Claims:We claim:

1. A pedal box mounting arrangement for a composite firewall structure (10) of a vehicle, comprising:
an outer panel (6) facing an engine compartment;
an inner panel (8) facing a cabin of the vehicle,
wherein, at least one of the outer panel (6) and the inner panel (8) is made of a polymeric material; and
a strengthening member (7) sandwiched between the outer panel (6) and the inner panel (8), wherein the strengthening member (7) is configured reinforce the vehicle firewall structure (10);
wherein, a cut-out (13) is defined in the firewall structure (10) for accommodating a pedal box assembly (11).

2. The vehicle firewall structure (10) as claimed in claim 1, wherein the polymeric material includes hard plastic.

3. The vehicle firewall structure (10) as claimed in claim 1, wherein the strengthening member (7) is a honey comb structure.

4. The vehicle firewall structure (10) as claimed in claim 3, wherein the honeycomb structure is made of aluminum material.

5. The vehicle firewall structure (10) as claimed in claim 1, wherein the pedal box assembly (11) comprises an outer pedal box (1) and an inner pedal box (5).

6. The vehicle firewall structure (10) as claimed in claim 5, wherein the outer pedal box (1) is mounted on to the outer panel (6) and is accommodated in the cut-out (13).

7. The vehicle firewall structure as claimed in claim 5, wherein the inner pedal box (5) is mounted onto the inner panel (8).

8. The vehicle firewall structure (10) as claimed in claim 1, wherein the outer pedal box (1) is configured to accommodate at least one of a brake pedal, clutch pedal and accelerator pedal and a steering column.

9. The vehicle firewall structure (10) as claimed in claim 5, wherein the inner pedal box (5) includes a pedal mounting portion (12) and a reinforcement panel (4).

10. The vehicle firewall structure (10) as claimed in claim 9, wherein the pedal mounting portion (12) is configured to accommodate at least one of brake pedal, clutch pedal and accelerator pedal.

11. The vehicle firewall structure (10) as claimed in claim 6, wherein the reinforcement panel (4) is made of a steel material.

12. A vehicle comprising a firewall structure (10) as claimed in claim 1.
, Description:TECHNICAL FIELD

The present disclosure relates in general to the field of automobiles. Particularly, but not exclusively, the present disclosure relates to a vehicle firewall structure. Further embodiments of the present disclosure discloses a vehicle firewall structure having a polymeric layers.

BACKGROUND

Generally, vehicles include chassis in which a large number of individual panels are joined together to form a stress-bearing structure. A number of components such as a suspension, transmission and drive components may be supported by the chassis of the vehicle. An integral part of the chassis is the firewall which typically separates a passenger compartment from an engine compartment. Thus, in a front-engine vehicle, the firewall extends transversely across the vehicle ahead of and below windscreen.

The firewall serves many purposes, including, protecting the occupants of the vehicle from invasion of the engine into the passenger compartment in the event of a collision, resist possible fire-breakthrough, and prevent entry of heat from the engine compartment to the passenger compartment. In addition to the above, the firewall may also firewall contribute to the stiffness of the vehicle chassis. Further, the firewall serves to support various auxiliary equipment’s, such as a dashboard, a steering column, a heater unit, a pedal box, a brake servo, and the like.

Conventionally, the firewall is made from a sheet of pressed steel and is welded to adjacent panels making up the vehicle chassis. These steel firewalls used may add up to the overall weight of the vehicle. Hence, plastic materials may be used to make firewalls for vehicles which would in turn cut down the cost and add up to the performance of the vehicle by reducing the overall weight.

However, the plastic firewall structures may have may face challenges in terms of load or pressure bearing capacity. Further, the plastic panels used to make the firewall structures may have low crash resistant properties and would fail in case of any sudden impact that may be acted upon the plastic firewall structures through the pedals. Thus, the plastic firewall structures may fail to withstand the pressure that may be acted upon them at particular instances such as sudden braking or sudden accelerations which would put high pressure on the plastic firewall structure.

The present disclosure is directed to overcome one or more limitations stated above or other limitations associated with the conventional structures.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional structure are overcome by the structure as claimed and additional advantages are provided through the provision of the structure as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure a pedal box mounting arrangement for a composite firewall structure of a vehicle is disclosed. The vehicle firewall structure includes an outer panel facing an engine compartment and an inner panel facing a cabin of the vehicle. At least one of the outer panel and the inner panel is made of the polymeric material. Also, a strengthening is sandwiched between the outer panel and the inner panel, wherein the strengthening member is configured reinforce the vehicle firewall structure. Further a cut-out is defined in the firewall structure for accommodating a pedal box assembly.

In an embodiment of the disclosure, the polymeric material includes hard plastics.

In an embodiment of the disclosure, the strengthening member is a honey comb structure and the honeycomb structure is made of aluminium material.

In an embodiment of the disclosure, the pedal box assembly consists of an outer pedal box and an inner pedal box. The outer pedal box is mounted onto the outer panel and is accommodated in the cut-out. The inner panel is mounted onto the inner panel.

