Front Wall Module

Abstract

A front wall module for delimiting a front of a passenger cell in a motor vehicle includes a planar carrier structure which forms a front wall portion where a functional shape for receiving a component is formed in the planar carrier structure and where the planar carrier structure is a cast aluminum structural part.

Claims

1-10. (canceled)

11. A front wall module for delimiting a front of a passenger cell in a motor vehicle, comprising: a planar carrier structure which forms a front wall portion, wherein a first functional shape for receiving a first component is formed in the planar carrier structure and wherein the planar carrier structure is a cast aluminum structural part.

12. The front wall module according to claim 11, wherein the planar carrier structure is a foamed cast aluminum structural part.

13. The front wall module according to claim 11, wherein the planar carrier structure has respective greater wall thicknesses in portions of high expected structural part loading than in portions of low expected structural part loading.

14. The front wall module according to claim 11, wherein the planar carrier structure has reinforcing ribs.

15. The front wall module according to claim 11, wherein the planar carrier structure has a peripheral flange for attaching to a body of the motor vehicle.

16. The front wall module according to claim 11, wherein a bearing block for a foot lever mechanism is integrated into the planar carrier structure.

17. The front wall module according to claim 11, wherein a plastics body is injection-molded onto the planar carrier structure.

18. The front wall module according to claim 17, wherein the plastics body is formed from foamed plastic.

19. The front wall module according to claim 17, wherein a second functional shape is integrated into the plastics body for receiving a second component or wherein the plastics body forms a second functional shape for receiving a second component.

20. The front wall module according to claim 17, wherein the planar carrier structure and/or the plastics body is configured such that the front wall module performs a function of an instrument panel support.

21. A method of forming a front wall module that delimits a front of a passenger cell in a motor vehicle, comprising the step of: forming a planar carrier structure by a casting method, wherein a functional shape for receiving a component is formed in the planar carrier structure and wherein the planar carrier structure is aluminum.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 shows a front view of an exemplary front wall module, and

[0023] FIG. 2 shows a rear view of the front wall module from FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is a schematic illustration showing a front view of an exemplary front wall module 1. Here, the front view shows that side which faces toward the vehicle front in the installed state. FIG. 2 correspondingly shows a schematic rear view of the front wall module 1 shown in FIG. 1.

[0025] The front wall module 1 is formed with a hybrid design and has a carrier structure 10 in the form of a cast aluminum structural part, and also two plastics bodies 20, 30 injection-molded onto the carrier structure 10. The number of the plastics bodies is purely by way of example. there can also be provided only a single plastics body or more than two plastics bodies.

[0026] The front wall module 1 serves for installation in a passenger motor vehicle, with a front wall portion 12 delimiting the passenger compartment toward the front.

[0027] The carrier structure 10 extends over the entire width and height of the front wall module 1 and has a peripheral flange 14. It is at the flange where the attachment to the vehicle body occurs, with the upper flange 14A being attached to a crossmember, the lateral flanges 14B, 14C to the A-pillars and the lower flange 14D to the floor pan.

[0028] The carrier structure 10 is formed as a cast aluminum structural part. It is thereby possible to provide a portion 16 of increased wall thickness in the region of the brake booster, and also to integrate into the carrier structure 10 a bearing block 18 which serves for receiving a foot lever mechanism.

[0029] The carrier structure 10 has furthermore a functional shape 19 in the form of a pot-shaped depression in which there can subsequently be received a headup display unit. Such deep formations can be produced without problem in the cast carrier structure and would not be able to be realized with a deep-drawn sheet metal structural part.

[0030] On the rear side of the front wall module 1, a first plastics body 20 is injection-molded onto the carrier structure 10. The plastics body 20 forms a functional shape in the form of a supporting structure for the instrument panel of the vehicle. For additional acoustic installation, the plastics body 20 can be formed for example as a foamed plastics body. On the front passenger side there is injection-molded a further plastics body 30 which, by way of a main body 32, forms a glovebox as functional shape. Projecting laterally away from the main body there is arranged a web 34 which forms a supporting structure for the instrument panel.

[0031] The front wall module 1 thus performs functions of the instrument panel support or tube and of the bearing block for the foot lever mechanism. This dispenses with assembly steps and the production of individual structural parts of the front wall, of the instrument panel support and of the bearing block of the foot lever mechanism.

LIST OF REFERENCE CHARACTERS

[0032] 1 Front wall module

[0033] 10 Carrier structure

[0034] 12 Front wall portion

[0035] 14 Peripheral flange

[0036] 14A, B, C, D Flanges

[0037] 16 Portion

[0038] 18 Bearing block of foot lever mechanism

[0039] 19 Functional shape

[0040] 20 Plastics body

[0041] 30 Plastics body

[0042] 32 Main body

[0043] 34 Web