FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
AND THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; Rule 13)
AN INSTRUMENT PANEL SUPPORT STRUCTURE FOR VEHICLES
MAHINDRA AND MAHINDRA LIMITED
an Indian Company,
of Mahindra Towers, Worli,
Mumbai - 400 018
Maharashtra, India
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD
The present disclosure relates to the field of mechanical engineering. Particularly, the present disclosure relates to the field of vehicles.
BACKGROUND
Conventional instrument panel support structures which extend transversely between the front pillars of the body of the vehicle to provide structural rigidity thereto. These structures also facilitate the mounting of various interior components such as steering columns, various instruments and the like thereon. In order to rigidly support such interior components, the conventional instrument panel structures are made of sufficient thickness and hence possess sufficient stiffness to meet the durability criteria.
Because of the stiffness, the conventional instrument panel support structures are incapable of absorbing or suppressing most of the shocks generated during a collision. During the collision, the head of the occupants of the front seats of the vehicle interact with the conventional instrument panel support structure which may cause serious injury if the shocks are not absorbed by the instrument panel support structure during the collision.
Hence, there is need to alleviate abovementioned drawbacks associated with the conventional instrument panel support structures of the vehicles.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

An object of the present disclosure is to provide an instrument panel support structure for vehicles that protects occupants of the front seats of the vehicle from injury during a frontal collision of a vehicle.
Another object of the present disclosure is to provide an instrument panel support structure for vehicles, which is capable of absorbing some of the shocks generated during a collision.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages an instrument panel support structure for vehicles which has a deformable portion. The deformable portion comprises at least one protruded portion and at least one recessed portion which extends from the at least one protruded portion and is formed sequentially adjacent to the at least one protruded portion. A plurality of openings is configured on the at least one protruded portion and the at least one recessed portion to facilitate a controlled and sequential deformation of the deformable portion.
Typically, the deformable portion has three protruded portions along with two recessed portions. The first protruded portion has an opening configured on an operative top face thereof. The first recessed portion is formed between the first protruded portion and the second protruded portion. The first recessed portion has an opening configured partially on the first recessed portion and on the adjacent face of the second protruded portion. Second protruded portion has another two openings respectively configured on an operative top face and an operative side face, which is

adjacent to the second recessed portion, of the second protruded portion respectively. The second recessed portion is formed between the second and third protruded portion and has an opening configured on an operative top face. The third protruded portion has an opening configured on an operative top face. Further, the second protruded portion forms an angle with the adjacent recessed portions, i.e., the first and the second recessed portions.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An instrument panel support structure for vehicles, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1a illustrates an isometric view of a conventional instrument panel support structure;
Figure 1b illustrates an isometric enlarged view of the portion ‘P’ of figure 1a;
Figure 2 illustrates a top view of an instrument panel support structure before a collision, in accordance with an embodiment of the present disclosure;
Figure 3a illustrates an enlarged isometric view of the top portion of the instrument panel support structure of figure 2;
Figure 3b illustrates a schematic outline representation of the top portion of figure 3a, depicting various angular profiles;
Figure 4a illustrates a side view of the instrument panel support structure of figure 2, depicting the instrument panel support structure before the collision;

Figure 4b illustrates a side view of the instrument panel structure support of the figure 4a depicting a first stage of deformation during the collision;
Figure 4c illustrates a side view of the instrument panel support structure of the figure 4a depicting a second stage of deformation during the collision;
Figure 4d illustrates a side view of the instrument panel support structure of the figure 4a depicting a third stage of deformation during the collision; and
Figure 4e and 4f illustrate a side view of the further deformation of the instrument panel support structure of the figure 4d during the collision.
DETAILED DESCRIPTION
A conventional instrument panel support structure 10a is illustrated in figure 1a. Figure 1b illustrates an isometric enlarged view of the portion ‘P’ of the conventional instrument panel support 10a.
The conventional instrument panel support structure 10a is configured to have a substantially uniform thickness. Owing to the substantially uniform thickness, the conventional instrument panel support structure 10a is stiff. During a collision, the head of the occupants, particularly a driver and a co-driver, interact with conventional instrument panel support structures. Due to the stiffness of the conventional instrument panel support structure 10a, the conventional instrument panel support structure 10a is not able to absorb the most of the shocks during the collision. If the shocks are not absorbed by the instrument panel support structure 10a, they may get transferred to the occupants, thereby causing serious injury to the occupants.
The present disclosure overcomes the abovementioned drawbacks by providing an instrument panel support structure for vehicles configured to

