This invention relates to a method of manufacture of a dashboard, for example for a vehicle such as automobile.

In automobiles, dashboards are provided for various purposes. For example, dashboards may accommodate various panels displaying various vehicle and engine parameters such as speed, fuel level and coolant temperature. The dashboard may be used for the mounting of various controls. Finally, the dashboard - through provision of a glove box or other enclosed spaces may allow for the storage of goods, valuables and other personal items. Hence the automobile dashboard is a vital multi-purpose item.

A dashboard for most motor vehicles or automobiles may be divided into three major parts (which may be modularised): one in front of the driver for mounting the instrument panel and other switches; the second in front of the co-driver or co- passenger seat for mounting the glovebox unit and perhaps air conditioning vent(s); and a third or intermediate part which lies in the central area and ordinarily mounts the climate control (HVAC controls), audio controls and - in some cases - the gear lever too. The actual configuration of mounting may change in line with the designer's concepts or requirements for the automobile.

Also important to dashboard construction is the question of whether the automobile is left hand drive (LHD) or right hand drive (RHD). The location of the various mountings and panels will vary in accordance with whether the automobile is LHD or RHD configured.

There are two well known and distinct methods for manufacturing a dashboard, that is integral manufacture and modular manufacture. In the integral version, the dashboard is a single piece dashboard. In the modular version, the dashboard is assembled from individual modules corresponding with the driver side, the intermediate area and the passenger side.

However, whenever there is a need, at the manufacturer's end, to have a dashboard that will fit in both LHD and RHD configurations for a vehicle, it is preferred to go for symmetrical constituents (i.e the passenger and driver side modules are made interchangeable). In this case, there is a need of multiple tools (each module having a set of die and punch) for each of the modules, which is a costly proposition. In the case of the modular method of manufacture, the constituent modules are made separately and then later assembled together. This method of manufacture has also been found, by the Applicant, to lead to a final assembly fitment problem due to variation in manufactured components or modules. Of course, time required for assembly of the modules also consumes time for assembly thus hampering productivity.

In the case of the integral method of manufacture, there is also a need for two sets of tooling, typically in the form of dies and punches, so as to cater for left hand drive and right hand drive configurations. Again, there is an excessive inventory of parts used for manufacturing of the dashboard.

The present invention relates in general to dashboard fabrication and the insertion die tooling associated with the fabrication of the dashboard. The present invention more specifically relates to the configuring of the die member forming the dashboard and associated insertion die tooling.

It is an object of the present invention is to provide a method of manufacture of a dashboard which reduces costs and defects in manufacture due to issues such as those outlined above.

The present invention provides a novel and obvious change to the prior art that has been used traditionally in the industry.

With this objective in view, the present invention provides, in one aspect, a method of manufacture of a dashboard for a vehicle comprising assembly of the dashboard from a plurality of dashboard modules wherein, whether the dashboard is of left hand drive configuration ("LHD") or right hand configuration ("RHD"), fabrication of dashboard modules to required shape is conducted in a single fabrication stage.

The present invention relates to the construction and arrangement of the die member and arrangement of the insertion of the die tooling and alternating that tooling assembly that directly relate to the different configurations of the dashboard formed.

The present invention is directed to an improvement in the insertion die tooling by forming atleast three cavities, first left hand side, second central and third right hand side cavity all adjacent and linear along the width of the dashboard and designing the extreme two cavities into identical in shape. The left hand side and right hand side cavities are thereby contoured to receive identical inserts. The tooling also includes three inserts, first, second and third inserts. The second insert is designed and contoured along its outer surface and lower surface so as to fit snugly up against the wall and into the central cavity. The first and third insert is designed and contoured along its outer surface and lower surface so as to fit snugly up against the wall and into the left hand side cavity and also into right hand side cavity.

The second insert is adapted and contoured to receive the central module of the dashboard.

The first insert is adapted and contoured to receive the driver module of the dashboard.

The third insert is adapted and contoured to receive the co-passenger module of the dashboard.

As such it is possible to insert the first insert into left hand side cavity or into the right hand side cavity. This particular changeable option in the insertion die tooling results in an improved structure, as it is possible to achieve two configurations of the dashboard, with the same tooling assembly.

One major manufacturing benefit derived from the present invention is the ability to change the manufacture of dashboard from one configuration to the second configuration without having change majority the die tooling facilities.

In a further aspect, the present invention provides a method of manufacture of a dashboard for a vehicle comprising the steps of:

determining whether the dashboard is to have left hand drive (LHD) or right hand drive (RHD) configuration;

selecting tooling for modules for assembly of the dashboard in the determined LHD or RHD configuration; and assembling the tooling of the modules to required configuration in a single fabrication stage with respect to determined dashboard configuration.

