DESC:CROSS REFERENCE TO RELATED APPLICATION
This Application is based on and derives the benefit of Indian Provisional Application 202241034641 filed on 16th June 2022, the contents of which are incorporated herein by reference.

TECHNICAL FIELD
[001] The embodiments herein relate to a pedal mounting assembly in a vehicle, which is jointly mounted onto a dash panel and a plenum panel thereby providing more strength and reduces deflection a pedal as well as reduces intrusion of the pedal in an event of collision of the vehicle. Further, embodiments herein achieve a method of mounting the pedal mounting assembly in the vehicle.

BACKGROUND
[002] Generally, a pedal mounting box is used for mounting pedals such as a clutch pedal and a brake pedal in a vehicle. Typically, the pedal mounting box is mounted onto a dashboard of the vehicle. In other vehicles, the pedal mounting box is mounted onto a floor panel. The pedal mounting box along with the brake pedal and/or the clutch pedal is a critical assembly in the occupant area that is bound to increase the injuries to the driver, if the driver comes into contact with it during collision of the vehicle. Excess movement of the clutch and brake pedals causes lower leg injuries to the driver as there are not enough load paths to absorb the operation load.
[003] In some vehicles, the pedal intrusions are reduced by using dash reinforcement on either side of the dash panel i.e., on the inner side of the dash panel that is facing an occupant compartment or on the outer side of the dash panel that is facing an engine compartment. Many times, a combination of both inner and outer dash reinforcement is also used. The aforementioned conventional assemblies pose complexity in installation and incur high manufacturing costs. Other conventional ways of reducing pedal intrusion include varying the joinery and thickness of parts adjacent to the brake and clutch pedal assemblies. However, such conventional ways include iterative processes and may not yield the desired results.
[004] Further, conventional brake pedal mounting box requires a separate mounting bracket for mounting a brake switch thereon. This results in complex assembly, consumes more packaging space and additional cost. Further, in conventional clutch pedal mounting box, a double torsion spring is positioned at a rear end of the clutch pedal mounting box in vicinity to the dash panel, where the double torsion spring is located in front of a pivot member of the clutch pedal. This arrangement of double torsion spring may pose difficulty in routing of heating, ventilation and air conditioning (HVAC) pipes with engine due to space constraint between engine and dash panel.
[005] Conventional vehicles have a clutch master cylinder (CMC) isolated from a clutch pedal mounting box and is connected with clutch pedal shank by snapping them with the body in white (BIW) or pedal box base plate ring. This allows higher degrees of freedom for shank movement as the CMC is not constrained within the clutch pedal mounting box. In such systems, the clutch pedal intrusion prediction will vary based on the impact generated at that moment of crash as degrees of freedom is available in clutch pedal shank, CMC connection and thus requiring a larger contact area for generating opposing reaction load. This requires add on features in the cross-car beam (CCB) to restrict movement of the clutch pedal travel or involve collapsible mechanism.
[006] Therefore, there exists a need for a pedal mounting assembly in a vehicle, which obviates the aforementioned drawbacks. Further, there exists a need for a method for mounting the pedal mounting assembly in the vehicle.

