Description:FIELD OF INVENTION

[001] The present invention relates to the arrangement of instruments in automotive vehicles. Particularly, the present invention relates to an integrated thermoformed automotive dashboard for the automotive vehicles. More particularly, the integrated thermoformed automotive dashboard allows customization of the dashboard by integrating multiple units of multiple sizes according to one’s need into the same dashboard thereby increasing the adaptability and reducing the cost.

BACKGROUND OF THE INVENTION

[002] A dashboard in a vehicle is the panel facing the driver's seat where most of the instruments and switches are installed. The car dashboard performs many important functions, which often provide drivers with invaluable help. The dashboard helps the driver to adjust various electronic components of vehicle, like the air conditioner/ heater, lights, music system.
[003] The automotive dashboard of a car is also known as a topper pad manufactured using various processes. The various processes include injection molding and thermoforming processes.
[004] The injection molding is a method to obtain molded products by injecting plastic materials molten by heat into a mold, and then cooling and solidifying them. A screw is used to rotate the melt plastic introduced from the hopper and to accumulate molten plastic in front of the screw. After the required amount of molten plastic is accumulated, injection process is stared. While the molten plastic is flowing in a mold, the machine controls the moving speed of the screw, or injection speed. On the other hand, it controls dwell pressure after molten plastic fills out cavities. The position of change from speed control to pressure control is set at the point where either screw position or injection pressure reaches a certain fixed value.
[005] Another method of manufacturing automotive dashboards includes thermoforming. Thermoforming is a process of heating a thermoplastic sheet to its softening point. The sheet is stretched across a single-sided mold and then manipulated. Then, it cools into the desired shape. The most common methods to get the sheet to conform to its final shape are vacuum-forming, pressure-forming, and mechanical forming. However, the above manufacturing process are highly costly to set up the machinery properly due to the design, testing and tooling. Moreover, the above process necessitates more plastic and due to film stretching, the gauge is not uniform.
[006] In low volume cars or commercial vehicles (like buses, trucks), interior trim parts are often manufactured using thermoforming process due to its cost effectiveness and functional adequacy. In contrast, with injection molded part, components like ducts, mountings and speaker casing are typically manufactured as separate units from the dashboard, which increases the number of parts and subsequently raises costs. For mounting these plastic thermoformed panels into vehicles, options include attaching a metal mount on the back side of the panel using industrial adhesives, or using visible fasteners on the trim panel surface. However, visible fasteners can pose safety risk to the driver or co-driver.
[007] There are several patent applications comprising the manufacturing process of the dashboard. A United States Patent application US5273310A discloses an instrument panel assembly for an automotive vehicle. The instrument panel assembly for an automotive vehicle includes a main panel having first and second openings formed there through. An air bag unit is mounted in the first, upper opening and a vehicle glove box is fitted in the second lower opening. A steering member is disposed behind the main panel and mounts the air bag unit. The first opening is closed by a lid which is retained by a lock associated with a bracket for guiding an inflation direction of an air bag. A vent duct is present disposed in a space between the first and second openings proximate the steering member and the ductwork act so as to isolate the air bag unit, a vehicle air conditioning unit and the glove box from each other to assure reliable operation of all components with a simple low cost instrument panel assembly.
[008] Another patent application JP 2002532332A discloses a vehicle instrument panel mounting structure. The structure comprises two mounting portions of the same design that are provided in a lateral direction of a vehicle design length. This mounting is compatible with the installation of a driver-designed module or a passenger-designed module. Each of the mounting portions and each of the modules are provided so that the modules can be attached and detached in a docking manner at any time during the endurance period of the vehicle. At least the equipment of the driver-side module, which is connected to each mounting part and includes elements for controlling the vehicle, so that signals can be transmitted between the module and the vehicle, are connected to relevant parts of the vehicle and connection provided for electrical connection to the vehicle.
[009] However, none of the above applications disclose integration of components into a single structure. As the part count increases, the cost also increases. The other procedures such as metal mounts and the visible fasteners are also dangerous in terms of crashes. To overcome the problem associated with the state of the arts, there is a need for the development of an efficient double-pass solar air heater that can overcome the aforesaid limitations in a more efficient manner.