have a deformable portion. Further, the instrument panel support structure for vehicles is capable of absorbing some of the shocks generated during the collision, thereby protecting the occupants of the front seat of the vehicle from injury, which can be fatal, during a frontal collision of a vehicle.
The instrument panel support structure for vehicles of the present disclosure will now be described with reference to figure 2 through figure 4f.
Figure 2 illustrates a top view of an instrument panel support structure 100 before a collision. Figure 3a illustrates an enlarged isometric view of the top portion of the instrument panel support structure figure 2a. Figure 3b illustrates a schematic outline representation of the top portion of figure 3a, depicting various angular profiles. Figure 4a illustrates a side view of the instrument panel support structure of figure 2a, depicting the instrument panel support structure before the collision. Figure 4b illustrates a side view of the instrument panel support structure of the figure 4a depicting a first stage of deformation during the collision. Figure 4c illustrates a side view of the instrument panel support structure of the figure 4a depicting a second stage of deformation during the collision. Figure 4d illustrates a side view of the instrument panel support structure of the figure 4a depicting a third stage of deformation during the collision. Figure 4e and 4f illustrate a side view of the instrument panel support structure of the figure 4a depicting further deformation of the instrument panel support structure of figure 4d during the collision.
The instrument panel support structure for vehicles, of the present disclosure has a deformable section. The deformable portion comprises at least one protruded portion, at least one recessed portion, which is extended from the at least one protruded portion and is formed sequentially adjacent

to the at least one protruded portion, and a plurality of openings, which are configured on the at least one protruded portion and the at least one recessed portion to facilitate a controlled and sequential deformation of said deformable portion.
In accordance with an embodiment of the present disclosure, a deformable portion 101 has a first protruded portion 102, a second protruded portion 104 and a third protruded portion 106. Further, the deformable portion 101 has first recessed portion 108, and a second recessed portion 110 configured thereon. The recessed portions are configured such that the first recessed portion 108 is formed between the first protruded portion 102 and the second protruded portion 104, whereas, the second recessed portion 108 is formed between the second protruded portion 104 and the third protruded portion 106. The protruded portions 102, 104 and 106, and the recessed portions 108 and 110 may be of various sizes depending upon various sizes and shapes of the vehicles. The instrument panel support structure 100 is configured to have a variable thickness at the protruded portions and at the recessed portions. Also, the protruded portions 102, 104 and 106 are protruded in such a way that the protruded portions 102, 104 and 106 form an angular connection with the respective recessed portions 108 and 110. More specifically, as illustrated in figure 3b, the second protruded portion 104 forms an angle ‘X’ with the first recessed portion 108, and an angle ‘Y’ with the second recessed portion 110. The angles ‘X’ and ‘Y’ may be varied depending upon various sizes of the vehicles. The first protruded portion 102 has an opening 112, referred as first opening, configured on an operative top face of the first protruded portion 102. The second protruded portion 104 has three openings configured thereon, such that:

- an opening 114, referred as second opening, is configured partially on the first recessed portion 108 and on an operative side face, adjacent to the first recessed portion 108, of the second protruded portion 104;
- another opening 116, referred as third opening, is configured on an operative top face of the second protruded portion 104; and
- another opening 118, referred as fourth opening, is configured on another operative side face, adjacent to the second recessed portion 110, of the second protruded portion 104.
The second recessed portion 110 has an opening 120, referred as fifth opening, wherein the opening 120 is configured on an operative top face of the second recessed portion 110. The third protruded portion 106 has one opening 122, referred as sixth opening, configured on an operative top face of the third protruded portion 106.
The number of protruded portions, the recessed portions and the openings may be varied depending upon the varying size of the vehicle and are not limited to the usage of three protruded portions, two recessed portions, and six openings mentioned in the present disclosure.
Further, a remaining portion 124, which includes a remaining portion of the instrument panel structure 100 apart from the deformable portion 101, may also be of variable thickness. In an embodiment, the deformable portion has varying thickness ranging from 1.5 mm to 3.0 mm to facilitate a sequential and controlled deformation thereof. The fifth opening 120 facilitates bending of the portion ‘A’, wherein dimensions of the fifth opening 120 is decided on the basis of the twist requirement. The fourth opening 118 facilitates secondary twisting. The dimension of the fourth opening 118 is