OBJECTS

[007] The principal object of embodiments herein is to provide a pedal mounting assembly in a vehicle, which is jointly mounted onto a dash panel and a plenum panel thereby providing more strength and reduces deflection of a pedal as well as reduces intrusion of the pedal in an event of collision of the vehicle.
[008] Another object of embodiments herein is to provide a method of mounting the pedal mounting assembly in the vehicle.
[009] Another object of embodiments herein is to provide to provide a pedal mounting assembly in the vehicle, which has an optimized design to minimize pedal deflection in vehicles.
[0010] Another object of embodiments herein is to provide to provide the pedal mounting assembly which has an optimized design to provide smooth and even load distribution on the pedal thereby improving structural durability of the pedal.
[0011] Another object of embodiments herein is to provide the pedal mounting assembly in the vehicle, which is durable, and has better noise, vibration and harshness (NVH) characteristics.
[0012] Another object of embodiments herein is to provide the pedal mounting assembly in a vehicle, which requires lesser number of parts/components for mounting and controlling pedals thereof to reduce the manufacturing cost and reducing the overall weight of the vehicle.
[0013] Another object of embodiments herein is to provide the pedal mounting assembly with integrated pedal catcher for restricting movement of pedal in event of collision.
[0014] Another object of embodiments herein is to provide the pedal mounting assembly which firmly secures pedal(s) such as clutch pedal/ brake pedal in the vehicle.
[0015] Another object of embodiments herein is to provide the pedal mounting assembly which allows easier routing of heating, ventilation and air conditioning (HVAC) pipes with engine.
[0016] Another object of embodiments herein is to provide the pedal mounting box assembly which allows tuning of moving arm and double torsion spring as per pedal feel requirements as more space was available towards the driver side.
[0017] Another object of embodiments herein is to provide a clutch pedal mounting assembly which is jointly mounted onto a dash panel and a plenum panel of the vehicle.
[0018] Another object of embodiments herein is to provide a brake pedal mounting assembly which is jointly mounted onto the dash panel and the plenum panel of the vehicle.
[0019] Another object of embodiments herein is to provide the pedal mounting assembly, which is reliable, easy to install and incur less manufacturing cost.
[0020] Another object of an embodiment herein is to increase the engine or passenger compartment space by installing a clutch master cylinder inside the clutch pedal mounting assembly.
[0021] Another object of an embodiment herein is to install the clutch master cylinder inside the clutch pedal mounting assembly thereby avoiding exposure of the clutch master cylinder to heat sources located in engine compartment of the vehicle.
[0022] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0023] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0024] Fig. 1 depicts a perspective view of a clutch pedal mounting assembly and a brake pedal mounting assembly mounted onto a dash panel and a plenum panel of a vehicle, according to first and second embodiments as disclosed herein;
[0025] Fig. 2 depicts a perspective view of a pedal mounting assembly, according to first embodiments as disclosed herein;
[0026] Fig. 3 depicts another perspective view of the pedal mounting assembly in which a double torsion spring is at rear of and spaced away from a pedal pivot member, and is closer to an integrated pedal catcher, according to first embodiments as disclosed herein;
[0027] Fig. 4 depicts a side view of the pedal mounting assembly showing the arrangement of double torsion spring and the pedal pivot member, according to first embodiments as disclosed herein;
[0028] Fig. 5 depicts another perspective view of the pedal mounting assembly in which a clutch master cylinder is positioned within a pedal mounting bracket of the pedal mounting assembly, according to first embodiments as disclosed herein;
[0029] Fig. 6 depicts a perspective view of a pedal mounting assembly, according to second embodiments as disclosed herein;
[0030] Fig. 7 depicts a front view of the pedal mounting assembly, according to second embodiments as disclosed herein;
[0031] Fig. 8 depicts another perspective view of the pedal mounting assembly in which a brake switch is mounted onto an integrated pedal catcher, according to second embodiments as disclosed herein; and
[0032] Fig. 9 depicts a flowchart indicating steps of a method for mounting a pedal mounting assembly in the vehicle, according to first and second embodiments as disclosed herein.
DETAILED DESCRIPTION
[0033] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed 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.
[0034] The embodiments herein achieve a pedal mounting assembly in a vehicle, which is jointly mounted onto a dash panel and a plenum panel thereby providing more strength and reduces deflection of a pedal as well as reduces intrusion of the pedal in an event of collision of the vehicle. Referring now to the figs. 1 through 9, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0035] Fig. 2 depicts a perspective view of a pedal mounting assembly (100), according to first embodiments as disclosed herein. Fig. 6 depicts a perspective view of a pedal mounting assembly (200), according to second embodiments as disclosed herein. In the first and second embodiments, the pedal mounting assembly (100, 200) includes a pedal mounting bracket (102, 202), an integrated pedal catcher (104, 204), a plurality of first fasteners (103, 203) (as shown in fig. 1) and a plurality of second fasteners (105, 205) (as shown in fig. 1). In the first embodiment, the pedal (10CP) is considered to be a clutch pedal. Further, in the second embodiment, the pedal (10BP) is considered to be a brake pedal.
[0036] In the first and second embodiments, the pedal mounting bracket (102, 202) is mounted onto a dash panel (10D) and a plenum panel (10P) (as shown in fig. 1) in a vertical mounting plane and a horizontal mounting plane respectively, where the vertical mounting plane is transverse to the horizontal mounting plane. The pedal mounting bracket (102, 202) includes a plurality of pedal mounting walls (102A, 202A), a plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) and a plurality of horizontal mounting flanges (102Z, 202Z). A portion of the pedal (10CP, 10BP) is adapted to be positioned within the pedal mounting walls (102A, 202A) and is pivoted to the pedal mounting walls (102A, 202A) through a pedal pivot member (10CSP, 10BSP) (as shown in fig. 3, fig. 4 and fig. 8). Each pedal mounting wall (102A, 202A) is parallel and spaced apart from another pedal mounting wall (102A, 202A).