In an embodiment of the disclosure, the outer pedal box is configured to accommodate at least one of brake pedal, clutch pedal, an accelerator pedal and a steering column.

In an embodiment of the disclosure, the inner pedal box includes a pedal mounting portion and a reinforcement panel. The pedal mounting portion is configured to accommodate at least one of a brake pedal or clutch pedal and the accelerator pedal.

In an embodiment of the disclosure, the reinforcement panel is made of a steel material.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

FIG.1 illustrates a perspective view of a vehicle firewall structure, with pedal box assembly mounted therein, in accordance with an embodiment of the present disclosure.

FIG.2 illustrates a perspective view of an outer pedal box of the pedal box assembly mounted in the vehicle firewall structure of FIG.1, in accordance with an embodiment of the present disclosure.

FIG.3 illustrates a perspective view of the inner pedal box of the pedal box assembly mounted in the vehicle firewall structure of FIG.1, in accordance with an embodiment of the present disclosure.

FIG.4 illustrates a perspective view of the vehicle firewall structure defined with a cut-out to accommodate the pedal box assembly, in accordance with an embodiment of the present disclosure.

FIG.5 illustrates a perspective view of the outer panel of the vehicle firewall structure of FIG.4, in accordance with an embodiment of the present disclosure.

FIG.6 illustrates a perspective view of the strengthening member mounted onto the outer panel of the firewall structure of FIG.4, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure.

It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other systems for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent processes do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

Embodiments of the present disclosure disclose a vehicle firewall structure. Conventionally, a firewall structure may be composed of metallic panels to separate the engine bay and the cabin. Due to various problems posed by the metallic firewall structures, efforts have been made to replace the metallic structure with polymeric or plastic structures. However, the polymeric firewall structure may have limited strength and thus may be prone to damages during vehicle usage.

Accordingly, the present disclosure provides a vehicle firewall structure which may have improved strength, less weight, increases fuel economy and performance of the vehicle.

The firewall structure of according to embodiments of the present disclosure may be made up of a polymeric material. The polymeric material used may be a hard plastic. The firewall structure includes an outer panel and an inner panel. In an embodiment, the outer panel may face engine bay or engine compartment and the inner panel may face the cabin of the vehicle. Further, a space may be defined between the outer panel of the firewall structure and the inner panel of the firewall structure, this space may accommodate a strengthening member. Thus, the strengthening member may be sandwiched between the two panels of the firewall structure of the vehicle. In an embodiment, as the name suggests, the strengthening member imparts strength to the vehicle firewall structure. The strengthening member used may be made of a light weight structure. Further, the strengthening member possesses high stiffness and may have good impact strength.

In an embodiment, the firewall structure of the vehicle may be defined with a cut-out to accommodate a pedal box assembly. The pedal box assembly may include an outer pedal box and an inner pedal box. The outer pedal box is mounted onto the outer panel and the inner pedal box is mounted on the inner panel. In an embodiment, the outer pedal box may be configured to be accommodated in the cut-out defined in the vehicle firewall structure. The outer pedal box may be configured to accommodate a steering column and at least one of a brake pedal, a clutch pedal or an accelerator pedal. In an embodiment, the inner pedal box further consists of a pedal mounting portion and a reinforcement panel. The reinforcement panel may be made of a metallic material such as but not limited to stainless steel. In an embodiment, the outer pedal box assembly may accommodate the brake pedal and the steering column, and the mounting portion of the inner pedal box accommodates the accelerator pedal. Thus, the configuration of the firewall structure offers flexibility to reduce the weight of the vehicle, at the same time maintain necessary strength required.

The terms “comprises”, “comprising”, or any other variations thereof used in the specification, are intended to cover a non-exclusive inclusion, such that an assembly that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or method. In other words, one or more elements in an assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly.

Henceforth, the present disclosure is explained with the help of one or more figures of exemplary embodiments. However, such exemplary embodiments should not be construed as limitation of the present disclosure. In the figures neither the vehicle nor the complete firewall structure are depicted for the purpose of simplicity. One skilled in the art would appreciate that the firewall structure may be employed in any vehicle including but not limiting to passenger vehicles, commercial vehicles and the like.

The following paragraphs describe the present disclosure with reference to FIGS.1-4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.

FIG.1 is an exemplary embodiment of the present disclosure, illustrating a perspective view of a firewall structure (10) of a vehicle. As shown in FIG.1, the firewall structure (10) broadly includes an outer panel (6), an inner panel (8), a cut-out (13) defined to accommodate a pedal box assembly (11) and a strengthening member (7). The firewall structure (10) may be configured to separate an engine compartment and a cabin of the vehicle. In an embodiment, the vehicle may be a passenger vehicle, however, is not limited to only passenger vehicles. In an embodiment, the firewall structure (10) may be arranged transversely in a vehicle.

In an embodiment, the outer panel (6) [best shown in FIG.5] may be facing an engine compartment (not shown) of the vehicle and the inner panel (8) [best shown in FIG.4] may be facing a cabin of the vehicle [not shown]. In an embodiment, at least one of the outer panel (6) and the inner panel (8) may be made of any one of the polymeric materials. In another embodiment, both the outer panel (6) and the inner panel (7) may be made of polymeric materials. The polymeric material used to make the outer panel (6) and the inner panel (8) may be at least one of a hard plastic. The outer panel (6) and the inner panel (8) of the firewall structure (10) may be secured to each other in a way such that a gap is defined between the outer and inner panels (6 and 8). Further, the strengthening member (7) [as shown in FIG.6] may be sandwiched between the outer panel (6) and the inner panel (8) in the gap. In an embodiment, the outer panel (6), the inner panel (8) may be secured either by mechanical joining process or by thermal joining process, such as but not limiting to welding, or fastening. In an embodiment, the two panels (6 and 8) may be secured either by riveting or any such like joining methods.

The strengthening member (7) provisioned between the two panels (6 and 8) may be first secured to at least one of the outer panel (6) or the inner panel (8) following which it may secured to the other panel (6). In an embodiment, the strengthening member (7) may be secured firmly onto the outer panel (8) either by mechanical joining process or by the thermal joining process, such as but not limiting to welding, or riveting. Once the strengthening member (7) is firmly secured to the outer panel (6) of the firewall structure (10), the inner panel (8) may be firmly fixed onto the strengthening member (7). The inner panel (8) may be firmly secured onto the strengthening member (7) either by mechanical or thermal joining process, such as but not limiting to riveting, or welding. In an embodiment, the strengthening member (7) may be a honeycomb structure. In an embodiment, the structure of the strengthening member (7) may be any other structure having a Zig-Zag pattern. In an embodiment, the strengthening member (7) which may be a honeycomb structure may be made of any of the metallic materials. As an example, the metallic material used for the honeycomb structure may be an aluminium material. The strengthening member (7) may increase the stiffness of the firewall structure (10) without weight addition to the vehicle.

Further, the cut-out (13) defined in the firewall structure (10) may accommodate a pedal box assembly (11). In an embodiment, the cut-out (13) may be a through hole in the firewall structure (10) [best shown in FIG.4]. The cut-out (13) may be made through the inner panel (8), outer panel (6) and the sandwiched strengthening member (7). In an embodiment, a plurality of through holes may be defined around the periphery of the cut-out (13). The through holes around the outer panel (6) may be used to connect the outer panel (6) with the strengthening member and the inner panel (8). The firewall structure (10) consisting of the strengthening member also decreases the inflow of heat to the cabin from the engine.

Referring to FIGS. 2 and 3, the pedal box assembly (11) may include an outer pedal box (1) and an inner pedal box (5). The outer pedal box (1) may be fixedly mounted onto the outer panel (6). Also, the outer pedal box (1) may be accommodated in the cut-out (13). Further, the inner pedal box (5) is configured to be secured onto the inner panel (8) [best shown in FIG.4]. In an embodiment, the outer pedal box (1) and the inner pedal box (5) may be provisioned with a plurality of through holes. In an embodiment, the outer pedal box (1) and inner pedal box (5) may be secured to the firewall structure (10) via the plurality of holes on the pedal box assembly (10) and the structure (11) by at least one of mechanical joining process such as but not limiting to the riveting or fastening process.

In an embodiment, the outer pedal box (1) and the inner pedal box (5) may be made of materials such as but not limiting to stainless steel or any other metallic material. In an embodiment, the outer pedal box (1) may be configured to house at least any one of a clutch pedal, an accelerator pedal and a brake pedal. In an embodiment, a provision may be made in the outer pedal box (1) to accommodate at least one or both of a steering column [not shown] and a brake booster. In an embodiment, the inner pedal box (5) which may be mounted onto the inner panel (8) further includes a pedal mounting structure (12) and a reinforcement panel (8). The pedal mounting structure (12) may be configured to house at least one of the brake pedal, the clutch pedal and the accelerator pedal. In an embodiment, the mounting structure (12) may be configured to accommodate the accelerator pedal. In an embodiment, the reinforcement panel (8) may be configured to impart additional strength and stiffness to the pedal box assembly (11). In an embodiment, the reinforcement panel (8) may be made of materials such as but not limiting stainless steel or any of such kind.

In an embodiment, the present disclosure discloses a firewall structure (10) of vehicle. The structure (10) offers advantages, including but not limited to, improved energy efficiency, weight reduction, higher fuel economy. There may be reduction or complete elimination in corrosion of the firewall structure (10). The firewall structure (10) of the present disclosure provides required strength and stiffness with the use of light-weight materials. The crash resistance or failure of the wall (10) is completely eliminated in case of excess pressure applied over the pedals during the emergency situations, thereby making it safer for the user or occupant operating the pedals.

It may be noted that, one skilled in the art would modify the configuration of the adaptive wheel assembly to suit different requirements without deviating from scope of the disclosure. Such modifications should be considered as a part of the present disclosure.

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description

Referral Numerals
Description Reference Number
Firewall structure 10
Outer pedal box 1
Reinforcement panel for inner pedal box 4
Inner pedal box 5
Outer panel 6
Strengthening member 7
Inner panel 8
Pedal box assembly 11
Pedal mounting portion of inner pedal box 12
Cut-out 13