Abstract:
A support assembly for a vehicle dashboard comprises a support beam having end faces. As seen from the end faces, in cross-section the support beam has five side faces, a forward face, upper face, lower face, upper rearward face, and lower rearward face. The upper face, lower face, upper rearward face and lower rearward face are each provided with a corresponding groove. The grooves are disposed peripherally of the support beam and each groove extends longitudinally of the support beam to support at least one dashboard module in a selected one of a plurality of positions. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates to a support assembly for a vehicle dashboard.  
           [0003]    2. Description of the Related Art  
           [0004]    It is known to provide support assemblies comprising support beams for vehicle dashboards which extend transversely of the vehicle to support the dashboard and to provide a mount for an instrument panel, air bag, trim for example. Such support beams are engineered for a specific vehicle, to accommodate the instrument panel etc. at a specific location.  
         SUMMARY OF THE INVENTION  
         [0005]    An aim of the invention is to provide a new           panel.  
           [0006]    According to a first aspect of the present inven           for a vehicle dashboard comprising a support beam said           of grooves disposed peripherally of said beam with each           of the support beam to support at least one dashboard module in a selected one of a plurality of positions.  
           [0007]    As a result the support beam is able to accommodate and support at least one dashboard module in different positions and so may be used in more than one vehicle type.  
           [0008]    At least one of said grooves may be T-shaped in cross-section, or may be dove-tailed in cross-section or any other cross-section as appropriate.  
           [0009]    Each groove may be of the same cross-section.  
           [0010]    The beam may comprise at least three grooves.  
           [0011]    The beam may comprise an extruded profile. The extruded profile may be hollow, and filled with a foam material to provide additional stiffness.  
           [0012]    The extruded profile preferably comprises a polymer material provided with reinforcing fibers. Alternatively, the extruded profile may comprise a light metal or alloy, for example aluminum.  
           [0013]    The beam may be polygonal in cross-section, with said grooves provided in a plurality of sides of said polygon. In cross-section, the support beam may have five sides, comprising a forward side, a top side, a bottom side, a first rearward side and a second rearward side wherein grooves are provided on the top, bottom and rearward sides.  
           [0014]    The support assembly may comprise mounting means having a first part for attachment to a vehicle body in engagement with said support beam.  
           [0015]    The mounting means may comprise a plurality of tags each adapted to engage a corresponding groove of said beam.  
           [0016]    The mounting means may have a forward face which is generally coplanar with the forward side of said support beam.  
           [0017]    The support assembly may comprise a dashboard module wherein said dashboard module comprises with at least one tag to be received in one of said grooves.  
           [0018]    The module may be disposed at a desired location longitudinal on the beam by engaging the tag with a corresponding groove in a longitudinal direction and sliding the module relative to the beam until the module is in its desired position.  
           [0019]    The module may be attached to the beam when said module is in its desired position. The module may be attached by for example high frequency welding vibration bonding, riveting or by use of adhesive or by any other means as desired.  
           [0020]    The dashboard module may comprise a contact surface to engage a face of said beam.  
           [0021]    The contact surface may be provided or a flange adjacent to a tag.  
           [0022]    The dashboard module may be shaped to provide energy absorption properties.  
           [0023]    To provide energy absorption properties, the dashboard module may comprise a first connecting part provided with a tag to engage one of said groove, and a second connecting pail, for example to support trim, an intermediate part located between the first connecting part and the second connecting, wherein the first connecting part is connected to the intermediate part by a forward pair of arms and the second connecting part is connected to the intermediate part by a rearward pair of arms.  
           [0024]    The dashboard modules may be made by molding, or extrusion or by any other means as desired, and may comprise polymer or an alloy material.  
           [0025]    The dashboard module may comprise a cavity, said cavity may be filled with a foam material to increase the strength of the module.  
           [0026]    Said dashboard module may comprise an instrument support bracket, a ventilation support bracket, a steering column support bracket, an air bag support, a glove box support or a structural bracket to engage a part of vehicle, or any other module as desired.  
           [0027]    According to a second aspect of the invention, we provide a method of making a support assembly comprising the steps of providing a support beam comprising a plurality of grooves disposed peripherally and extending longitudinally of said support beam, providing at least one dashboard module comprising at least one tag, engaging the or each tag with a corresponding groove in a longitudinal direction and sliding the dashboard module relative to the beam until the dashboard module is in its desired position.  