The fabrication stage may form part of a production line of an automotive plant with the fabrication stage using a single fabrication tool (which may be operated automatically or with the assistance of an operator). The fabrication or production operation may involve providing the fabrication tool and/or the module(s) with tooling in the form of forming components for a dashboard fabrication operation; the forming components being fitted to the tool and/or the modules in mutually interchangeable positions dependent on whether the determined configuration of the dashboard is an LHD or RHD configuration.

The forming components / molding tool may include inserts such as punches and dies suitable for fabricating the dashboard into the desired design. The tooling for use in the above method of manufacture also forms an aspect of the invention as does the fabrication tool.

The fabrication tool, which may be a pressing machine used to press the modules to required shape, is provided with tooling in the form of a set of dies, which may include core and cavity, which set of dies may be the same for both manufacture of a dashboard in an LHD configuration and manufacture of a dashboard in an RHD configuration. The only requirement is to interchange the tooling for the fabrication tool dependent on the selected dashboard configuration. For example, the inserts of dies in the die cavities of the tool may be interchanged with the core inserts in the core cavities of the tool being correspondingly changed dependent on whether the manufactured dashboard module is that required for LHD or RHD automobile configuration. To this end, mounting faces of die cavities and inserts may be identical so that any insert may be mounted in any cavity.

The same fabrication tool or machine may be employed irrespective of the determined configuration of dashboard. This results in lower capital costs for the dashboard manufacturing step or line. Space required for manufacturing may also be reduced by the use of a single fabrication tool.

The modules used for LHD and RHD operation may be the same to reduce inventory and the influence of manufacturing variance on final assembly operations. This results in easier fitment and greater product dashboard quality. However, interchangeability of the punches and dies provides the finished module with the correct design for the determined configuration and so the finished module will vary dependent on whether the determined configuration is LHD or RHD configuration.

A dashboard manufactured in accordance with the above described methods forms another aspect of the invention. Such dashboards may be used in OEM vehicle manufacture and/or supplied for aftermarket fitting.

An automotive vehicle comprising a dashboard manufactured in accordance with the above described methods forms a still further aspect of the invention. In this regard, a so manufactured dashboard is particularly suitable for use in three or four wheeled vehicles.

This method is original in that it implements a die member having atleast three cavities, one each at remote end i.e., left hand side and right hand side and one at the central position. The two remote cavities are identical. The die member is created such that it includes the above three cavities and the two remote end cavities i.e., left hand side and right hand side are having identical shape that match the useful or required shape of a module, which may be either a driver module or a co-passenger module to be mounted on the dashboard.

The invention relates to manufacture of dashboard such that left hand side drive dashboard and right hand side drive dashboard as the driver module and co- passenger module have to be different for the two configurations mentioned above. In traditional method there is two separate tooling means is used to create a left hand side drive dashboard and right hand side drive dashboard. This type of manufacturing operation increase the production cost. The applicant has therefore attempted to overcome these drawbacks and difficulties while achieving the product accuracy of the end product i.e., a dashboard. The applicant has designed and developed the method for manufacturing dashboard with a tooling arrangement that eliminates use of two separate tooling means for manufacturing left hand side drive dashboard and right hand side drive dashboard.
The invention herein discloses a modular tooling arrangement that utilizes die members having recesses/cavities adapted to couple with inserts, thereby being flexible to create different configuration of the end product, which in this invention is a dashboard of a vehicle.

Firstly, the pluggable driver module is configured for insertion into the first insert. The first insert is configured to retain the driver module in the insert.

Secondly, the pluggable co-passenger module is configured for insertion into the third insert. The third insert is configured to retain the driver module in the insert.
Thirdly, the first insert and the third insert can be interchangeably mounted either in the left hand side cavity or right hand side cavity. This means the same tooling arrangement can be utilized for manufacturing the two configuration of the dashboard i.e. for LHS and RHS drive configuration.

As such the invention relates to a method for designing a tool for dashboard manufacturing, the said tool comprising a die and a set of three inserts to form a dashboard as end product having a predefined component geometry which includes a driver module, central module and a co-passenger module.

The method of manufacture of a dashboard in accordance with the present invention may be more fully understood from the following description of preferred embodiments of the invention made with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a dashboard in left hand drive (LHD) integral configuration in accordance with the prior art;

Figure 2 provides perspective views of the driver side, passenger side and intermediate or central area as manufactured using separate tooling in accordance with the prior art;

Figure 3 is a perspective view of a dashboard for LHD configuration of an automobile in accordance with one embodiment of the present invention;

Figure 4 is a perspective view or a dashboard for right hand drive (RHD) configuration of an automobile in accordance with one embodiment of the present invention;

Figure 5 is a perspective view of the tooling set up for manufacturing a dashboard by a process in accordance with one embodiment of the present invention and showing the cavity having interchangeable inserts for RHD configuration;

Figure 6 is a perspective view of the tooling set up for manufacturing a dashboard by a process in accordance with one embodiment of the present invention and showing the interchangeable inserts from the core side for RHD configuration;

Figure 7 is a perspective view of the tooling set up for manufacturing a dashboard by a process in accordance with one embodiment of the present invention and showing the cavity having interchangeable inserts for LHD configuration; and

Figure 8 is a perspective view of the tooling set up showing the interchangeable inserts from the core side for LHD configuration.

