DESC:FIELD OF INVENTION

The present invention relates to an important structural component, i.e. a cross-car beam (CCB) of the automotive vehicle bodies. In particular, the present invention relates to a CCB with local brackets in automotive vehicle bodies. More particularly, the present invention relates to a CCB made with light-weight local steel brackets in automotive vehicle bodies.

BACKGROUND OF THE INVENTION

In today’s cost-conscious automotive sector, the vehicle pricing is an important factor. Any cost-reduction is based on substantial weight optimization of all structural parts, either by reducing weights of component by optimization of design or by substituting the material/s used for manufacturing the same.

Accordingly, a lot of effort is spent for reducing the weight of automobile to improve the fuel economy and performance thereof. In interior trims, the cross-car beam (CCB) plays a major role in reducing weight of an automobile. This cross-car beam is used to support some of the components of the instrument panel (IP) system, such as steering column; heating, ventilation, and air-conditioning (HVAC), fuse box, cable harness, instrument panel, gear shifter unit etc. CCB imparts a high torsional rigidity and enhanced crash performance of to the IP system and also absorbs any impact energy during a crash.

PRIOR ART

US publication no. US 2011 0215614 A1 entitled- “Lightweight cross-car beam and method of constructing a structural member” discloses a cross car beam or other elongated structural member including a series of walled open-ended sections fixed end to end in a linear array by having ends joined to respective sides of a series of interposed junction plates. The junction plates may have locator features formed thereon to properly position the respective ends of adjacent sections and to be located in a welding fixture.

US Patent No. US 7216927 B2 entitled- “Lightweight hybrid tubular/casting instrument panel beam” discloses an instrument panel beam including an elongated main member having a bent tubular configuration, and a plurality of structural supports connected to the member. The beam is formed of a lightweight material, such as a magnesium or aluminum alloy. The beam is preferably constructed utilizing a die-cast process, wherein at least a portion of the member is over molded by each support so as to cooperatively form a soldered region there between.

None of the prior art references describe the constructional features of the present invention which are disclosed in the following.

DISADVANTAGES WITH THE PRIOR ART

The major disadvantages with the above prior art and the presently available CCBs are discussed in the following in more detail:

The trend for low-weight construction of automobiles has led to attempts to use high pressure die cast aluminum or magnesium for the cross-car beam, but these are normally more expensive than steel and not sufficiently lighter to justify their higher costs.

The instrument panel cross-car beam on most vehicles is constructed of metal and requires a large number of welds. As a result, these beams are relatively heavy.

Aluminum or magnesium can replace steel to obtain a low-weight construction, but these are very expensive materials for mass-produced vehicles.
Magnesium alloy die-cast CCB are quite light-weight (1.8 g/cm3) than either aluminium (2.7 g/cm3) or steel (7.8 g/cm3). Aluminum CCBs also have packaging problems, forming constraints as well as these are more challenging to bond than steel CCBs.

Plastic CCBs still lack the necessary stiffness to satisfy noise, vibration and handling (NVH) criteria. There are still many other manufacturing and cost constraints with all above materials.

Therefore, there is felt an existing need for manufacturing a low-weight and low-cost CCB by setting specific weight and cost-optimization targets by using steel material, as compared to a full CCB by suitably meeting the performance requirements under the stipulated crash and durability tests.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide a low-cost cross-bar beam for automotive vehicles.

Another object of the present invention is to provide a cross-bar beam with local brackets for automotive vehicles.

Still another object of the present invention is to provide a weight-optimized cross-bar beam with local steel brackets for automotive vehicles.

Yet another object of the present invention is to provide a cross-bar beam with local steel brackets with proper mount for sub-assemblies and body wiring harness routine for automotive vehicles.
A further object of the present invention is to provide a cross-bar beam with local steel brackets, satisfying the performance targets of automotive vehicles.

These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with a first embodiment of the present invention, there is provided a cross car beam with local brackets in automotive vehicles, wherein the cross car beam is configured as a low-weight sub-assembly by using the steering column mounting brackets of box section.

Typically, the local brackets comprise:

• dash bracket;

• upper steering column support bracket;

• a lower steering column support bracket welded to the upper steering column support bracket;

• a steering column bracket for mounting steering column thereon;

• a plurality of IP mounting brackets for fixing sub-parts of IP cluster;

• a dash panel cross member;

• a bracket for accessories, such as a music system;

• at least two tubes for welding gear shifter unit mounting bracket and IP mounting bracket thereon, the tubes being welded between the dash panel cross member and the vehicle floor;

• a bracket for welding the tubes to the vehicle floor;

wherein the steering column mounting brackets are welded directly in the dash panel cross member; and the steering mounting bracket and the steering column bracket are in turn welded to the upper steering column mounting bracket.

Typically, the cross car beam is made of steel and equipped with the tubes having a profile suitable for mounting the gear shifter unit mounting bracket and the IP mounting bracket thereon.

Typically, the upper steering column support bracket welded to the lower steering column support bracket to configure the box section as a hollow section to reduce the weight of the cross car beam.

Typically, the hollow section reduces the overall weight of the cross car beam in a range of 55-65% with respect to the existing cross car beam.