[0037] The plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) are adapted to be mounted onto the dash panel (10D), wherein at least one of the vertical mounting flanges (102YA, 102YB, 202YA, 202YB) is co-planar to the vertical mounting plane. The plurality of horizontal mounting flanges (102Z, 202Z) are disposed at a top end (102TP, 202TP) (as shown in fig. 2 and fig. 6) of pedal mounting walls (102A), 202A), The horizontal mounting flanges (102Z, 202Z) are adapted to be mounted onto the plenum panel (10P). The horizontal mounting flanges (102Z, 202Z) are co-planar to the horizontal mounting plane. The plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) are mounted onto the dash panel (10D) through the plurality of first fasteners (103) (as shown in fig. 1), wherein each first fastener (103) is disposed along a horizontal direction. Each first fastener (103) is a bolt. The horizontal mounting flange (102Z, 202Z) is adapted to be mounted onto the plenum panel (10P) through the plurality of second fasteners (105) (as shown in fig. 1), wherein each second fastener (105) is disposed along a vertical direction. Each second fastener (105) is a bolt. It is also within the scope of the invention to use any other temporary joints or permanent joints for attaching the pedal mounting bracket (102) to the dash panel (10D) and the plenum panel in the vertical mounting plane and the horizontal mounting plane respectively, without otherwise deterring the intended function of the fasteners (103, 105) as can be deduced from the description and corresponding drawings.
[0038] In the first and second embodiments, the plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) includes a pair of first vertical mounting flanges (102YA, 202YA) and a pair of second vertical mounting flanges (102YB, 202YB) (as shown in fig. 2, fig. 3 and fig. 5 to fig. 7). Each first vertical mounting flange (102YA, 202YA) transversely extends from corresponding pedal mounting wall (102A, 202A) and is connected to corresponding horizontal mounting flange (102Z, 202Z). Each first vertical mounting flange (102YA, 202YA) is transverse to corresponding horizontal mounting flange (102Z, 202Z). Each second vertical mounting flange (102YB, 202YB) transversely extends from corresponding pedal mounting wall (102A, 202A) and is disposed below and spaced away from corresponding first vertical mounting flange (102YA, 202YA). Each horizontal mounting flange (102Z, 202Z) transversely extends from corresponding pedal mounting wall (102A, 202A) at the top end (102TP, 202TP).
[0039] In the first and second embodiments, the pedal catcher (104, 204) extends between the pedal mounting walls (102A, 202A) thereby connecting the pedal mounting walls (102A, 202A) with each other. The integrated pedal catcher (104, 204) is adapted to restrict a movement of the pedal (10CP, 10BP) beyond a predefined position in the event of collision of the vehicle thereby reducing the possibility of injury to driver of the vehicle. A portion (104A, 204A) (as shown in fig. 2 and fig. 6) of the integrated pedal catcher (104, 204) is near to the top end (102TP, 202TP) of the pedal mounting walls (102A, 202A).
[0040] If the pedal (10CP) is a clutch pedal, a double torsion spring (10SP) (as shown in fig. 3 and fig. 4) is positioned within the pedal mounting walls (102A) and each end of the double torsion spring (10SP) is connected to corresponding pedal mounting wall (102A). The double torsion spring (10SP) is connected to the pedal pivot member (10CS) through a moving arm (10MA) (as shown in fig. 3 and fig. 4). One end of the moving arm (10MA) is connected to the pedal pivot member (10CS) and another end of said moving arm (10MA) is connected to the double torsion spring (10SP). This arrangement of the double torsion spring (10SP) allows tuning of moving arm (10M) and the double torsion spring (10SP) as per pedal feel requirements as more space was available towards the driver side. The pedal pivot member (10CS) is located in vicinity of the dash panel (10D) and is in front of and spaced away from the double torsion spring (10SP). The double torsion spring (10SP) is positioned closer to the integrated pedal catcher (104) and is at rear of and spaced away the pedal pivot member (10CS).
[0041] If the pedal (10CP) is the clutch pedal, a clutch master cylinder (10CMC) (as shown in fig. 5) is positioned within the pedal mounting walls (102A) at a predefined angle with respect to the pedal (10CP). One end of the clutch master cylinder (10CMC) is connected to the pedal (10CP) and another end of the clutch master cylinder (10CMC) is connected to the pedal mounting walls (102A) through a cylinder mounting bracket (10CMB) (as shown in fig. 5). In an embodiment, the predefined angle is at least 45°.
[0042] If the pedal (10BP) is the brake pedal, the integrated pedal catcher (204) is adapted to mount a brake switch (10BS) (as shown in fig. 1 and fig. 8) thereon. The integrated pedal catcher (204) defines a brake switch receiving portion (204R) (as shown in fig. 6 and fig. 7) adapted to receive a portion of the brake switch (10BS) thereby facilitating mounting of the brake switch (10BS) thereon.
[0043] Fig. 9 depicts a flowchart indicating steps of a method (400) for mounting a pedal mounting assembly (100, 200) in the vehicle, according to first and second embodiments as disclosed herein. At step (402), the method (400) includes, mounting, by a plurality of first fasteners (103), a plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) of a pedal mounting bracket (102, 202) with a dash panel (10D) in a vertical mounting plane. At step (404), the method (400) includes, mounting, by plurality of second fasteners (105), a plurality of horizontal mounting flanges (102Z, 202Z) of the pedal mounting bracket (102, 202) with a plenum panel (10P) in a horizontal mounting plane.
[0044] The technical advantages of the pedal mounting assemblies (100, 200) are as follows. The pedal mounting assembly allows easier routing of heating, ventilation and air conditioning (HVAC) pipes with engine. The pedal mounting assembly which allows tuning of moving arm and double torsion spring as per pedal feel requirements as more space was available towards the driver side. The pedal mounting assembly is provided with integrated pedal catcher as a feature within the pedal assembly which restricts movement of both the clutch pedal/ the brake pedal beyond a desired limit in the event of collision. The pedal mounting assembly is reliable, easy to install and incur less manufacturing cost.
[0045] The foregoing description of the specific embodiments will so fully reveal 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 embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim,
1. A pedal mounting assembly (100, 200) for mounting a pedal (10CP, 10BP) in a vehicle, said pedal mounting box assembly (100) comprising:
a pedal mounting bracket (102, 202) adapted to be mounted onto a dash panel (10D) and a plenum panel (10P) in a vertical mounting plane and a horizontal mounting plane respectively.

