Plastic cross beam assembly for a vehicle having integrally formed duct connectors

A vehicle comprising:

• an automobile body including a pair of opposed door pillars;
• a heating ventilation or air conditioning system affixed to the automobile body;
• a plastic cross car beam assembly extending between the pair of opposed door pillars in fluid communication with the heating ventilation or air conditioning system, the plastic cross car beam assembly comprising a first panel having at least one channel formed in the inner surface of the panel, a second panel mounted adjacent the first panel having at least one channel formed in the inner surface of the second panel and at least one opening defined in the outer surface of the second panel in fluid communication with the at least one channel of the second panel, at least one air flow passage defined by the at least one channel in the first and second panels in fluid communication with the heating ventilation or air conditioning system, and a third panel mounted adjacent the second panel including at least one tubular male connecting projection integrally formed into an outer surface of the third panel having an outer periphery extending away from the outer surface of the third panel terminating at a distal end and an opening formed in the distal end extending therethrough in fluid communication with the at least one opening in the second panel;
• and
• at least one air feeder tube in fluid communication with the plastic cross car beam assembly to supply air to a passenger compartment, the at least one air feeder tube having a proximate end in communication with a vent in the passenger compartment and a distal end including a tubular female connector sized to telescopically fit over the at least one tubular male connecting projection of the cross car beam assembly to receive air from the heating ventilation or air conditioning system.

A cross car beam assembly for interfacing with an instrument panel having a plurality of air vent ducts to receive air from a heating ventilation or air conditioning system, the assembly comprising:

• a first plastic panel having an outer surface and an inner structural surface, wherein the inner surface comprises a first sealing area disposed about the outer periphery of the first panel and an intermediate sealing area extending the length of the first panel to define at least one channel extending the length of the first panel;
• a second plastic panel mounted adjacent the first panel, the second panel including an inner structural surface having a second sealing area disposed about the outer periphery of the second panel and an intermediate sealing area extending the length of the second panel to define at least one channel extending the length of the second panel and an outer surface including at least one opening defined therethrough in fluid communication with the at least one channel of the second panel;
• at least one air flow passage defined by the at least one channel in the first panel and the at least one channel in the second panel when the inner surface of the first panel is mounted to the inner surface of the second panel;
• a third plastic panel mounted adjacent the second panel, the third panel including an inner structural surface securable to the outer surface of the second panel and an outer surface;
• at least one tubular male connecting projection integrally formed into the outer surface of the third panel to supply air to the ducts in the instrument panel assembly, wherein the at least one tubular male connecting portion of the third panel is mounted adjacent the at least one opening in the second panel and includes an outer periphery extending away from the outer surface of the third panel terminating at a distal end and an opening formed in the distal end extending therethrough in fluid communication with the at least one opening in the second panel;
• and
• at least one air feeder tube corresponding to the at least one male connecting member to supply air to the air ducts in the instrument panel assembly, the at least one air feeder tube having a proximate end in communication with the vent in the instrument panel assembly and a distal end including a tubular female connector sized to telescopically fit over the at least one tubular male connecting projection of the cross car beam assembly to receive air from the heating ventilation or air conditioning system.