           [0028]    The method may comprise the step of providing a said support beam of a desired length before or after providing said at least one dashboard module.  
           [0029]    The method may comprise the step of providing said support beam of a desired length by cutting a stock beam to the desired length.  
           [0030]    The method may comprise fixing the dashboard module to the support beam when said dashboard module is in its desired position.  
           [0031]    The method may comprise providing mounting means having a first part in engagement with said support beam and a second part for attachment to a vehicle body.  
           [0032]    The method may comprise the step of attaching said mounting means to a vehicle body. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0033]    The invention will now be described by way of example only with reference to the accompanying drawings wherein;  
         [0034]    [0034]FIG. 1 is a perspective view of a support assembly according to the present invention, and  
         [0035]    [0035]FIG. 2 is a view of an alternative configuration of the support assembly of FIG. 1.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0036]    Referring now to the Figures, a support assembly is shown at  10 , comprising a support beam  11  having end faces  12 . As seen from the end faces  12 , in cross-section the support beam  11  in the present example has five side faces, a forward face  13 , upper face  14 , lower face  15 , upper rearward face  16  and lower rearward face  17 . The upper face  14 , lower face  15 , upper rearward face  16  and lower rearward face  17  are each provided with a corresponding groove  14   a ,  15   a ,  16   a ,  17   a . The grooves  14   a ,  15   a ,  16   a ,  17   a  are disposed peripherally of the beam.  
         [0037]    In the present example “forward” and “rearward” refer, when the support assembly is mounted in a forward part of a passenger compartment of a vehicle, to the directions forwardly of the vehicle and rearwardly of the vehicle, i.e. away from and towards the passenger compartment respectively.  
         [0038]    In the present example, the grooves  14   a ,  15   a ,  16   a ,  17   a  are generally T-shaped, although the grooves may be dove-tailed or of any other shape as desired. The grooves  14   a ,  15   a ,  16   a ,  17   a  extend longitudinally of the respective face  14 ,  15 ,  16 ,  17  along the length of beam  11 .  
         [0039]    The support beam  11  in the present example is hollow having a longitudinally extending aperture  18 . The aperture  18  is filled with a foam material  19  for additional stiffness.  
         [0040]    Although the beam in the present example is shown as polygonal in cross-section, and in particular pentagonal, in cross section, it will be apparent that the beam may have any cross section as desired. The beam may have any number of grooves as desired, preferably at least two, more preferably at least three, to accommodate modules in a desired on one of a plurality of orientations.  
         [0041]    Preferably, the support beam  11  comprises an extrusion. Forming the beam  11  by extrusion is particularly appropriate since the beam has a constant cross-section along its length. Further, since the beam  11  may be cut to any length as desired, it can thus be adapted to be located in any desirable vehicle body of any width simply by cutting the support beam to length. The support beam  11  may comprise a polymer material, preferably provided with reinforcing fibers, or may comprise a light metal, e.g. aluminum or alloy material if desired.  
         [0042]    To maintain the support beam  11  in place in a vehicle, the support assembly  10  comprises mounting means  20 . In the present example, the mounting means  20  each comprise a downwardly extending first part  21  having an abutment face  21  a and apertures  22  to receive fastening means to attach the mounting means  20  to a part of a vehicle body, particularly a vehicle body in white, and a second pail  23  disposed above the first part  22 . The second pail  23  comprises an inner face  24  adapted to embrace the upper face  14 , upper rearward face  16 , lower rearward face  17  and lower face  15  of the support beam  10 . The inner face  24  further comprises tags  24   a ,  24   b ,  24   c ,  24   d  which are received in the grooves  14   a ,  15   a ,  16   a ,  17   a , respectively. The support beam  11  is thus firmly held in engagement with the second part  23  of the mounting means  20 . The forward face  13  of tile support beam  11  and the abutment face  21  a of the mounting means  20  are preferably generally coplanar, to facilitate mounting of the support assembly  10  on a vehicle body.  
         [0043]    The shape of the support beam  11  is thus highly adaptable and can receive one or more dashboard modules to provide support for any desired elements to be supported oil the beam, for example a steering column, a glove box, ventilation means, an instrument panel and so on. Such modules are shown in FIGS. 1 and 2 and are discussed in more detail below.  