Referring now to Figure 1, dashboard 1 is manufactured by an integral method of manufacture. That is, the dashboard 1 is manufactured in a single piece. The driver side portion, central or intermediate portion and passenger side portions are identified 2, 3 and 4 respectively. Various switches, panels and controls are mounted on dashboard 1 as per requirements of the vehicle, perhaps an automobile or 3 wheel vehicle, for left hand drive (LHD configuration). Such a configuration is unsuitable for use in a right hand drive (RHD configuration) context. Legislation often mandates this as well. Therefore, in accordance with the prior art method of manufacture, an RHD dashboard pattern is different and calls for a different set of tooling than for the LHD dashboard configuration.

The requirement for separate tooling is also maintained for the driver and passenger side modules 10 and 30, as shown in Figure 2 in the case where a dashboard is manufactured by the modular method of manufacture and assembly. The intermediate or central module is indicated 20 in Figure 2, Therefore, the integral and modular methods of manufacture of a dashboard in the prior art involve more than one fabrication stage or tool for different drive configuration and hence are not cost effective.

Referring now to Figure 3, there is shown a dashboard 500 manufactured by a single fabrication tool in accordance with the method of manufacture of a preferred embodiment of the invention. Dashboard 500 is in LHD configuration and comprises three modules: driver side module 100, central module 200 and co-passenger side module 300. Required panels, switches, controls and so on may be mounted on dashboard 500 through mounting points provided on each of the modules 100, 200 and 300. Figure 4 shows a dashboard 600 of the same basic design but arranged for RHD configuration.

The method of manufacture of dashboards 500 and 600 may now be described with reference to Figures 5 to 8 which depict the tooling set up 170 forming part of a single fabrication tool to be used in a single fabrication stage of an automobile production line. Dashboard 500 is manufactured by a single tool comprising tooling for each module. This tooling comprises forming components in the form of a set of die and punch marked as 101 and 201 (and shown in Figures 7 and 8). Die 101 is provided with three cavities, viz. driver side cavity 103, central module cavity 104 and co-passenger module die cavity 105. Driver side module die cavity 103 and co-passenger side module die cavity 105 are fitted or mounted with inserts 106 and 107 respectively using suitable mounting arrangements. Similarly, the punch 201 is provided with core cavities, viz driver side module core cavity 203, central module core cavity 204 and co-passenger side module core cavity 205. The driver side module core cavity 203 and co-passenger side module cavity 205 are fitted or mounted with inserts 206 and 207 respectively using suitable mounting arrangements.

The above die punch set (101, 201) fitted with inserts 106, 107, 206, 207 is used to manufacture, through injection moulding, a modular dashboard 500 for LHD configuration. Where the production schedule dictates that a dashboard 600 of RHD configuration be manufactured, the same die punch set (101, 201) is used in the manufacturing operation. So, the same single fabrication tool may be employed for dashboard manufacture irrespective of dashboard configuration. The only effort required is to interchange the inserts of dies 106, 107, 206, 207 in the die cavities; and correspondingly interchange the inserts of punches in the core cavities. In other words, the insert 106 is fitted or mounted in the die cavity 105 and insert 107 is fitted or mounted in die cavity 103. Similarly, the insert 206 is fitted or mounted to core cavity 205 and insert 207 is fitted or mounted to core cavity 203. Such interchange of inserts may be achieved because corresponding mounting faces of die cavities marked as 110 and 111 (as shown in Figure 5) and of inserts marked as 112 and 113 (as shown in Fig. 5) are identical so that any of the inserts 106, 107 can be mounted in any cavity 103 or 105. Similarly inserts 206, 207 can be mounted in any cavity 203 or 205. Similarly, the mounting faces of core cavity 114 and 115 (as shown in Figure 6) and inserts 116 and 117 (as shown in Figure 6) of the modules are identical so that any of the inserts are identical so that any of the inserts 116, 117 can be mounted in any of the cores/cavities 114, 115. Such interchangeability is not a feature of prior art methods where sets of dies and punches corresponding with both LHD and RHD configurations are required. The prior art manufacturing method therefore has a cost in parts and time which is avoided using the above described method of manufacture of a dashboard.

Dashboards 500 and 600, manufactured as described above, may be employed in automobiles manufactured at the same, or a different, production plant Such dashboards may also be supplied for aftermarket use.

