CN1615565A - Instrument panel center stack with integrated wiring - Google Patents

Abstract

A center stack for an instrument panel assembly includes a thermoplastic housing having at least one wall. At least one conductor assembly is molded into at least one wall of the housing.

Description

Dashboard center group with integrated wiring

technical field

The present invention relates generally to a vehicle dashboard assembly and, more particularly, to a dashboard center cluster assembly having an integral conductor assembly.

Background technique

Known instrument panel assemblies include a beam structure and at least one trim panel attached to the beam structure, some of the trim panels serving as knee pads to protect vehicle occupants in the event of a crash. The instrument panel assembly is disposed within the passenger compartment of an automobile having a beam structure attached to the body of the automobile, typically to the A-pillar. Known instrument panel beam structures are manufactured from steel, aluminium, magnesium or plastic.

Additionally, known instrument panel assemblies include a center cluster, which is typically connected to a beam structure. The center cluster is sized and shaped to hold various vehicle systems and controls such as heating and air conditioning controls, radio and capacitor discharge transducers. These systems and controls require electrical power to operate and require connection to the main panel wiring harness. Typically, the junction box is connected to the main wiring harness and is located inside the instrument panel assembly. Individual harnesses connect the junction box to the electrical components of the central stack. This configuration of central stack electrical component connections requires many parts and prolongs the assembly work time.

Contents of the invention

In one aspect, a center cluster for an automotive dashboard assembly is provided. The central stack includes a thermoplastic shell having at least one wall. At least one conductor assembly is molded into at least one wall of the housing.

In another aspect, a center cluster for an automotive instrument panel assembly is provided that includes a housing comprised of at least one wall. A junction box housing is molded into one wall of the housing.

In another aspect, a method of manufacturing a center cluster for an instrument panel is provided. The central stack includes a housing having at least one wall. The method includes providing a mold, disposing at least one conductor assembly at least partially in the mold, and filling the mold with thermoplastic material to mold the central stack.

In another aspect, an automotive dashboard center cluster kit is provided. The kit includes a thermoplastic housing having at least one wall and a junction box housing molded into one wall of the housing. The kit also includes a connector plate and is sized to fit within the junction box housing.

Description of drawings

FIG. 1 is an exploded view of a dashboard center cluster according to an embodiment of the present invention.

FIG. 2 is an exploded view of the junction box shown in FIG. 1 .

FIG. 3 is a schematic cross-sectional view of the junction box shown in FIG. 1 .

4 is a rear perspective view of a center stack housing according to another embodiment of the present invention.

Figure 5 is a schematic exploded view of the center stack housing mold.

Figure 6 is a cross-sectional view of the mold shown in Figure 5 in an open position.

Figure 7 is a cross-sectional view of the mold shown in Figure 5 in a closed position.

Detailed ways

A dashboard center cluster assembly, which includes a thermoplastic housing with an integrally molded-in conductor assembly, is described in detail below. The molded conductor assembly reduces the number of wiring and parts in the center stack assembly, and reduces assembly time and weight.

The thermoplastic center stack housing can be molded from one of many thermoplastic materials. Suitable thermoplastic materials include, but are not limited to, acrylonitrile-butadiene-polyester (ABS), polycarbonate, polycarbonate/ABS blends, copolycarbonates, acrylic-styrene-acrylonitrile (ASA), acrylic Nitrile-(ethylene-polypropylene diamine modified) styrene (AES), phenylene ether resins, glass-filled blends of polyphenylene oxide and polystyrene, polyphenylene ether/polyamide ( GE’s NORYL GTX®), polycarbonate/PET/PBT, polybutylene terephthalate and impact modifier (GE’s XENOY® resin), polyamide, phenylene vulcanizate , polyvinyl chloride PVC, high impact polystyrene (HIPS), low/high density polyethylene, polypropylene and thermoplastic olefins (TPO).

Referring to the drawings, FIG. 1 is an exploded view of an instrument panel center group assembly 10 according to an embodiment of the present invention. The center stack 10 includes a thermoplastic center stack housing 12 having side walls 14 and 16 and a rear wall 18 . A center cluster bezel 20 is attached to the housing 12 . Center cluster housing 12 is sized and shaped to receive various vehicle systems and controls, such as audio system 22 , heating and air conditioning controls 24 . The junction box 26 is connected to the housing 12 . Junction box 26 includes a connector plate 28 having connectors 30 and 32 configured to connect junction box 26 to instrument panel main wiring 34 via conductor assemblies 36 and 38 .

The center stack housing 12 includes a conductor assembly 40 molded into the rear wall 18 . The conductor assembly 40 may be any known wire, such as an insulated flat wire assembly, an insulated ribbon wire assembly with multiple individual wires, and an insulated single wire assembly. Conductor assembly 40 includes pigtails 42 , 44 , 46 , 48 , 50 , 52 , 54 , 56 , and 58 . The pigtails 42 - 58 extend from the conductor assembly to a location outside the rear wall 18 . An electrical connection is connected to each outlet 42-58. Electrical connections 60 are configured to connect to various vehicle systems and controls, such as audio system 22 , heating and air conditioning controls 24 . The conductor assembly 40 is connected to the main distribution harness 34 through the junction box connector plate 28 . In particular, the conductor assembly 40 is connected to an integral connector 62 (shown in FIG. 3 ) in the housing rear wall 18 . Connectors 64 located on junction box connector plate 28 connect to integral connectors 62 .

