the dash panel  5  to enable the gap to be filled in. 
   Further, as shown in  FIGS. 8A ,  9 A and  10 A, a post bracket  17  is provided on the support member  2  of the cockpit module  1  and extends forward of the vehicle body to be coupled to the vehicle body. An end face (mounting surface)  17   a , of a front side at a distal end of the post bracket  17 , and an abutment surface  5   a  of the dash panel  5  are mutually brought into abutting engagement, after which a bolt  19 , passing through -holes  17   b ,  5   b , is coupled to a weld nut  20  provided at a rear side (in an forward area of the vehicle body) of the dash panel  5 . Such a structure enables to improve rigidity of a portion that supports the steering mechanism  4  of the support member  2 . Both the end face  17   a  of the post bracket  17  and the abutment surface  5   a  of the dash panel  5  are slanted forward and downward from the vehicle body backside and, more particularly, extend parallel to an extending direction of the channel  12   a  to be inclined at the angle β with respect to the horizontal direction  13 . 
   Hereunder, further detailed description is made of relative positional variations of various parts, with reference to  FIGS. 8A to 10C , during transfer of the cockpit module  1  to the mount position. Incidentally, in  FIGS. 8B ,  9 B and  10 B, the pipes  14  and the like to be inserted through the through-hole  15  are shown as a single pipe for the sake of convenience. 
   As shown in  FIG. 8A , the guide pin  8 A of the cockpit module  1  is shown under a condition located in the inlet  12   i  of the associated channel  12 A and, under such a condition, the pipes  14  and the like of the cockpit module  1  are not inserted through the though-hole  15  of the dash panel  5  while the locate pin  7  of the dash panel  5  is not inserted through a locate hole  18  of the instrument panel  3  forming one side of the cockpit module  1  as shown in  FIGS. 8B and 8C . 
   Next, under a condition shown in  FIGS. 8A to 8C , if the cockpit module  1  is moved forward and upward of the vehicle body in the oblique direction along the channel  12 A, the cockpit module  1  reaches a position shown in  FIGS. 9A to 9C . More particularly, with such a position, the guide pin  8 A is located at the lower end of the segment  12   b  of the channel  12 A as shown in  FIG. 9A  and, as shown in  FIG. 9B , the pipes  14  and the like are inserted through the through-hole  15  while, as shown in  FIG. 9C , the seal member  16  around the pipes  14  and the like is brought into abutment with the dash panel at an area around the through-hole  15 . 
   Then, under a condition shown in  FIGS. 9A to 9C , if the cockpit module  1  is moved forward and upward of the vehicle body in the oblique direction along the extending direction of the channel  12 A, the cockpit module  1  reaches a position shown in  FIGS. 10A to 10C . More particularly, with such a position, the through-hole  17   b  provided in the end face  17   a  of the post bracket  17  and the through-hole  5   b  provided in the abutment surface  5   a  of the dash panel  5  are caused to overlap each other, as shown in  FIG. 1A , and under such a condition, using the bolt  19  inserted through the through-holes  17   b ,  5   b  enables the post bracket  17  and the dash panel  5  to be coupled. 
   Simultaneously, as shown in  FIG. 10B , upon movement of the cockpit module  1  forward and downward of the vehicle body in the oblique direction from the position shown in  FIGS. 9A to 9C  to the position shown in  FIGS. 10A to 10C , the seal member  16  is collapsed from the configuration, shown in a phantom line, to a shape shown in a solid line. Thus, the gap of the through-hole  15  around the pipes  14  and the like are filled in by the seal member  16  and, as shown in  FIG. 10C , the locate pin  7  is inserted through the locate hole  18 . 
   As set forth above, with the mounting structure of the cockpit module of the presently filed embodiment, since the cockpit module  1  is configured to move downward of the vehicle body in the oblique direction, an own weight of the cockpit module  1  and, more specifically, component forces oriented along the channels  12 A to  12 D are caused to act on the seal member  16  serving as the resilient member to be utilized for collapsing the seal member  16 . That is, the presently filed embodiment enables reduction in a pressing force of the cockpit module  1  during mounting work. 
   Also, since the end face  17   a  of the post bracket  17  and the abutment surface  5   a  of the dash panel  5  are slanted downward from the vehicle body backside toward the vehicle body front in the oblique direction, the bolt can be used to achieve coupling work from the vehicle body back side and the downward area of the vehicle body to the upper area of the vehicle body in the oblique direction, enabling improvement in work attitude. Especially, the presence of the end face  17   a  and the abutment surface  5   a  made parallel to the direction in which the cockpit module  1  moves in the oblique direction enables the post bracket  17  and the dash panel  5  to more easily and reliably move to a mutually associated joint position. 
   Further, with the respective channels  12 A to  12 D, since the inlet  12   i  and the mount position  12   j  are aligned on the substantially same height, during an initial stage of assembling work, an assembly worker is enabled to predict a height position under a final mount condition, making it possible to more easily and reliably execute mounting work. 
   Incidentally, while the presently filed embodiment has been described in connection with the cockpit module with which, in addition to the instrument panel, the steering mechanism is unitized, the present invention is not limited to such a particular structure and an alternative may include a structure with which no steering mechanism is unitized or another alternative may include other component parts. 
   Also, as shown  FIGS. 11 and 12 , the guide mechanism may take a structure wherein the guide pins representatively with reference numeral such as  8 A′ and  8 B′ are provided in the cockpit module and, in the meantime, the guide channels with reference numerals such as  12 A′ to  12 D′ may be provided in the vehicle body (such as front pillars). However, it is, of course, needless to say that in such a case, the guide channels may take structures that correspond to inversed configurations in shape of the guide channels of the presently filed embodiment, as shown in  FIGS. 1 ,  4 ,  11  and  12 . 
   The entire content of a Patent Application No. TOKUGAN 2004-172716 with a filing date of Jun. 10, 2004 in Japan is hereby incorporated by reference. 
   Although the invention has been described above by reference to a certain embodiment of the invention, the invention is not limited to the embodiment described above. Modifications and variations of the embodiment described above will occur to those skilled in the art, in light of the teachings. The scope of the invention is defined with reference to the following claims.