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The increase in instrument panel design and functional performance requirements has resulted in a variety of structural architectures that have been utilized in different passenger vehicles, vans, and light trucks. Each architecture can be designed and engineered to meet corporate and federal requirements using different levels of integration, functionality consolidation, and assembly simplification. The present paper reviews three basic IP design architectures, i.e., traditional, hybrid, and structural, and discusses the performance requirement-functionality matrix in each case. Emphasis is given at explaining the role components play in the different architectures, defining their contribution to static, dynamic and crash performance and their relation to the overall assembly process and sequence. Performance and functionality requirements are linked to basic material characteristics that guide material selection for achieving design targets.

The opportunity for composites in engine closure systems such as valve covers, oil pans, and timing belt covers is expanding rapidly. The primary driving forces are lighter weight finished components, integrated designs, improved isolation of engine noise, improved materials systems, and matured manufacturing processes for composite materials. Thermoset-based composite materials, particularly those based on high-temperature resistant epoxy vinyl ester matrices, offer improved performance with respect to thermoplastic and thermoset polyester-based composites and can be manufactured using different processing methods. This paper presents the current state-of-the-art design, engineering and optimization techniques for engine closure systems. The performance requirements of different systems such as valve covers and oil pans are explained in detail. Techniques for long-term structural stiffness evaluation, vibration performance assessment and noise transmission estimation are described.

Structural instrument panels are an excellent alternative to traditional constructions since they can provide substantial part consolidation, weight reduction, tool and cost savings, and manufacturing and assembly simplification. In structural panels, the main energy absorbing element for decelerating an unrestrained occupant is the plastic integrated retainer-structural duct. The role of the components in the instrument panel needs to be clearly understood for adequately engineering the system and properly selecting the polymeric material for optimum system performance in the different operating environments. The present paper discusses the performance of the structural instrument panel, the engineering and design requirements, and provides guidelines for selection of materials.