OBJECTIVE OF THE INVENTION

[0010] The primary objective of the present invention is to provide a thermoformed automotive dashboard with integrated mounting and defogger ducting with structural integrity.
[0011] Another objective of the present invention is to provide structural support to the dashboard by ultrasonically welded.
[0012] Another objective of the present invention is to reduce the parts by customizing the dashboard according to one’s need and the space available in the vehicle.
[0013] Yet another objective of the present invention is to reduce the cost by integrating multiple sizes and multiple units into a single structure.
[0014] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION
[0015] The present invention relates to an integrated thermoformed automotive dashboard for vehicles. The thermoformed automotive dashboard assembly (100) comprises a structural part (102), an integrated defogger duct (104), a plurality of an integrated/casted mounting slots (106), an integrated speaker casing (110), a tweeter (112), a speaker (114), an automotive dashboard top panel (116), a pair of defogger outlet (118) and a pair of side defogger outlet (120). The structural dashboard (102) has an integration of defogger duct (104), and mounting slots (106) used to mount/assemble the thermoformed dashboard assembly (100) to the Car Cross beam (Not shown in Figure.). The structural integrity of multiple sizes into the single structural part (102) to reduce the number of parts counts, thereby reducing the cost of manufacturing. The defogger ducts (104) are integrated into the same structure to reduce the part count into the vehicle. The structure behind the dashboard is configured to be fitted into multiple sizes and can be customized according to one’s need and space available behind the dashboard.

BRIEF DESCRIPTION OF DRAWINGS

[0016] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0017] Figure 1 illustrates the example of thermoformed dashboard top panel on which defogger and side defogger grills are installed;
[0018] Figure 2 illustrates the sub-assembly of plastic structural part which has provision of integrated slots for mounting plastic clips, provision to mount speaker and tweeter and integrated defogger ducts;
[0019] Figure 3 illustrates the pictorial representation of clips being snap fitted into the mounting slots and speaker and tweeter are bolted on plastic structure with the help of metal inserts; and
[0020] Figure 4A illustrates the pictorial representation of subparts being snap fitted and bolted on the plastic structural member and the whole subassembly is ultrasonically welded on bottom side of top panel.
[0021] Figure 4B illustrates the sectional view of the thermoformed automotive dashboard assembly.
[0022] Reference numerals with respect to the present invention are discussed herein:

Sr. No. Reference Numeral Components
1. 100 THERMOFORMED AUTOMOTIVE DASHBOARD ASSEMBLY
2. 102 STRUCTURAL PART
3. 104 INTEGRATED DEFOGGER DUCT
4. 106 INTEGRATED MOUNTING SLOT
5. 108 MOUNTING CLIPS
6. 110 INTEGRATED SPEAKER AND TWEETER CASING
7. 112 TWEETER
8. 114 SPEAKER
9. 116 DASHBOARD TOP PANEL
10. 118 PAIR OF DEFOGGER OUTLET
11. 120 PAIR OF SIDE DEFOGGER OUTLET
12 122 Ultrasonic weld joints

DETAILED DESCRIPTION OF INVENTION

[0023] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.

[0024] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0025] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0026] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0027] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.