2. The pedal mounting assembly (100, 200) as claimed in claim 1, wherein said pedal mounting bracket (102, 202) includes,
a plurality of pedal mounting walls (102A, 202A);
a plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) adapted to be mounted onto said dash panel (10D), wherein at least one of said vertical mounting flange (102YA, 102YB, 202YA, 202YB) is co-planar to said vertical mounting plane; and
a plurality of horizontal mounting flanges (102Z, 202Z) disposed at a top end (102TP, 202TP) of pedal mounting walls (102A), 202A), wherein said horizontal mounting flanges (102Z, 202Z) are adapted to be mounted onto said plenum panel (10P), wherein said horizontal mounting flanges (102Z, 202Z) are co-planar to said horizontal mounting plane.

3. The pedal mounting assembly (100, 200) as claimed in claim 1, wherein said pedal mounting bracket (102, 202) includes an integrated pedal catcher (104, 204) extending between said pedal mounting walls (102A, 202A) thereby connecting said pedal mounting walls (102A, 202A) with each other,
wherein
at least a portion of said pedal (10CP, 10BP) is adapted to be positioned within said pedal mounting walls (102A, 202A) and is pivoted to said pedal mounting walls (102A, 202A) through a pedal pivot member (10CSP, 10BSP);
each of said pedal mounting wall (102A, 202A) is parallel and spaced apart from another said pedal mounting wall (102A, 202A);
said pedal catcher (104, 204) is adapted to restrict a movement of said pedal (10CP, 10BP) in an event of collision of said vehicle; and
a portion (104A, 204A) of said integrated pedal catcher (104, 204) is near to said top end (102TP, 202TP) of said pedal mounting walls (102A, 202A).

