Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of cross-car beam. More particularly the present disclosure relates to an improved hybrid cross-car beam (CCB) assembly for vehicles, which withstands the load of the instrument panel that is mounted thereon and is also capable of absorbing impact and restricting separation of the CCB from a BiW of the vehicle in an event of a crash.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] An instrument panel (IP) is the largest inner trim part of a vehicle, which is directly visible to the passengers and has not only beauty and function requirements but also noise/vibration and safety requests. A cross-car beam (CCB) assembly acts as instrument panel support that integrates a cross-car structure, steering column, air conditioning module, airbag system, electrical components, plastic enclosure, and the likes, into one beam structure. Moreover, the CCB assembly plays a vital role in accomodating and securing multiple interior modules of the vehicle. Further, any vibration and noise on the dashboard can be directly transferred from the CCB to a Body in White (BiW) parts of the vehicle.
[0004] Existing CCBs include multiple tubes (braces) fitted with one another to form a CCB structure. The tubes have a hollow construction and extend between the frame uprights on each side of the vehicle, which are secured to the vehicle frame using a support mounting bracket on each side of the CCB structure. The tubes are conventionally secured with each other and to the bracket by adhesive and/or a ratchet grip. The adhesive is supplied in a capsule which is ruptured when the tube is fitted with another tube or with the bracket. The existing CCBs also have a hybrid/injected design made of metal tubes and plastic members to make them lightweight. In such assemblies, metal tubes (braces) are used, where the longitudinal edges of the latter section are connected in one section to a structural element of plastic. The connection between the metal tubes and the structural element of plastic is by an adhesive bond
[0005] The existing hybrid/injected CCB assemblies are capable of withstanding IP load, however, in an event of a crash or impact on the vehicle, the existing CCB structures fail to absorb the force of impact and fall or separate from the vehicle frame, which is highly undesirable. Besides, the separation of the CCB structure also affects the modules such as the steering column, air conditioning module and airbag system, and electrical components, which are supported over the CCB structure.
[0006] There is, therefore, a need to overcome the drawbacks, limitations, and shortcomings associated with existing CCB assemblies, and provide an improved hybrid cross-car beam (CCB) assembly for vehicles, which withstands a load of instrument panel being mounted thereon and is also capable of absorbing impact and restricting separation of the CCB structure from the BiW of the vehicle in an event of a crash.

OBJECTS OF THE PRESENT DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy are as listed hereinbelow.
[0008] It is an object of the present disclosure to restrict the separation of CCB assembly from the vehicle frame in an event of impact/crash.
[0009] It is an object of the present disclosure to provide an impact/shock absorption capability in existing CCB assemblies.
[0010] It is an object of the present disclosure to provide a lightweight yet strong cross-car beam (CCB) assembly that accommodates instrument panels and other modules thereon.
[0011] It is an object of the present disclosure to provide an improved fusible fixation link that coaxially connects and locks tubes (braces) of a CCB structure and also allows displacement of one tube in/on another tube in an event of a vehicular crash, in order to absorb the impact of the crash.
[0012] It is an object of the present disclosure to provide an improved hybrid cross-car beam (CCB) assembly for vehicles, which can withstand the load of the instrument panel being mounted thereon and can also absorb impact and restrict separation of the CCB structure from the BiW of the vehicle in an event of a crash.