Typically, the gear shifter unit mounting bracket is welded on the tubes.

Typically, the IP mounting bracket is welded on one of the tubes.

Typically, the bracket for mounting accessories is welded between the tubes.

In accordance with a second embodiment of the present invention, there is provided a cross car beam with local brackets in automotive vehicles, the local brackets comprising:

• a dash bracket;

• an upper steering column support bracket;

• a lower steering column support bracket welded to the upper steering column support bracket to configure the box section;
• a steering column bracket for mounting steering column thereon;

• IP mounting brackets for fixing sub-parts of IP cluster; the bracket welded on the dash bracket;

• a dash panel cross member;

• at least two tubes welded between the dash panel cross member and the vehicle floor; and the cross member welded between the lower steering column support bracket and the tube;

• a bracket for accessories welded between the tubes;

• a gear shifter unit mounting bracket;

• an IP mounting bracket; and

• a bracket for welding the tubes to the vehicle floor;

wherein the tubes are configured with a profile suitable for mounting the gear shifter unit mounting bracket and the IP mounting bracket thereon; and the steering column mounting brackets are welded directly in the cross member.

Typically, the local brackets are made of steel hollow sections of material thicknesses optimized to reduce the overall weight of the cross car beam in the range of 50-70%, preferably 55-65% with respect to the existing cross car beams.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with respect to the accompanying drawings, which include:

Figure 1 shows a perspective view of cross-car beam (CCB) with local brackets configured in accordance with the present invention.
Figure 2 shows a top view of CCB of Fig. 1 marked with the section lines A-A, B-B and C-C are respectively.

Figure 3 shows a transverse cross-sectional view of CCB along the section line A-A of Fig. 2.

Figure 4 shows a longitudinal cross-sectional view along the section line B-B of Fig. 2.

Figure 5 shows a cross-sectional view along section line C-C of Fig. 2.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Figure 1 shows a perspective view of cross-car beam (CCB) with local steel bracket configured in accordance with the present invention. The steel used has sufficient material thickness to satisfy NVH criteria. The bracket carries impact loading from the steering column and gear shift lever (GSL) unit. It also carries the static loading of the steering column, wheel assembly and instrument panel (IP) assembly. However, here the connecting tube between A-pillar panels is successfully eliminated. The bracket includes dash bracket 02, upper steering column mounting bracket 04, lower steering column mounting bracket 06 made of box section having a structurally stronger section for stiffening the steering column assembly. The brackets 04, 06 are directly welded on the dash bracket 02 and this unit is then welded in panel cross member (not shown). The thickness of these brackets 02, 04 and 06 could be selected according to the vehicle specification, e.g. as per its requirement during modal analysis, strength analysis etc. Other brackets, i.e. IP mounting brackets 08, 10, and 12 for fitting IP sub-parts can be welded directly to these brackets 04, 06 as per the requirement. This bracket 14 is welded between two tubes 16 which are mounted on the dash panel cross member and cabin floor (not shown) respectively. This bracket 14 maintains the geometrical constraint. Another bracket 18 is provided for mounting the music systems. The tubes 16 are also welded to another bracket 20 for mounting the gear shifter unit and to the IP mounting brackets 22 on which a bracket 24 is also welded to maintain the geometrical constraint. Additional brackets can also be added as per requirement, e.g. HVAC mounting brackets, switches etc.

Figure 2 shows a top view of CCB of Fig. 1, in which section lines A-A, B-B and C-C are respectively marked for further illustration of the characteristic constructional features of the present invention.

Figure 3 shows a transverse cross-sectional view of CCB along the section line A-A of Fig. 2 and depicting the profile features of the brackets 04, 06 thereof.

Figure 4 shows a longitudinal cross-sectional view with steering column assembly along the section line B-B of Fig. 2 and depicting sectional view of the brackets 02, 04, 06 and 08.

Figure 5 shows a cross-sectional view along section line C-C of Fig. 2 and depicting the tubes 16 welded with the bracket 20 for mounting the gear shifter unit (not shown).

The main function of the cross-car beam (CCB) is to support the steering column and gear shifter unit (when not packaged in the floor) and to provide mountings for instrument panel (IP), to bear weight of all electronic components like IP cluster, radio, switches, IP parts.

However, it uses local brackets in comparison to the conventional CCBs. The main object and advantage of the present invention is to make a light-weight CCB as compared to the conventional CCBs, which is also cost-effective in the terms of manufacturing, packaging, material cost and assembly costs thereof. A more detailed description is provided hereinbelow.

Therefore, the present invention comprises an optimized low-weight configuration using local brackets (weight 3.5 Kg), which acts as an alternative to conventional cross car beam (8 to 10 kg) to support the steering column and gear shifter unit and thereby reducing weight by 33% and cost by Rs 180/part.

The present invention uses steel material with sufficient structural stiffness to satisfy the noise, vibrations and harshness (NVH) criteria. This steel bracket bears any impact loading of the steering column; cable type gear, shift and select arrangement (GSL unit). It also bears the static loading of the steering column and wheel assembly and instrument panel (IP) assembly.

