The key to the new approach lies in a light-weight hybrid construction, a composite steel (in blue) and plastic (in green) structure. (Photo: Johnson Controls)As with most vehicles these days, this cockpit uses a single cross-car beam as the key component in its structure. It provides the cockpit with stability and also interfaces with the steering column, airbag and instrument panel. Most traditional structures are made of steel, magnesium, aluminum or, in some cases, entirely of plastic, each with specific advantages and disadvantages. The key to the new EcoSpace approach lies in its lightweight hybrid construction - a composite steel and plastic structure - that makes it possible to do away with half of the cross-car beam. Since structural rigidity is required mainly in the steering column area, the engineers used the steel for the driver's side in the form of a tripod. The central component is a third-generation Thyssen Tailored Tube. This is a closed profile tube with load-dependent geometry, to which the steering column can be directly attached. The plastic, consisting of long fiber reinforced polypropylene, comes from Johnson Controls. The plastic is used across the full cockpit width. Air channels, the connection to the airbag and the back of the glove box are integrated directly into the plastic structure. These parts also assume a reinforcing function. The hybrid structure has all the advantages and none of the disadvantages of the traditional material combinations, such as low weight, high integration potential, good structural properties and general applicability. The result of these measures is that there is no need for a one-piece cross-car beam. Tripod structure and steering column connection