SUMMARY
[0013] The present disclosure relates to the field of cross-car beams. More particularly the present disclosure relates to an improved hybrid cross-car beam (CCB) assembly for vehicles, which withstands the load of the instrument panel that is mounted thereon and is also capable of absorbing impact and restricting separation of the CCB from a BiW of the vehicle in an event of a crash.
[0014] An aspect of the present disclosure pertains to a cross-car beam assembly for vehicle. The CCB assembly comprises at least two hollow metallic tubes (braces or members) coaxially fitted with each other, such that a portion of one of the two tubes overlaps a portion of the other tube. The extreme ends of the CCB structure are further fitted to a body-in-white (BiW) of the vehicle or vehicle frame using mounting brackets. The outer diameter of a first tube (inner tube) may be equal or smaller to an inner diameter of the second tube (outer tube), which may allow coaxial fitting and overlapping of one end of the outer tube over the end of the inner tube. The CCB assembly may further include additional bended tube structures and frames extending from the coaxially-fitted tube structure to form a space for accommodating and fitting the instrument panel and other modules of the vehicle thereon. These modules may include steering column, air conditioning module, airbag system, electrical components, plastic enclosure, and the likes, fitted into the cross-car beam structure.
[0015] The CCB assembly further comprises a fusible fixation link configured between the overlapped portions of the two tubes to lock the corresponding members, which allows the assembly to withstand the load of the instrument panels. The fusible fixation link is adapted to facilitate displacement of a length of one of the two tubes in/on the other tube upon application of a predetermined force on the vehicle in an event of an impact. Accordingly, the displacement of tubes results in absorption of the impact, which also restricts separation of the CCB assembly from the BiW of the vehicle. Besides, the extremities of the tubes (opposite to the fusible fixation link) are overmolded in a plastic portion that is further coupled to the BiW of the vehicle, thereby providing a hybrid CCB assembly that is light weight yet strong.
[0016] In an aspect, a first set of holes may be provided at one end of the outer tube and a second set of holes may be provided at one end of the inner tube such that the second set of holes comes in line with the first set of holes upon overlapping of the outer tube and the inner tube. Further, a set of pins (fusible fixation link) may be configured through the corresponding holes of the overlapped portion of the tubes to lock them, such that upon application of the predetermined force on the vehicle, the set of pins may break and facilitate displacement of a length of the inner tube within the outer tube, which may result in absorption of the impact and also restricts separation of the CCB assembly from the BiW of the vehicle.
[0017] In another aspect, the fusible fixation link may involve a set of apertures configured at one end of the inner tube; and a set of bending on an inner surface of one end of the outer tube. The set of bending may be engaged with the set of apertures of the first member to lock the first member with the second member, such that upon application of the predetermined force on the vehicle, the set of bending disengages with the set of apertures to facilitate displacement of a length of the first member within the second member, which may result in absorption of the impact and also restrict separation of the CCB assembly from the BiW of the vehicle.
[0018] In yet another aspect, stampings may be used as the fusible fixation link, wherein the overlapped portion of the tubes may be stamped at predefined positions to lock the tubes. However, upon application of the predetermined force on the vehicle, the corresponding stampings of the tubes may disengage to facilitate displacement of a length of the first member within the second member, which results in absorption of the impact.
[0019] Thus, the present invention provides an improved hybrid cross-car beam (CCB) assembly that is lightweight yet strong, which withstands a load of instrument panel being mounted thereon and is also capable of absorbing impact and restricting separation of the CCB structure from the BiW of the vehicle in an event of a crash.
[0020] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0022] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0023] FIG. 1A illustrates an exemplary view of a first embodiment of the proposed CCB assembly having metal pins as the fusible fixation link, in accordance with an embodiment of the present disclosure.
[0024] FIG. 1B illustrates exemplary views of the tubes of FIG. 1A fitted with the metal pins.
[0025] FIG. 2A illustrates an exemplary view of a second embodiment of the proposed CCB assembly having bendings and apertures configuration as the fusible fixation link, in accordance with an embodiment of the present disclosure.
[0026] FIG. 2B illustrates exemplary views of the tubes of FIG. 2A fitted with the bendings.
[0027] FIG. 3 illustrates an exemplary view of a third embodiment of the proposed CCB assembly having stampings as the fusible fixation link on the tubes, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0028] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0029] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0030] The present disclosure relates to the field of cross-car beams. More particularly the present disclosure relates to an improved hybrid cross-car beam (CCB) assembly for vehicles, which withstands the load of the instrument panel that is mounted thereon and is also capable of absorbing impact and restricting separation of the CCB from a BiW of the vehicle in an event of a crash.