Modifications and variations to the method of manufacture of a dashboard described above will be apparent to those skilled in the art reading this disclosure. Such modifications and variations are deemed within the scope of the present invention. For example, the method of manufacture has been described with reference to the driver side module and co-passenger side module. However, the method of manufacture may be applied to other modules as per various designs of dashboard.

WE CLAIM :-

1. A tool assembly for molding a dashboard of an automobile which may be a left hand drive configuration(500) or which may be right hand drive configuration(600), the dashboard having contours adapted for mounting atleast a driver module (100), a central module (200) and co-passenger module (300) within a plurality of cavities formed therein, with a tool assembly (170), the said tool assembly comprising :

a. a die punch member (101,201) having an elongated shape with opposite ends, defining a first fitting die cavity on left hand side end (105,203), a second fitting die cavity in the center (104,204) and the third die fitting cavity on the right hand side (103,205) end for receiving corresponding first, second and third insert therein.

b. a first set of insert (106,206) having a first surface (301,401) and a second surface (302A,402A), configured to matingly engage into the first cavity and also into the said third cavity along its first surface and further predefined for receiving a driver module on its second surface,

c. a second set of insert having a first surface (501) and a second surface (502) configured to matingly engage into the second cavity along its first surface and further predefined for receiving a central module along its second surface and

d. a third set of insert (107,207) having a first surface (301,401) and a second surface (302B.402B) configured to matingly engage into the first cavity and also into the said third cavity along its first surface and further predefined to receive a co-passenger module along its second surface,

e. the first and third cavity in the die member being identical to each other in size and configuration.

f. the first and third cavity in the die member further sized and configured to receive first and third inserts.

wherein the first insert and third insert are identical excepting to the extent for receiving a driver module and a co-passenger module respectively on the second surface and such that a distinct first and second dashboard configuration is selectively constructed from interchangeable first and third inserts fitting either into first or third cavity of the die member, wherein the first dashboard configuration comprises the first insert inserted into the first cavity and third Insert inserted into the third cavity and alternatively wherein the second dashboard configuration comprises the first insert inserted into third cavity and third insert inserted into first cavity and wherein the second insert inserted into second cavity in both the configurations.

2. A method of molding a dashboard of an automobile which may be a left hand drive (500) or which may be right hand drive (600), the dashboard having contours adopted for mounting atleast a driver module (100), a central module (200) and co-passenger module (300) within a plurality of cavities formed therein, with a tool assembly (170), the said tool assembly comprising:

a. a die member (101,201) having an elongated shape with opposite ends, defining a first fitting die cavity on left hand side end (105,203), a second fitting die cavity in the center (104,204) and the third die fitting cavity on the right hand side (103,205) end for receiving corresponding first, second and third insert therein.

b. a first insert (106,206) having a first surface and a second surface, configured to matingly engage into the first cavity and also into the said third cavity along its first surface and further predefined for receiving a driver module on its second surface.

c. a second insert having a first surface and a second surface configured to matingly engage into the second cavity along its first surface and further predefined for receiving a central module along its second surface and

d. a third insert (107,207) having a first surface and a second surface configured to matingly engage into the first cavity and also into the said third cavity along its first surface and further predefined to receive a co- passenger module along its second surface,

e. the first and third cavity in the die member being identical to each other in size and configuration.

f. the first and third cavity in the die member further sized and configured to receive first and third inserts.

wherein the first insert and third insert are identical excepting to the extent for receiving a driver module and a co-passenger module respectively; on the second surface and such that a distinct first and second dashboard configuration is selectively constructed from interchangeably fitting first and third inserts either into first or third cavity of the die member, wherein the first dashboard configuration comprises inserting the first insert into the first cavity and inserting the third insert into the third cavity and alternatively wherein the second dashboard configuration comprises inserting the first insert into third cavity and inserting third insert into first cavity and wherein inserting the second insert into second cavity in both the configurations,

3. The method as claimed in claim 2, further including the step of selectively inserting the inserts into cavities.

4. The tooling assembly as claimed in claim 1 is such that wherein the die member of claim 1 joined together with the set of three inserts of claim 1 forms a dashboard component die.

5. The method as claimed in claim 2 is such that wherein the die member of claim 2 is joined together with the set of three inserts of claim 2 to form a dashboard component die.

6. The method as claimed in claim 5, wherein the said dashboard component die is formed in a sequence with :-

- an elongated die member defined with three cavities a first left hand side, second central cavity and a third right hand side cavity and

- a set of three inserts a first, a second and a third insert inserted selectively into said three cavities, and furthermore the first insert is adapted for mounting the driver module and third insert is adapted for mounting the co-passenger module and also the second insert is adapted for mounting the central module.

- inserting the second insert always into the second central cavity and characterized in that the first and third cavity and the first and third insert are so sized and configured for interchangeably inserting of an insert into a cavity to form a selective dashboard component die.