Referring also to FIG. 2 , the junction box 26 includes an extension 66 of the housing side wall 14 dimensioned to receive the connector plate 28 . The extension 66 defines a junction box housing 67 integrally molded into the housing side wall 14 . Junction box cover 68 is joined to side wall extension 64 to close junction box 26 . In other embodiments, the junction box 26 is not integrally molded into the housing 12, but is a separate element attached to the housing 12 by suitable means, such as by fasteners or adhesives.

Referring to FIG. 3 , the conductor assembly 40 is connected to an integral connector 62 which is integral with the housing rear wall 18 . The integral connector 62 may be molded into the rear wall 18 or snapped into place in an appropriately sized opening in the rear wall 18 . The connector 64 is positioned on the connector plate 28 to align with the integral connector 62 . The conductor assembly 36 includes connectors 70 sized and shaped to connect with the connectors 30 on the connector plate 28 .

4 is a rear perspective view of a center stack housing according to another embodiment of the present invention. Housing 72 includes a rear wall 74 and side walls 76 and 78 . The conductor assembly 80 is connected to an integral connector 84 at a first end 82 . Connector assembly 80 is molded into housing 72 and extends through rear wall 74 and side wall 76 . Conductor assembly 80 includes pigtails 86 , 88 , 90 and 92 that extend through housing 72 to a location outside of housing 72 . Connectors 94, 96, 98 and 100 are connected to outlets 86, 88, 90 and 92, respectively. Connectors 94 , 96 , 98 and 100 are sized to be received in housing rear wall 74 . In particular, connectors 94 , 96 , 98 , and 100 are sized to be received in connector openings 102 , 104 , 106 , and 108 in housing sidewall 74 . Connectors 94, 96, 98 and 100 include notches 110 sized to receive housing rear wall 74 to secure connectors 94, 96, 98 and 100 in connector openings 102, 104, 106 and 108 in its proper place.

Referring to Figures 5-7, in one embodiment, the thermoplastic center stack shell 12 described above is formed by injection casting using a suitable mold 112 configured to produce a center stack shell of the desired shape 12. 5 and 6 show the mold 112 in an open state, while FIG. 7 shows the mold 112 in a closed state. The mold 112 includes a first mold piece 114 and a second mold piece 116 . The first mold 114 is sized and configured to mate with a second mold that forms a cavity 117 that receives the thermoplastic material used to form the center stack shell 12 .

The conductor assembly 40 is disposed in the mold 112, a portion of the conductor 40 extending outside the cavity of the mold 112 when the mold is in a closed state. Mold 112 includes positioning rollers 118 and 120 which are positioned on outer surfaces 122 and 124 of first mold part 114, respectively. The first module 114 includes locating protrusions 126 and 128 extending from an inner surface 130 , while the second module 116 includes cooperating locating members 132 and 134 extending from an inner surface 136 . Locating protrusions 126 , 128 , 132 , and 134 hold conductor 40 in place within mold 112 during the molding process. In this embodiment, the first module further includes positioning protrusions 138 and 140 extending from the inner surface 130 . The mating recess 142 in the second module 116 receives the conductor 40 . The locating protrusions 138 and 140 act with the cooperating recess 142 to position the conductor 40 along the inner surface 136 and the conductor 40 will protrude through the housing 12 after molding.

After the mold 112 is closed, a predetermined thermoplastic material is injected into the mold cavity 117 through the injection port 144 to form the center stack shell 12 . The mold 112 is then opened and the center stack housing 12 is removed. Appropriate connectors are connected to the conductors 40 and the junction box connector plate 28 is bonded to the housing 12 and connected to the integral connector 62 .

The thermoplastic center cluster assembly 10 described above with a thermoplastic housing 12 having at least one molded conductor 40 and an integral junction box reduces the amount of wiring in the instrument panel assembly. In addition, assembly time is reduced and production costs are reduced because of the reduction in the number of wiring and parts.

While the invention has been described in terms of various specific embodiments, it will be understood by those skilled in the art that the invention may be modified within the spirit and scope of the claims.