[0031] According to an aspect, the present disclosure elaborates upon a cross-car beam (CCB) assembly for a vehicle. The CCB assembly includes at least two members coaxially configured with each other, where a portion of one member overlaps a portion of the other member. Further, a fusible fixation link can be configured between the overlapped portion of the two members to lock the corresponding members. Further, the fusible fixation link can be adapted to facilitate displacement of a length of one of the two members in/on the other member upon application of a predetermined force on the vehicle in an event of an impact, which can result in absorption of the impact and restricts separation of the CCB assembly from a body-in-white (BiW) of the vehicle.
[0032] In an embodiment, the at least two members can include a first member and a second member. A first end of the first member of the at least two members can be coupled with the BiW of the vehicle. In another aspect, a first end of the first member of the at least two members can be configured with a third member preferably made from plastic and a first end of the second member of the at least two members can overlap a second end of the first member. The fusible fixation link can be configured between the overlapped second end of the first member and the first end of the second member.
[0033] In an embodiment, the fusible fixation link comprises: a first set of holes at the second end of the first member; a second set of holes at the first end of the second member, wherein the second set of holes comes in line with the first set of holes upon overlapping the second end of the first member and the first end of the second member; and a set of pins configured through the corresponding holes of the overlapped portion of the first member and the second member to lock the first member with the second member, such that upon application of the predetermined force on the vehicle, the set of pins is adapted to break and facilitate displacement of a length of the first member within the second member, which results in absorption of the impact and restricts separation of the CCB assembly from the BiW of the vehicle.
[0034] In an embodiment, the set of pins can include two pins configured preferably perpendicular to each other.
[0035] In an embodiment, the fusible fixation link can include a set of apertures configured at the second end of the first member; and a set of bending on an inner surface of the first end of the second member. The set of bending can be engaged with the set of apertures of the first member to lock the first member with the second member, such that upon application of the predetermined force on the vehicle, the set of bending can disengage from the set of apertures to facilitate displacement of a length of the first member within the second member, which can result in absorption of the impact and restrict separation of the CCB assembly from the BiW of the vehicle.
[0036] In an embodiment, the overlapped portion of the second end of the first member and the first end of the second member can be stamped at predefined positions to lock the first member with the second member, such that upon application of the predetermined force on the vehicle, the corresponding stampings of the first member and the second member can disengage to facilitate displacement of a length of the first member within the second member, which can result in absorption of the impact.
[0037] In an embodiment, the first end of the first member can be overmolded in third portion preferably made from plastic that can be coupled to the BiW of the vehicle.
[0038] In an embodiment, upon application of the predetermined force on the vehicle in the event of a side impact, the first member can move axially towards the second member and along a longitudinal axis of the second member, such that a predefined length of first member slides or displaces within the second member, which can result in absorption of the impact and can restrict separation of the CCB assembly from the BiW of the vehicle.
[0039] In an embodiment, the at least two members of the CCB assembly can be configured to accommodate an instrument panel of the vehicle thereon and withstand loading of the instrument panel.
[0040] In an embodiment, the at least two members can be hollow cylindrical members made of metal.
[0041] Referring to FIGs. 1A to 3, the proposed CCB assembly 100 can include two or more members 102, 104 (also referred to as tubes or braces, herein) coaxially fitted with each other, such that a portion of one members 102, 104 overlaps a portion of the other member. The extreme ends of the CCB structure 100 can be further fitted to a body-in-white (BiW) of the vehicle or vehicle frame using mounting brackets 106. In an exemplary embodiment, the members 102, 104 can be hollow cylindrical metallic tubes. For instance, as shown, the members can include a first member 102 (also referred to as first tube 102 or inner tube 102, hereinafter) and a second member 104 (also referred to as second tube 104 or outer tube 104, hereinafter), where a first end of the first tube 102 can be configured with the BiWof the vehicle . In another aspect first end of first tube 102 can be configured with third tube 106 and a first end of the second tube 104 overlaps a second end of the first member 102.
[0042] In an embodiment, the outer diameter of the first tube 102 (inner tube) can be equal or smaller to the inner diameter of the second tube 104 (outer tube), which can allow coaxial fitting and overlapping of one end of the outer tube 104 over the adjacent end of the inner tube 102. In another embodiment, the CCB assembly 100 can further include additional bent tube structures and frames of predefined shape and size, extending from the coaxially-fitted tube structure to form a space for accommodating and fitting the instrument panel and other modules of the vehicle thereon. These modules can include but are limited to a steering column, air conditioning module, airbag system, electrical components, and plastic enclosure, fitted into the cross-car beam structure.