Although, local brackets are used as compared to conventional cross-car beam, they do not adversely affect any of the functions of vehicle CCB which supports steering column, gear shifter unit and provides mountings for instrument panel, holding weight of all electronic components like IP cluster, radio, switches, other IP parts etc.).

These brackets still satisfy all the statutory performance criteria during crash and durability tests, but with added advantages of weight optimization, cost-reduction, ease of assembly, which reduces the overall weight and cost of the vehicle.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

• Reduces time due to easy packaging and assembly on assembly line.

• Easy to operate and simple in construction and assembly.

• Reduces no. of parts/components, requires no additional component.

• Optimized local brackets provide a weight-reduction of almost 33%.

• Substantial cost-saving of about Rs. 180 per part as compared to the one of the benchmarked vehicle.
• Optimized space management and packaging by using local brackets to support the steering column and gear shifter unit.

• Optimized construction reduces weight without compromising with the requirements of durability, strength and reliability of the cross-car beam.

• Improves safety by meeting safety regulation even with this low-weight construction.

• Ease of serviceability by using less manpower due to need for less no. of parts and linkage parts.

• Uses steel material, a comparatively low-cost material and weight optimization also helps in increasing the fuel efficiency of the vehicle.

It is to be understood that the present invention is not limited in its application to the details of the construction and to the arrangements of the components as mentioned in the above description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the terminologies used herein are for the purpose of description and should not be regarded as limiting.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept.

Therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention.

The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

Therefore, while the embodiments herein have been described in terms of preferred embodiments, the skilled person will recognize that the embodiments herein can be practiced with modification within the spirit and scope of embodiments described herein.

The skilled person can easily make innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies, assemblies and in terms of the size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention. ,CLAIMS:We claim:

1. A cross car beam with local brackets in automotive vehicles, wherein said cross car beam is configured as a low-weight sub-assembly by using the steering column mounting brackets of box section.

2. Cross car beam as claimed in claim 1, wherein said local brackets comprise:

• dash bracket (02);

• upper steering column support bracket (04);

• a lower steering column support bracket (06) welded to said upper steering column support bracket (04);

• a steering column bracket (08) for mounting steering column (30) thereon;

• a plurality of IP mounting brackets (10, 12) for fixing sub-parts of IP cluster;

• a dash panel cross member (12);

• a bracket (18) for accessories, such as a music system;

• at least two tubes (16) for welding gear shifter unit mounting bracket (20) and IP mounting bracket (22) thereon, said tubes being welded between said dash panel cross member (14) and the vehicle floor;

• a bracket (24) for welding said tubes (16) to the vehicle floor;

wherein said steering column mounting brackets (04, 06) are welded directly in said dash panel cross member (14); and said steering mounting bracket (06) and said steering column bracket (08) are in turn welded to said upper steering column mounting bracket (04).
3. Cross car beam as claimed in claim 2, wherein said cross car beam is made of steel and equipped with said tubes (16) having a profile suitable for mounting said gear shifter unit mounting bracket (20) and said IP mounting bracket (22) thereon.

4. Cross car beam as claimed in claim 2, wherein said upper steering column support bracket (04) welded to said lower steering column support bracket (06) to configure said box section as a hollow section to reduce the weight of said cross car beam.

5. Cross car beam as claimed in claim 4, wherein said hollow section reduces the overall weight of said cross car beam in a range of 50-70%, preferably 55-65% with respect to the existing cross car beam.

6. Cross car beam as claimed in claim 2, wherein said gear shifter unit mounting bracket (20) is welded on said tubes (16).

7. Cross car beam as claimed in claim 2, wherein said IP mounting bracket (12) is welded on one of said tubes (16).

8. Cross car beam as claimed in claim 2, wherein said bracket (18) for mounting accessories is welded between said tubes (16).

9. A cross car beam with local brackets in automotive vehicles, said local brackets comprising:

• a dash bracket (02);

• an upper steering column support bracket (04);

• a lower steering column support bracket (06) welded to said upper steering column support bracket (04) to configure said box section;
• a steering column bracket (08) for mounting steering column (30) thereon;

• IP mounting brackets (10, 12) for fixing sub-parts of IP cluster; said bracket (10) welded on said dash bracket (02);

• a dash panel cross member (14);

• at least two tubes (16) welded between said dash panel cross member (14) and the vehicle floor; and said cross member (14) welded between said lower steering column support bracket (06) and said tube (16);

• a bracket (18) for accessories welded between said tubes (16);

• a gear shifter unit mounting bracket (20);

• an IP mounting bracket (22); and

• a bracket (24) for welding said tubes (16) to the vehicle floor;

wherein said tubes (16) are configured with a profile suitable for mounting said gear shifter unit mounting bracket (20) and said IP mounting bracket (22) thereon; and said steering column mounting brackets (04, 06) are welded directly in said cross member (14).

10. Cross car beam as claimed in claim 9, wherein said local brackets are made of steel hollow sections of material thicknesses optimized to reduce the overall weight of said cross car beam in the range of 50-70%, preferably 55-65% with respect to the existing cross car beams.

Digitally Signed.

Dated: this 28th day of December 2017. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT