Abstract:
The present invention provides an apparatus and method of assembly for securely attaching an instrument panel to an automobile. In one embodiment of the invention, a housing containing electronic components for the instrument panel is attached to the frame structure of an automobile. The bezel panel containing the control and display areas is then attached to the housing. The cover panel is then attached to the bezel panel and the housing by fasteners extending through the bezel panel.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates generally to the field of automobile instrument panel assembly, in particular instrument panels having structural components interconnected to each other.  
         BACKGROUND OF THE INVENTION  
         [0002]    Instrument panels are located in the cockpit of automobiles and are often the command center allowing for the driver to monitor and control the workings of the automobile. As such, the fixing of the instrument panel and its components to the rest of the car is crucial. An instrument panel should be securely fastened to the body of the automobile and minimize rattling and improper alignment. There are three major components of an instrument panel including the housing that contains electrical components, the bezel panel containing the dials, displays, knobs, and buttons commonly thought of as the controls, and a bezel cover overlying the controls and integrating the instrument panel into the automobile and sometimes referred to as trim.  
           [0003]    Previous instrument panel assemblies include the housing affixed to the automobile and the bezel panel rigidly affixed to the housing. The cover bezel is then brought over and around the joined housing and bezel panel and itself affixed to the automobile, such as at to a frame, cowl or cross-beam. Such construction, however, can result in gaps between the bezel panel and the cover bezel creating rattling as the panel and cover move independently of one another due to standard automobile vibrations. Such gaps may perhaps even obscure the view of the periphery of the bezel panel. Such inferior construction can cause noise and is not visually pleasing to the passengers.  
           [0004]    As such, it is an object of this invention is to decrease gaps between the bezel panel and the cover bezel when installed in an automobile. A further object of the invention is to reduce instrument panel vibration and rattling noise caused by the movement and contact of the bezel panel with the cover bezel.  
         BRIEF SUMMARY OF THE INVENTION  
         [0005]    The present invention provides an apparatus and method of assembly for securely attaching an instrument panel to an automobile. In one embodiment of the invention, a housing containing electronic components for the instrument panel is attached to the frame structure of an automobile. The bezel panel containing the control and display areas is then attached to the housing. The cover panel is then attached to the bezel panel and the housing by fasteners extending through the bezel panel.  
           [0006]    In a further embodiment of the invention, the housing and the cover panel are joined via the bezel panel. The bezel panel has bilateral fastening means, which align with the housing and the cover bezel to allow for attachment of all three components together.  
           [0007]    Another embodiment of the invention allows for lateral movement among the three components. This allows for movement of the components while retaining alignment of the instrument panel as a whole.  
           [0008]    The invention may also be embodied in a method for assembling an automobile instrument panel. The method includes the steps of providing a housing and attaching a cover panel to the housing via a bezel panel having bilateral fastening means.  
           [0009]    It is to be understood that both the preceding summary and the following detailed description are intended to be exemplary and explanatory and are intended to provide a further explanation of the invention claimed. The invention will be best understood by reference to the following detailed description read in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0010]    These and other advantages of the present invention will become more fully apparent as the following description is read in conjunction with the accompanying drawings, wherein:  
         [0011]    [0011]FIG. 1 is an exploded perspective view showing the main components of an instrument panel assembly in accordance with the present invention;  
         [0012]    [0012]FIG. 2 is a side view of the assembly of FIG. 1; and  
         [0013]    [0013]FIG. 3 is a side view of the completed assembly of FIG. 2 in accordance with the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]    A first preferred embodiment of the instrument panel assembly in accordance with the present invention is shown in the exploded view of FIGS. 1 and 2. The instrument panel assembly unit  10  is preferably implemented as part of an automotive vehicle centerstack (not shown), which is a collection of occupant controls mounted to a portion of the central dashboard area of a vehicle interior. Typically, the centerstack is formed over a rack (not shown), which may comprise a stable mounting structure integrated into the automotive interior frame. Other mounting structures are possible and contemplated, as is well-known in the art.  
         [0015]    The unit  10  preferably includes at least three interconnected components for mounting on the rack, namely a centerstack panel or an instrument panel cover  12 , a bezel  14  and an instrument housing  16 . In the preferred embodiment, the instrument housing  16  typically contains the electronics, circuitry and the bulk of the various control mechanisms that the operator uses to control various functions within the vehicle. For example, the instrument housing  16  may contain switch housings, potentiometers, printed circuit boards, digital readouts, liquid crystal displays membrane pushbutton contact boards, stereo componentry and other electronics. The housing preferably includes a component mounting recess  18  and a front face  20 .  