[0028] Accordingly, the present invention relates to an arrangement of instruments in automotive vehicles. Particularly, the present invention relates to thermoformed automotive dashboard for the automotive vehicles. The integrated thermoformed automotive dashboard allows customization of the dashboard by integrating multiple units into multiple sizes according to one’s need into the same dashboard thereby increasing the adaptability and reducing the cost.
[0029] The present invention relates to thermoformed automotive dashboard (100) for vehicles. The thermoformed automotive dashboard (100) comprises a structural part (102) and an automotive dashboard top panel (116).
[0030] The structural part (102) integrated with a defogger duct (104), a plurality of mounting slots (106), a speaker casing (110), a tweeter (112) and a speaker (114) are installed in the speaker casing (110).
[0031] The automotive dashboard top panel (116) comprises a pair of a defogger outlet (118) and a pair of side defogger outlet (120).
[0032] The structural part (102) of the thermoformed automotive dashboard assembly as (100) welded to the automotive dashboard (116).
[0033] In a preferred embodiment of the present invention, the thermoformed automotive dashboard (100) with integrated mounting, ducting, and speaker casing, offering structural integrity, is ultrasonically welded below the vehicle’s dashboard area. The automotive dashboard (116) can accommodate various sizes and can be customized according to the available space behind the dashboard.
[0034] The thermoformed dashboard assembly (100) is mounted using plastic clips integrated into a plastic part on the cross-car beam. It is positioned horizontally between the A-pillars of the vehicle, allowing it to perform multiple functions.
[0035] In this thermoformed automotive dashboard assembly (100), mounting slots and defogger duct of various sizes with structural integrity are integrated into a single structural part (102), which reduces the number of components and, consequently, manufacturing costs.
[0036] In the preferred embodiment illustrated in Figure 1, the automotive dashboard top panel (116) is a critical interior component of the vehicle. The dashboard (116) includes a pair of defogger outlets (118) and side defogger outlets (120). The defogger outlets (118 and 120) facilitate the removal of condensed water droplets or fog from both the front and rear windshields, as well as from the side windows. The pair of defogger outlets (118) are casted on the edges of the automotive dashboard (116). The pair of side defogger outlet (120) are casted on the ends of the automotive dashboard (116) and provides the same usage as the pair of defogger outlet (118) provides.
[0037] In an exemplary embodiment of the present invention, the pair of defogger outlet (118) are casted on the edges of the automotive dashboard (116) on top of the integrated defogger duct (104) and the pair of side defogger outlet (120) are casted on the ends of the automotive dashboard (116) upon the integrated defogger duct (104).
[0038] In the present invention, figure 2 illustrates the structural part (102) of the thermoformed automotive dashboard (100) welded to the automotive dashboard assembly (116). The structural part (102) of the thermoformed automotive dashboard (100) comprises an integrated defogger duct (104) integrated at both the ends of the structural part (102) is used for combating condensation. The defogger duct helps to remove condensation and fog from the interior surface of windows and enhancing visibility for the driver. The front windshield uses the car's heating system to blow warm air thereby preventing the moisture buildup. The defogger utilizes electrical heating elements to heat the glass and evaporate moisture thus ensuring a clear view.
[0039] In the preferred embodiment of the present invention, figure 2 also illustrates the plurality of an integrated mounting slots (106) mounted on the inner side of the structural part (102) a plurality of an integrated mounting slots (106) integrated/casted on the structural part (102); the dashboard assembly (100) mounted to the Cross Car Beam (CCB) (not shown in the Fig.) with the help of mounting slots (106) and mounting clips (108); The integrated speaker casing (110) are casted at the center of the structural assembly adjacent to the integrated defogger duct slots (104) is shown in figure 2. The integrated speaker casing (110) is designed to house and enhance the performance of car speakers and plays a crucial role in producing high-quality sound, thereby maximizing the overall audio experience within a vehicle. Figure 2 also represents the tweeter (112) wired on the integrated speaker casing110. The tweeter (112) is relatively small speakers used to emit the upper range of sounds for reproducing music and speech. The speaker (114) as shown in figure 2, is mounted on the integrated speaker casing (110).
[0040] Figure 4A illustrates the pictorial representation of subparts being snap fitted and bolted on the plastic structural member and the whole subassembly is ultrasonically welded on bottom side of top panel and in combination with Figure 4B illustrates the sectional view of the thermoformed automotive dashboard assembly
[0041] The sectional view of the thermoformed automotive dashboard assembly having the Ultrasonic weld joints (122).
[0042]
[0043] In an exemplary embodiment of the present invention, the structural part (102) of the thermoformed automotive dashboard assembly (100) is made up of plastic. The structural part (102) includes mounting points where plastic clips are used for mounting as shown in Figure 3. The structural part (102) is fitted into different sizes and shapes according to need and space available for packaging.
[0044] In an exemplary embodiment of the present invention, the dashboards usage is not limited to a group of cars, trucks.
[0045] In an embodiment the advantages of the present invention are enlisted herein:
• The present invention provides a thermoformed automotive dashboard with integrated mounting & defogger ducting with structural integrity.
• The present invention provides structural support to the dashboard by ultrasonically welded (122).
• The present invention helps to reduce the count of parts into the vehicle by customizing the dashboard according to one’s need and the space available.
• The present invention helps to reduce the cost by integrating multiple sizes and multiple units into the same structure to avoid the additional mounting features like brackets, columns etc.

[0046] While this 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 limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:1. A thermoformed automotive dashboard assembly (100), comprising:
a. a structural part (102) to integrate the thermoformed automotive dashboard (100) on to the vehicle, comprising:
i. an integrated defogger duct (104) covers the three sides of the structural part (102);
ii. an integrated speaker and tweeter casing (110) cast at the center of the structural assembly adjacent to the integrated mounting slots (106);
iii. a tweeter (112) wired on the integrated speaker casing (110); and
iv. a speaker (114) mounted on the integrated speaker casing (110);
v. a plurality of an integrated mounting slots (106) cast on the structural part (102); the dashboard assembly (100) mounted to the Cross Car Beam (CCB) with the help of mounting slots (106) and mounting clips (108);
b. an automotive dashboard top panel (116) ultrasonically welded (122) to the structural part (102);
c. a pair of defogger outlet grills (118) snapped on the edges of the automotive dashboard (116); and
d. a pair of side defogger outlet grills (120) snapped on the ends of the automotive dashboard (116).
2. The dashboard (100) as claimed in claim 1, wherein, the thermoformed automotive dashboard has integration of the mounting slots (106) and the defogger ducts (104) with structural integrity.
3. The dashboard (100) as claimed in claim 1, wherein, the structural part (102) is made up of plastic.
4. The dashboard (100) as claimed in claim 1, wherein the mounting slots (106) are made up of plastic.
5. The dashboard (100) as claimed in claim 1, wherein the mounting clips (108) are made up of plastic.