Claims (33)

1. A central set (10) for an automobile instrument panel assembly, the central set comprising: a thermoplastic housing (12) comprising at least one wall (14, 16, 18); and At least one conductor assembly (40) is molded into at least one wall of the housing. 2. The central stack (10) of claim 1, wherein said at least one conductor assembly (40) extends longitudinally through said at least one housing wall (14, 16, 18). 3. The central stack (10) of claim 1, wherein each conductor assembly (40) comprises a first end and a second end. 4. The central stack (10) of claim 3 further comprising connectors (60) joined to the first and second ends of the conductor assembly (40). 5. The central stack (10) according to claim 4, wherein said connector (60) coupled to said first end of said conductor assembly (40) is located at least partially in at least one of said housings. in the wall. 6. Central stack (10) according to claim 5, wherein said connector (60) joined to said first end of said conductor assembly (40) is molded to said at least one housing wall (14, 16, 18). 7. The central stack (10) of claim 3, wherein the conductor assembly (40) includes a plurality of outlet ends (42-58) configured such that the conductor assembly includes at least one first end portion and a plurality of second end portions, and each second end portion includes a lead-out end. 8. Central stack (10) according to claim 7, wherein each of said outlet ends (42-58) is joined to a connection piece (60). 9. The central cluster (10) according to claim 8, wherein said housing (12) further comprises at least one connector opening (102-108), each said connector opening being sized to Receive connector (60). 10. The center cluster (10) of claim 1, further comprising a junction box (26) coupled to said at least one connector assembly (40), said junction box configured to be coupled to a main instrument panel wiring (34). 11. The central cluster (10) according to claim 1, further comprising a junction box housing (67) molded to said at least one wall (14, 16, 18) in one of. 12. Central cluster (10) according to claim 11, further comprising a connector plate (28) dimensioned to fit into said junction box housing (67). 13. The central cluster (10) of claim 11, further comprising a terminal box cover (68) coupled to said terminal box housing (67). 14. A central set (10) for an automotive instrument panel assembly, the central set comprising: a housing (12) comprising at least one wall (14, 16, 18); and A junction box housing (67) molded into one of said at least one wall of said central stack housing. 15. Central cluster (10) according to claim 14, further comprising a connector plate (28) dimensioned to fit into said junction box housing (67). 16. Central cluster (10) according to claim 14, further comprising a terminal box cover (68) integrated into said terminal box housing (67). 17. Central stack (10) according to claim 14, further comprising at least one conductor assembly (40) molded into at least one wall (14, 16, 18), said at least one conductor assembly longitudinally extending through the at least one wall. 18. The central stack (10) of claim 17, wherein each said conductor assembly (40) comprises a first end and a second end. 19. The central stack (10) of claim 18, further comprising connectors (60) coupled to the first and second ends of the conductor assembly (40). 20. The central stack (10) of claim 17, wherein the conductor assembly (40) comprises a plurality of outlet ends (42-58) configured such that the conductor assembly comprises at least one first end and a plurality of second end portions, and each second end portion includes a lead-out end, and each of the lead-out ends is connected to a connector (60). 21. The central stack (10) of claim 17, further comprising at least one connector opening (102-108), each of said connector openings being sized to receive a bond to said at least one conductor assembly (40) connector (60). 22. A method of manufacturing a central cluster (10) for an instrument panel, the central cluster comprising a housing (12) having at least one wall (14, 16, 18), the method comprising: Provide a mold (112); disposing at least one conductor assembly (40) at least partially in the mold; and Thermoplastic material is loaded into a mold to mold the center stack. 23. The method of claim 22, wherein the mold (112) includes a plurality of positioning protrusions (126, 128) to position each conductor assembly (40) within the mold. 24. The method according to claim 23, wherein at least one of the plurality of positioning protrusions (126, 128) is provided in the mold to position the side surface of the conductor assembly (40) such that the side surface Visible in the body wall (14, 16, 18). 25. The method according to claim 22, wherein at least one conductor assembly (40) comprises a plurality of lead-outs (42-58) configured such that said conductor assembly comprises at least one first end and a plurality of second Two end portions, each second end portion including a lead-out, and disposing at least one conductor assembly at least partially in the mold (112) includes disposing the at least one conductor assembly in the mold such that a portion of each lead-out is located in the mold Outside. 26. A method according to claim 22, wherein a wall (14, 16, 18) of the central stack housing (12) comprises a junction box housing (67). 27. The method of claim 22, further comprising: removing the center stack (10) from the mold (112); and An electrical connector (60) is bonded to each conductor assembly (40) end. 28. A kit (10) for the central assembly of an automobile instrument panel, comprising: comprising a thermoplastic housing (12) molded over at least the walls (14, 16, 18); a junction box housing (67) molded into one of said at least one wall of the housing; and The connector plate (28) is sized to fit in the junction box housing. 29. A kit according to claim 28, wherein said housing (12) further comprises at least one conductor assembly (40) molded into at least one wall (14, 16, 18), said at least one A conductor assembly extends longitudinally across the at least one wall. 30. A kit according to claim 28, wherein said housing (12) further comprises connectors (60) coupled to said conductor assembly (40) first and second ends. 31. A kit according to claim 30, wherein said connector (60) coupled to said first end of said conductor assembly (40) is at least partially located in said at least one part of said housing (12). In one wall (14, 16, 18). 32. A kit according to claim 30, wherein said connector (60) joined to said first end of said conductor assembly (40) is molded to said at least one of said housings (12) in the walls (14, 16, 18). 33. A kit according to claim 28, further comprising at least one automotive system control (24) sized to be at least partially received by said housing (12).

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