         [0044]    Referring to FIG. 1, general purpose support brackets are shown at  25 , comprising a first connection pail  26 , a second part  27  spaced from said connection part  26 , and an intermediate part  28 . The first connection part  26  is provided with a tag  29 , received in the present example in groove  17   a  of the support beam  11 , and contact surfaces comprising flanges  30  disposed either side of the tag  29  which engage the lower rearward face  17  of support beam  11  to minimize relative movement between the bracket  27  and the support beam  11 . The first connection part  26  is connected to the intermediate part  28  by forward arms  31   a ,  31   b . The arms  31   a ,  31   b  are angularly shaped such that they define a four sided aperture  32 . The second support pail  25  is connected to the intermediate part  28  by rearward arms  33   a ,  33   b . The rearward arms  33   a ,  33   b  and the second connection part  25  define a sector shaped aperture  34 .  
         [0045]    The brackets  25  thus shaped provide energy absorbing properties, and can be tuned to provide the desired energy absorption. In the present example, the forward arms  31   a ,  31   b  in particular will flex to absorb the energy of an impact, in the position shown in FIG. 1 particularly of a passenger&#39;s knee. The second connection pail  27  is provided with apertures  35  to receive fastening means to attach desired elements thereto, for example an instrument panel, dashboard casing or any other elements as required. In the example shown in FIG. 1, the left hand pair of general support brackets  25  is located to provide support for an instrument panel, whilst the right hand pair of brackets  25  are disposed to provide support for a glove compartment. The general support brackets  25  preferably comprise an injection molded or extruded polymer material.  
         [0046]    Casing support brackets are generally indicated at  40 , three of said casing support brackets;  40  being disposed adjacent to the upper face  16  of the support beam  11  and one being disposed adjacent to the lower rearward face  17  of the support beam  11 . Each casing support bracket  40  is provided with a tag  41  to be received in a groove of the support beam  11  and flanges  42  disposed either side of the tag  41  to engage the responding face of the beam  11 . The tag  41  is connected to a generally cylindrical intermediate part  43 , the cavity of which is filled with a foam material  44  to provide increase structural strength. A connection part  45  is provided with an aperture  46  to receive fastenings for connecting a casing thereto, connected to the cylindrical intermediate part  43  by arms  47   a ,  47   b . Each of the arms  47   a ,  47   b  is generally angular in cross section, each having an inwardly directed elbow located pail way between the connection pail  45  and the cylindrical intermediate part  43 .  
         [0047]    A steering panel support bracket is generally indicated at  50  comprising a rearwardly directed flange  51  and an upwardly extending part  52 . The flange  51  is provided with aperture  53  to receive fastening means for steering column. The steering column support bracket  50  has a rearward face  54  provided with tags (not shown) received in groove  15   a  of the lower face  15  and groove  17   a  of the lower rearward face  17 . The forward face  54  is further shaped to engage the lower face  15  and lower rearward face  17  of the beam  11  to provide a rigid connection between the steering column support bracket  50  and the beam  11 . The steering column support bracket  50  comprises molded aluminum or polymer as desired, and are relatively stiff compared to the general purpose support brackets  25 .  
         [0048]    An airbag support bracket is shown at  55 , comprising a channel-shaped part  56  and a tag  57  received in groove  16   a  of the upper rearward face  16 , such that the channel-shaped pail  55  is directed rearwardly and upward of the support assembly  10 .  
         [0049]    Ventilation support brackets are generally shown at  60  to provide support for a heating/ventilation/air conditioning (HVAC) module. Each ventilation support bracket  60  comprises a downwardly extending part  61  provided with an aperture  62  to receive fastening means to engage the HVAC module. An upper pail  63  of each ventilation support bracket  60  is provided with tags to be received in at least groove  16   a  of the upper rearward face  16  and groove  15   a  of the lower face  15 . The upper pail  63  has an inner face  64  shaped to engage at least in part the upper rearward face  16 , lower rearward face  16  and lower face  15  of the beam  1 . The support brackets  60  are disposed at the appropriate spacing to receive a HVAC module.  