[0043] The CCB assembly 100 can further include a fusible fixation link (108, 202, 302) configured between the overlapped portions of the two tubes 102, 104, which locks the corresponding tubes 102, 104 and also allows the CCB assembly 100 to withstand the load of the instrument panels. The fusible fixation link can be adapted to facilitate displacement of a length of one of the two tubes 102 in/on the other tube 104 upon application of a predetermined force on the vehicle in an event of an impact on the vehicle. In an implementation, upon application of a predetermined force on the vehicle in the event of a side impact/crash, the fusible fixation link breaks/fuses thereby the first tube 102 can move axially towards the second tube 104 and along a longitudinal axis of the second tube 104, such that a predefined length of first tube 102 can slide or displace within the second tube 104. Accordingly, the displacement of tubes 102, 104 results in absorption of the impact, which also restricts the separation of the CCB assembly 100 from the BiW of the vehicle. Besides, the extremities of the tubes (opposite to the fusible fixation link) can be overmolded in a third tube 106 prefarably madde from plastic that is further coupled to the BiW of the vehicle, thereby providing a hybrid CCB assembly 100 that is lightweight yet strong.
[0044] In an embodiment, as illustrated in FIGs, 1A and 1B, the fusible fixation link can involve a first set of holes provided at one end of the outer tube 104 and a second set of holes provided at one end of the inner tube 102 such that the second set of holes comes in line with the first set of holes upon overlapping of the outer tube 104 and the inner tube 102. Further, the fusible fixation link can be a set of pins 108 that can be configured through the corresponding holes of the overlapped portion of the tubes 102, 104 to lock them, such that upon application of the predetermined force on the vehicle, the set of pins 108 can break and facilitate displacement of a length of the inner tube 102 within the outer tube 104, which can result in absorption of the impact and can also restrict separation of the CCB assembly 100 from the BiW of the vehicle in the event of an impact.
[0045] In an exemplary embodiment, two deformable or breakable metal pins 108 can be configured perpendicular to each other through the holes of the overlapped portions of the tubes 102, 104. These metal pins 108 can be adapted to break or deform upon application of the predetermined force by one of the tubes 102, 104 in an event of an impact on the vehicle.
[0046] In another embodiment, as illustrated in FIGs. 2A and 2B, the fusible fixation link can involve a set of apertures configured at one end of the inner tube 102; and a set of bending 202 on an inner surface of one end of the outer tube. The set of bending can be engaged with the set of apertures of the first tube 102 to lock the first tube 102 with the second tube 104, such that upon application of the predetermined force on the vehicle, the set of bending 202 can disengage from the set of apertures to facilitate displacement of a length of the first tube 102 within the second tube 104, which can result in absorption of the impact and can also restrict separation of the CCB assembly 100 from the BiW of the vehicle.
[0047] In an exemplary embodiment, three bending 202 can be provided circumferentially around the second tube 104 making a predefined angle from an inner surface of the second tube 104, which can engage with three apertures of the first tube 102, thereby locking the tubes 102, 104 for normal working conditions. However, the bending 202 can be configured such that upon application of the predetermined force by one of the tubes 102 on the other 104 in an event of an impact on the vehicle, the set of bending 202 can disengage from the set of apertures to facilitate displacement of a length of the first tube 102 within the second tube 104.
[0048] In yet another aspect, as illustrated in FIG. 3, stampings 302 can be used as the fusible fixation link. The overlapped portion of the first tube 102 and second tube 104 can be stamped circumferentially at predefined positions around the overlapped tubes to lock the tubes. However, upon application of the predetermined force on the vehicle, the corresponding stampings 302 of the tubes 102, 104 can disengage to facilitate displacement of a length of the first tube 102 within the second tube 104, which can result in absorption of the impact.
[0049] Thus, the present invention provides an improved hybrid cross-car beam (CCB) assembly that is lightweight yet strong, which can withstand a load of instrument panel being mounted thereon, and can also absorb impact and restrict separation of the CCB structure from the BiW of the vehicle in an event of a crash or impact on the vehicle
[0050] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0051] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0052] The proposed invention restricts the separation of CCB assembly from the vehicle frame in an event of impact/crash.
[0053] The proposed invention provides an impact/shock absorption capability in existing CCB assemblies.
[0054] The proposed invention provides a lightweight yet strong cross-car beam (CCB) assembly that accommodates instrument panels and other modules thereon.
[0055] The proposed invention provides an improved fusible fixation link that coaxially connects and locks tubes (braces) of a CCB structure and also allows displacement of one tube in/on another tube in an event of a vehicular crash, in order to absorb the impact of the crash.
[0056] The proposed invention provides an improved hybrid cross-car beam (CCB) assembly for vehicles, which can withstand the load of the instrument panel being mounted thereon and can also absorb impact and restrict separation of the CCB structure from the BiW of the vehicle in an event of a crash.
, Claims:1. A cross-car beam assembly (100) for a vehicle, the cross-car beam assembly (100) comprising:
at least two members (102, 104) coaxially arranged with each other, wherein a portion of one of the member (102, 104) overlaps a portion of the other member (104, 102); and
a fusible fixation link (108, 202, 302) arranged in the overlapped portion of the two members (102, 104) to lock the corresponding members (102, 104), wherein the fusible fixation link (108, 202, 302) is adapted to facilitate displacement of a length of one of the coaxially member (102, 104) in/on the other member (104, 102) upon application of a predetermined force on the vehicle in an event of an impact, which results in absorption of the impact.