         [0016]    The outer periphery of the housing  16  preferably defines a plurality of upstanding flanges  30  spaced around the periphery. Each flange  30  may include a receiving wall  32  and a pair of side reinforcements  32   a . Preferably the receiving wall  32  is aligned generally parallel to the front face  20  and the front of the instrument panel  22 . Each of the flanges  30  preferably define a pair of apertures or openings  34  and  36  as shown, which are receiving means for fasteners described below. The housing  16  is preferably mounted to the rack via fasteners or rivets  38  that extend through the opening  34  in each of the flanges  30  into the rack.  
         [0017]    The bezel component  14  in the preferred embodiment is sandwiched between the panel cover  12  and the housing  16  as shown. The bezel  14  preferably comprises a clear resin or plastic member that is injection molded to conform to the shape of the rear surface of the instrument panel cover  12 , the front face of the housing  16 , or both. Preferably, the resin or plastic material of the bezel  14  has light-transmitting opaque or transparent qualities to allow digital displays or illuminating components in the housing to be viewed by the user though corresponding openings in the instrument panel cover  12 . In some configurations, the bezel component  14  may be used to illuminate certain instrument panel components (not shown). The bezel  12  may also cover and bezel with components such as registers, stereo components or controls.  
         [0018]    The outer periphery of the bezel  14  preferably defines a plurality of upstanding bezel flanges  40  spaced around the periphery. Each flange  40  preferably comprises a flat wall  42  which may be aligned with the wall  32  of each flange  30  of the housing  16 , and a pair of forwardly facing side reinforcements  42   a . Preferably, the wall  42  is aligned generally parallel to the plane of the receiving wall  32  of the housing  16  and the front of the instrument panel  22 .  
         [0019]    In order to attach the bezel  14  to the housing  16  in a sufficiently secure fashion in accordance with the present invention, a bilateral connector  50  is defined on the rearwardly facing side of the flat wall  42  of the bezel flange  40 . Preferably, the bilateral connector  50  projects rearwardly and is aligned with the opening  36  in the housing flange  30 . Each bilateral connector preferably includes a plurality of projecting sections  52  arranged annularly around a receiving means or opening  54  defined in the bezel flange  40  to form a cylindrical member having axially aligned slits. In the preferred embodiment, four projecting sections  52  are implemented which define pie-shaped wedges in axial cross-section. The distal end of each projecting section  52  includes a flared portion  56 . In the preferred embodiment, the flared portions  56  of each of the projection sections  52  combine to create an annular flared area  58  of the bilateral connector  50 .  
         [0020]    Each projection section  52  is preferably molded from plastic or resin material, and is deformable radially inwardly toward the center of the opening  54  and outwardly to allow the connector  50  to be inserted through the opening  36  in the housing flange  30 . Once inserted, the bezel is held securely by the bilateral connector  50  within the opening  36 , since the flared area  58  provides an annular securement to the flange  30  upon outward deformation of each projection section  52 . Preferably, the front portions of each flared portion  56  includes a slightly domed nose portion  56   a  to facilitate insertion into the opening  36 . Furthermore, it is preferred that the size of the opening  36  is slightly smaller than the diameter of the flared area  56  to allow for proper securement. The assembled connection is shown in FIG. 3.  
         [0021]    The instrument panel cover  12  preferably includes a user side  22  and a rear side  24  that faces rearwardly toward the centerstack. The rear side  22  preferably defines a plurality of posts  60  projecting rearwardly to allow secure attachment of the panel cover  12  to the bezel  14 . Each post  60  is preferably aligned with the opening  54  in the bezel flange  40 , and includes a tapered nose portion  62  to facilitate insertion into the opening  54 . A collar  64  extends radially from the outer wall of the post  60  to engage the periphery  54   a  of the front portion of the bilateral connector  50  and prevent withdrawal from the opening  54 . The collar  64  may be a separate ringlike component that resides in an annular groove on each post  60 , or it can be integrally molded thereto.  
         [0022]    In an alternative embodiment, the post  60  may include threads or other known fastening means, and may be long enough to be attached through both the bezel  14 , the housing  16 , and the frame itself.  
         [0023]    The present invention allows secure, simplified attachment of the housing, bezel and instrument cover, and allows these main components to move together. This prevents misalignment of the bezel with the other components during vibration or other common movements and flexing of the vehicle. Furthermore, aligned, accurate assembly of the instrument panel components to the centerstack frame is more easily accomplished.  
         [0024]    While the invention has been described in connection with a specific embodiment thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. For example, the post  30  and the receiving means could be reversed in position. The post  30  could be located on the housing and the receiving means located on the cover bezel  14 . Accordingly, it is intended that the invention includes all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.