         [0050]    The ventilation support brackets  60  may comprise molded aluminum or polymer or any other materials as desired and are relatively stiff compared to the general purpose support brackets  25 .  
         [0051]    Referring now to FIG. 2, a combined steering column and instrument panel casing support is shown at  70 . The combined support  70  has a forward face  71  provided with tags to engage at least the grooves  16   a ,  15   a . The forward face  71  is shaped to engage at least partly the upper rearward face  16 , lower rearward face  17  and lower face  15  of the support beam  11 . The combined support  70  has a pair of generally parallel side members  72  extending rearwardly and downwardly of the support beam  11 , each provided at their free end with an outwardly directed flange  73  having an aperture  74  therein. Disposed between the side members  72  is an instrument panel support  75  to receive an instrument panel and casing.  
         [0052]    A combined glove box and instrument panel casing support is shown generally at  80 . As in the combined steering column support  70 , the combined glove box support  80  comprises a forward face  81  provided with tags (not shown) to engage at least grooves  16   a ,  17   a . The forward face  81  is shaped to engage faces  16 ,  17  of the support beam  11  to ensure a rigid fit between the support beam  11 and combined glove box support  80 . The combined glove box support  80  comprises a pair of spaced generally parallel arms  82  extending rearwardly and downwardly of the support beam  11 , provided at their free ends with outwardly directed flanges  83 , each provided with an aperture  84  for suitably fastening means. The generally parallel arms  82  are interconnected by a back plate  85  and provided with suitable stiffening means  86 . The combined glove box support  80  may comprise alloy or a reinforced polymer or any other appropriate material as desired.  
         [0053]    To provide additional strength to the beam assembly  10 , strengthening brackets  90  may be provided. The strengthening brackets  90  may be provided with a tag to be received in the groove  14   a  of the upper face  14 , and may comprise a flange part  91  to engage a forward part of the upper face  14 . Projecting forwardly from the flange pail  91  is a connecting part  92 , provided with reinforcing ridge parts  93 . The connecting part  92  engages an appropriate part of the vehicle structure, for example a windscreen rail and may be connected thereto to provide additional support for the support beam assembly  10 . Each strengthening bracket  90  further comprises an upstanding part  94  having a slot  95  provided in an upper pail thereof to support, for example, an instrument panel casing. The strengthening brackets  90  may comprise alloy or reinforced polymer or any other material as desired.  
         [0054]    In assembling a support assembly  10 , a stock beam is first cut to the desired length to provide a support beam  11  for the vehicle in which it is intended to mount the support assembly  10 . The appropriate modules  25 ,  40 ,  50 ,  55 ,  60 ,  70 ,  80 ,  90  are then provided as desired to provide support brackets for the elements to be supported by tile support assembly  10  and as appropriate for the vehicle of which tile dashboard assembly  10  is to form a part. The appropriate modules are mounted oil the beam  11  by engaging tags with the appropriate grooves  14   a ,  15   a ,  16   a ,  17   a  to provide the desired orientation of each module and then sliding the tags into the respective groove in a longitudinal direction. The module is then slid along the support beam  11  in a longitudinal direction until it reaches its desired location. The module is then connected in place by for example, welding, riveting or bolting, vibration bonding or adhesive bonding or by any other means as desired. The support assembly is assembled preferably by a robot jig but may be wholly or partly manually assembled if desired. Mounting means  20  are then provided at each end of the support beam  11 . The support assembly  10  is then be introduced into the vehicle body and attached thereto by means of fasteners passing through the holes  22 . Where a strengthening bracket  90  is provided, the bracket  90  may be connected to the appropriate rail of the vehicle body.  
         [0055]    The high degree of flexibility and adaptability of the support beam assembly  10  provided by the current invention will be apparent. It will be clear the assembly  10  may be adapted for mounting in any appropriate vehicle, and may receive appropriate modules disposed at a desired orientation and at any location along the length of the beam  11 . Although the grooves  14   a ,  15   a ,  16   a ,  17   a  and associated tags are shown as having the same shape or cross-section, it will be appreciated that different grooves and/or tags may be provided with differing cross-sections or shapes as desired.  
         [0056]    In the present specification “comprise” means “includes or consists of” and “comprising” means “including or consisting of.” 
         [0057]    The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof.  
         [0058]    While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.