2. The cross-car beam assembly (100) as claimed in claim 1, wherein a first end of a first member (102) of the at least two members (102, 104) is coupled with the body in white of the vehicle or with a third member (106) and a first end of a second member (104) of the at least two member (102, 104) overlaps a second end of the first member (102), and wherein the fusible fixation link (108, 202, 302) is arranged in the overlapped second end of the first member (102) and the first end of the second member (104).

3. The cross-car beam assembly (100) as claimed in claim 2, wherein the fusible fixation link comprises:
a first set of holes at the second end of the first member (102);
a second set of holes at the first end of the second member (104), wherein the second set of holes comes in line with the first set of holes upon overlapping the second end of the first member (102) and the first end of the second member (104); and
a pin (108) configured through the corresponding holes of the overlapped portion of the first member (102) and the second member (104) to lock the first member (102) with the second member (104), such that upon application of the predetermined force on the vehicle, the pin (108) is adapted to break and facilitate displacement of a length of the first member (102) within the second member (104).

4. The cross-car beam assembly (100) as claimed in claim 3, wherein the pin (108) comprises two pins (108) configured substantially perpendicular to each other.

5. The cross-car beam assembly (100) as claimed in claim 2, wherein the fusible fixation link comprises:
a set of apertures configured at the second end of the first member (102); and
a set of bending (202) on an inner surface of the first end of the second member (104), wherein the set of bending (202) is engaged with the set of apertures of the first member (102) to lock the first member (102) with the second member (104), such that upon application of the predetermined force on the vehicle, the set of bending (202) disengages from the set of apertures to facilitate displacement of a length of the first member (102) within the second member (104).

6. The cross-car beam assembly (100) as claimed in claim 2, wherein the overlapped portion of the second end of the first member (102) and the first end of the second member (104) are stamped at predefined positions to lock the first member (102) with the second member (104), such that upon application of the predetermined force on the vehicle, the corresponding stampings (302) of the first member (102) and the second member (104) disengage to facilitate displacement of a length of the first member (102) within the second member (104).

7. The cross-car beam assembly (100) as claimed in claim 2, wherein the first end of the first member (102) is attached to the third member (106) which is made of plastic material, wherein the first end of third member (106) is coupled to the BiW of the vehicle.

8. The cross-car beam assembly (100) as claimed in claim 2, wherein upon application of the predetermined force on the vehicle in the event of the impact, the first member (102) moves axially towards the second member (104) and along a longitudinal axis of the second member (104), such that a predefined length of first member (102) slides or displaces within the second member (104).

9. The cross-car beam assembly (100) as claimed in claim 1, wherein the at least two members (102, 104) of the CCB assembly (100) are configured to accommodate an instrument panel of the vehicle thereon and withstand loading of the instrument panel.

10. The cross-car beam assembly (100) as claimed in claim 1, wherein the at least two members (102, 104) are hollow cylindrical members (102, 104) made of metal.