4. The pedal mounting assembly (200) as claimed in claim 3, wherein said pedal (10CP) is a clutch pedal, a double torsion spring (10SP) is positioned within said pedal mounting walls (102A) and each end of said double torsion spring (10SP) is connected to corresponding said pedal mounting wall (102A),
wherein
said double torsion spring (10SP) is connected to said pedal pivot member (10CSP) through a moving arm (10MA), wherein one end of said moving arm (10MA) is connected to said pedal pivot member (10CSP) and another end of said a moving arm (10MA is connected to said double torsion spring (10SP);
said pedal pivot member (10CSP) is located in vicinity of said dash panel (10D) and is in front of and spaced away from said double torsion spring (10SP); and
said double torsion spring (10SP) is positioned closer to said integrated pedal catcher (104) and is at rear of and spaced away said pedal pivot member (10CSP).

5. The pedal mounting assembly (200) as claimed in claim 3, wherein said pedal (10CP) is a clutch pedal, a clutch master cylinder (10CMC) is positioned within said pedal mounting walls (102A) at a predefined angle with respect to said pedal (10CP), wherein one end of said clutch master cylinder (10CMC) is connected to said pedal (10CP) and another end of said clutch master cylinder (10CMC) is connected to said pedal mounting walls (102A) through a cylinder mounting bracket (10CMB),
wherein
said predefined angle is at least 45°.

6. The pedal mounting assembly (200) as claimed in claim 3, wherein said pedal (10BP) is a brake pedal, said integrated pedal catcher (204) is adapted to mount a brake switch (10BS) thereon,
wherein
said integrated pedal catcher (204) defines a brake switch receiving portion (204R) adapted to receive a portion of said brake switch (10BS) thereby facilitating mounting of said brake switch (10BS) thereon.
7. The pedal mounting assembly (100, 200) as claimed in claim 2, wherein plurality of said vertical mounting flanges (102YA, 102YB, 202YA, 202YB) are mounted onto said dash panel (10D) through a plurality of first fasteners (103), wherein each of said first fastener (103) is disposed along a horizontal direction; and
said horizontal mounting flange (102Z, 202Z) is adapted to be mounted onto said plenum panel (10P) through a plurality of second fasteners (105), wherein each of said second fastener (105) is disposed along a vertical direction.

8. The pedal mounting assembly (100, 200) as claimed in claim 4, wherein said plurality of said vertical mounting flanges (102YA, 102YB, 202YA, 202YB) includes,
a pair of first vertical mounting flanges (102YA, 202YA), wherein each of said first vertical mounting flange (102YA, 202YA) transversely extends from corresponding pedal mounting wall (102A, 202A) and is connected to corresponding said horizontal mounting flange (102Z, 202Z), wherein each of said first vertical mounting flange (102YA, 202YA) is transverse to corresponding said horizontal mounting flange (102Z, 202Z); and
a pair of second vertical mounting flanges (102YB, 202YB), wherein each of said second vertical mounting flange (102YB, 202YB) transversely extends from corresponding pedal mounting wall (102A, 202A) and is disposed below and spaced away from corresponding said first vertical mounting flange (102YA, 202YA),
wherein
each of said horizontal mounting flange (102Z, 202Z) transversely extends from corresponding said pedal mounting wall (102A, 202A) at said top end (102TP, 202TP).

9. A method (400) of mounting a pedal mounting assembly (100, 200) in a vehicle, said method (400) comprising:
mounting, by a plurality of first fasteners (103), a plurality of vertical mounting flanges (102YA, 102YB, 202YA, 202YB) of a pedal mounting bracket (102, 202) with a dash panel (10D) in a vertical mounting plane; and
mounting, by plurality of second fasteners (105), a plurality of horizontal mounting flanges (102Z, 202Z) of said pedal mounting bracket (102, 202) with a plenum panel (10P) in a horizontal mounting plane.

10. The method (400) as claimed in claim 9, wherein at least one of said vertical mounting flanges (102YA, 102YB, 202YA, 202YB) is co-planar to said vertical mounting plane;
said horizontal mounting flanges (102Z, 202Z) are co-planar to said horizontal mounting plane;
each of said first fastener (103) is disposed along a horizontal direction; and
each of said second fastener (105) is disposed along a vertical direction.