so configured so as to optimize the stiffness and acceleration values. The second opening 114 opens up to allow both primary and secondary twist. The first recessed portion 108 provides the space required to absorb the energy of the head impact and prevents striking any hard component during the collision.
In an exemplary embodiment as illustrated in figure 4a to figure 4f, various deformation patterns of the instrument panel support structure 100 are depicted. Figure 4a illustrates an isometric side view of the instrument panel support structure 100 before occurrence of collision. Figure 4b to figure 4f illustrate isometric views of the instrument panel support structure 100 depicting stages of deformations when subjected to impact during collision. In the first stage of deformation denoted by ‘I’ in figure 4b, a portion ‘A’ (i.e. operative bottom portion) of the second protruded portion 104 is subjected to bending. In the second stage of deformation denoted by ‘II’ as illustrated in figure 4c, the instrument panel structure 100 in which a portion ‘A’ of the second protruded portion 104 is subjected to initial twisting in the ‘D’ direction. Also, the remaining portion 124, of the instrument panel 100, starts bending and twisting.
In the third stage of deformation, a weak area is formed at the second recessed portion 110 due to the openings 118 and 120, and because of the lower thickness of the second protruded portion 104. The weak area, denoted by III, facilitates further twisting of the second protruded portion 104 along the ‘A’ section. Further, as illustrated in figure 4e and 4f, a second twist deformation is initiated at the section ‘B’ (i.e., the operative top portion of the second protruded portion 104).
The unique combination of strategically located the protruded portions, the recessed portions, and the openings and the variable thickness hereof

facilitates the absorption of most of the shocks generated due to head impact on the instrument panel structure 100 during the collision. Also, the bending and the twisting deformation of the protruded portions along with the recessed portions facilitate the controlled and sequential deformation of the instrument panel during impact, thereby absorbing most of the shocks during collision. The instrument panel structure 100 is in accordance with the instrument panel criteria such as Noise, Vibration and Harshness requirement.
Due to the controlled bending and twisting deformations of the instrument panel support structure 100, the energy generated due to frontal impact on the instrument panel support structure 100 is absorbed and hence the instrument panel structure protects the occupants, particularly the driver and the co-driver, from severe injuries.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of:
• an instrument panel support structure for vehicles that protects occupants of the front seat of the vehicle from injury during a frontal collision of a vehicle; and
• an instrument panel support structure for vehicles that is capable of absorbing some of the shocks generated during a collision.
The disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

WE CLAIM:
1. An instrument panel support structure for a vehicle having a deformable
portion, said deformable portion having:
- at least one protruded portion;
- at least one recessed portion extending from said at least one protruded portion and formed sequentially adjacent to said at least one protruded portion; and
- a plurality of openings configured on said at least one protruded portion and said at least one recessed portion to facilitate a controlled and sequential deformation of said deformable portion.
2. The instrument panel support structure as claimed in claim 1, wherein
said deformable portion includes:
- a first protruded portion, a second protruded portion, and a third protruded portion; and
- a first recessed portion formed between said first protruded portion and said second protruded portion, and a second recessed portion formed between said second protruded portion and said third protruded portion.
3. The instrument panel support structure as claimed in claim 2, wherein
said deformable portion has varying thickness ranging from 1.5 mm to
3.0 mm to facilitate a sequential and controlled deformation thereof.

4. The instrument panel support structure as claimed in claim 2, wherein,
in case of frontal collision, said secondary protruded portion undergoes
three stages of deformation as follows:
- first stage of deformation includes bending at the base of said second protruded portion;
- second stage of deformation includes twisting at the base of said second protruded portion;
- third stage of deformation includes twisting at an operative middle portion of said second protruded portion, wherein said twisting is facilitated by formation of a weak area due to openings configured on said second protruded portion and variable thickness of said second protruded portion.
5. The instrument panel support structure as claimed in claim 2, wherein
said deformable portion comprises:
- first opening configured on an operative top face of said first protruded portion;
- second opening configured partially on said first recessed portion and an operative side face, adjacent to said first recessed portion, of said second protruded portion;
- third opening configured on an operative top face of said second protruded portion;
- fourth opening configured on another operative side face, adjacent to the second recessed portion, of said second protruded portion;

- fifth opening configured on an operative top portion of said third protruded portion;
- sixth opening configured on an operative top face of said second recessed portion.