# US 7,607,691 B2 · Lost core structural instrument panel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,607,691 B2 - Document ID: US7607691B2 - Status: Granted - Kind: B2 - Application number: 10/928,793 - Filed: 2004-08-27 - Published: 2005-03-03 - Granted: 2009-10-27 - Earliest claimed: 2003-08-27 - Assignees: Mahle International GmbH - Inventors: Paul Arnold; Spero Boutsikaris - Web page: https://patentgrep.com/patent/US7607691B2 ## CPC - B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)} - B29C 33/52: soluble or fusible {(in particular used in injection moulding B29C45/4457)} - B29L 2031/3008: {Instrument panels} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A support structure for an automotive instrument panel includes a single unitary molded article fabricated from a lost core molding process. The support structure includes integrally formed support segments for knee bolsters. A plurality of air passages are formed from hollow cores within different segments of the support structure. ## Claims ### Claim 1 A plastic support structure for an instrument panel comprising: a first segment having a hollow core defining an air passage; a support segment for an instrument panel; and at least one knee bolster support segment, wherein said first segment, said support segment and said at least one knee bolster support segment comprise a single unitary plastic molded article, said at least one knee bolster support segment including a substantially oval cross-section having a wall thickness that varies along a length of the knee bolster support segment. ### Claim 2 (depends on 1) The support structure as recited in claim 1, including a plurality of air passages in communication with said hollow core of said first segment. ### Claim 3 (depends on 1) The support structure as recited in claim 1, wherein said first segment includes a wall thickness, said wall thickness comprising at least two different thicknesses disposed within said first segment. ### Claim 4 (depends on 1) The support structure as recited in claim 1, wherein said oval cross-section comprises a circumferentially variable wall thickness. ### Claim 5 (depends on 1) The support structure as recited in claim 1, including a flange member disposed at opposite ends of said support structure. ### Claim 6 (depends on 5) The support structure as recited in claim 5, wherein said flange member is integrally formed to said support structure. ### Claim 7 (depends on 1) The support structure as recited in claim 1, including a center mount segment comprising a plurality of air passages and a mounting structure. ### Claim 8 (depends on 7) The support structure as recited in claim 7, wherein said center mount segment comprises a continuous portion of said first segment and said knee bolster support segment. ### Claim 9 (depends on 1) The support structure as recited in claim 1, including a steering column mount segment comprising a continuous portion of said support structure. ### Claim 10 (depends on 1) The support structure as recited in claim 1, wherein said support structure comprises a lost core molded article. ### Claim 11 An instrument panel support structure comprising: a center support structure comprising a first plurality of air passages; a first knee bolster support segment extending laterally from said center support structure to a first flange member; and a second knee bolster support structure extending laterally in a direction opposite said first knee bolster support structure to a second flange member, wherein said center support structure and said first and second knee bolster support segments include a common continuous exterior surface; and a plurality of hollow segments forming a structure between a first end adjacent said first flange member and a second end adjacent said second flange member, wherein said center support structure and said first and second knee bolster support segments comprise a single unitary plastic molded article. ### Claim 12 (depends on 11) The support structure as recited in claim 11, wherein said plurality of hollow segments are in communication with said first plurality of air passages. ### Claim 13 (depends on 11) The support structure as recited in claim 11, wherein said first knee bolster support segment and said second knee bolster support segment comprises a substantially oval cross-section. ### Claim 14 An instrument panel support structure comprising: a center support structure comprising a first plurality of air passages; a first knee bolster support segment extending laterally from said center support structure to a first flange member; a second knee bolster support structure extending laterally in a direction opposite said first knee bolster support structure to a second flange member, wherein said center support structure and said first and second knee bolster support segments include a common continuous exterior surface; a plurality of hollow segments forming a structure between a first end adjacent said first flange member and a second end adjacent said second flange member; and a second plurality of air passages disposed on opposite sides of said center support structure. ### Claim 15 An instrument panel support structure comprising: a center support structure comprising a first plurality of air passages; a first knee bolster support segment extending laterally from said center support structure to a first flange member; a second knee bolster support structure extending laterally in a direction opposite said first knee bolster support structure to a second flange member, wherein said center support structure and said first and second knee bolster support segments include a common continuous exterior surface, said first knee bolster support segments and said second knee bolster support structure comprise a substantially oval cross-section include a wall having a thickness varying within said oval cross-section.