CROSS CAR BEAM FOR A VEHICLE

Abstract

The present disclosure relates to a cross car beam for a vehicle including a first main body extending in a longitudinal direction from a first end to a second end. The first main body has a substantially u-shaped cross section following the longitudinal direction. The cross car beam is formed integrally by at least one fiber reinforced polymer.

Claims

1. A cross car beam for a vehicle, the cross car beam comprising: a first main body comprising a first end and a second end, wherein the first main body extends in a longitudinal direction from the first end to the second end, wherein the first main body has a u-shaped cross section following the longitudinal direction, and wherein the cross car beam is formed integrally by at least one fiber reinforced polymer.

2. The cross car beam of claim 1, wherein the cross car beam is made from an injection molded fiber reinforced polymer.

3. The cross car beam of claim 1, wherein the first main body comprises a first opening dividing the first main body into an upper part and a lower part, wherein the upper part and the lower part have a u-shaped cross section.

4. The cross car beam of claim 3, wherein the u-shaped cross section of the upper part and the u-shaped cross section of the lower part further comprises inner ribs reinforcing the first main body.

5. The cross car beam of claim 1, wherein the first main body having a u-shaped additional cross section following parallel to the longitudinal direction.

6. The cross car beam of claim 1, further comprising a second main body including a first end and a second end, wherein the second main body extends from the first end of the second main body to the second end of the second main body following the longitudinal direction, wherein the second main body having a u-shaped cross section following the longitudinal direction.

7. The cross car beam of claim 6, wherein the first end of the first main body corresponds to the first end of the second main body.

8. The cross car beam of claim 6, wherein the first main body having the u-shaped cross section and the second main body having the u-shaped cross section are arranged adjacent to each other, wherein lateral openings of the u-shaped cross section of the first main body and lateral openings of the u-shaped cross section of the second main body are facing each other.

9. The cross car beam of claim 8, wherein the first main body and the second main body are welded to each other such that the u-shaped cross section of the first main body and the u-shaped cross section of the second main body define a closed shell cross section.

10. The cross car beam of claim 1, wherein the first main body comprises a glove box housing.

11. The cross car beam of claim 10, wherein a wall thickness of the glove box housing facing the first main body is thicker compared to the wall thickness of the glove box housing facing a passenger compartment.

12. The cross car beam of claim 11, wherein a wall thickness of the glove box housing is continuously decreasing from the first main body to the passenger compartment.

13. The cross car beam of claim 1, wherein the first main body comprises a steering column carrier.

Description

DRAWINGS

[0062] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0063] Further advantages and developments as well as features of the present disclosure are revealed by the following detailed description of a variation made with reference to the accompanying drawings.

[0064] FIG. 1 shows a rear side view of a cross car beam in accordance with the teachings of the present disclosure;

[0065] FIG. 2A shows two facing u-shaped cross-sectional views in accordance with the teachings of the present disclosure;

[0066] FIG. 2B shows two welded u-shaped cross-sectional views in accordance with the teachings of the present disclosure;

[0067] FIG. 3 shows a rear side view of a first main body and a second main body in accordance with the teachings of the present disclosure;

[0068] FIG. 4 shows a front side view of a further cross car beam in accordance with the teachings of the present disclosure;

[0069] FIG. 5 shows a cross section view of a cross car beam in accordance with the teachings of the present disclosure;

[0070] FIG. 6 shows a detailed view of the excerpt of FIG. 5 in accordance with the teachings of the present disclosure;

[0071] FIG. 7 shows a crash pad in a front view in accordance with the teachings of the present disclosure; and

[0072] FIG. 8 shows a further cross section view of a cross car beam in accordance with the teachings of the present disclosure.

[0073] Consequently, in the different views, identical parts are designated by identical reference numerals.

[0074] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0075] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0076] FIG. 1 shows a view of a cross car beam 100 from a rear side view. The cross car beam 100 includes a first main body 110 extending from a first end 111 to a second end 112. From the first end 111 to the second end 112 extends a longitudinal direction. The longitudinal direction describes the connection from a left hand door to a right hand door of a vehicle in whose passenger compartment the cross car beam 100 is provided for.

[0077] For reasons of rigidity, the cross car beam 100 includes a u-shaped cross section 150 (not shown). The u-shaped cross section follows the longitudinal direction of the first main body 110 from the first end 111 to the second end 112. The space between the legs of the u-shaped cross section includes inner ribs 158 which are used to further increase the stiffness of the cross car beam 100.

[0078] The complete cross car beam 100 from the first end 111 to the second end 112 including the inner ribs 158 is formed integrally by at least one fiber reinforced polymer.

[0079] In a middle section, the cross car beam 100 includes a first opening 120 and a second opening 130. The first opening 120 and the second opening 130 divide the first main body 110 into an upper part 121 a middle part 122 and a lower part 123. Also, the upper part 121, the middle part 122 and the lower part 123 have each a u-shaped cross section 150 for reasons of rigidity. Additionally, each u-shaped cross section 150 includes inner ribs 158 to further increase the stiffness of the cross car beam 100.

[0080] At the first end 111 of the cross car beam 100 a first sub body 220 is arranged in a transversal direction. Also, the first sub body 220 is having a u-shaped cross section 150, wherein a first upper fixing point 131 and a first lower fixing point 132 is placed within the first sub body 220. To further increase the stiffness, the first sub body 220 includes inner ribs 158.

[0081] At the second end 112 of the cross car beam 100 a second sub body 230 is arranged in a transversal direction. Also, the second sub body 230 is having a u-shaped cross section 150, wherein a second upper fixing point 133 and a second lower fixing point 134 is placed within the second sub body 230. To further increase the stiffness, the second sub body 230 includes inner ribs 158.

[0082] The cross car beam 100 includes a first center line L1 that is running through the first upper fixing point 131 at the first end 111 and the second upper fixing point 133 at the second end 112.

[0083] The first center line L1 runs through the middle part 122 to provide a continuous progression of a u-shaped cross section 150 from the first end 111 to the second end 112.

[0084] Between the first end 111 and the middle section comprising the upper part 121, the middle part 122 and the lower part 123 a steering column carrier 170 is provided at the cross car beam 100. Again, the complete cross car beam 100 from the first end 111 to the second end 112 including the first sub body 220, the second sub body 230, steering column carrier 170 and the middle section comprising the upper part 121, the middle part 122 and the lower part 123 is formed integrally by at least one fiber reinforced polymer.

[0085] FIG. 2A shows two facing u-shaped cross sections 150, 450. The respective open side of each u-shaped cross section 150, 450 is directed towards each other. The u-shaped cross sections 150, 450 differ slightly and both include inner ribs 158 to further increase the stiffness.

[0086] FIG. 2B shows two welded u-shaped cross sections 150, 450. The u-shaped cross sections 150, 450 and additionally the inner ribs 158 are welded with each other. In this welded state, the two cross sections define a common shell cross section 500.

[0087] FIG. 3 shows a view of a first main body 110 and a second main body 410 from a rear side view.

[0088] The first main body 110 corresponds identically to the first main body 110 described in FIG. 1. A repeated description of identical features is thus dispensed with. In the following the description is therefore restricted to the second main body 410.

[0089] The second main body 410 is designed to be aligned with the first main body 110. For example, the first main body 110 and the second main body 410 are welded together according to the cross sectional view shown in FIG. 2B to increase the stiffness of the cross car beam 100.

[0090] The second main body 410 also has a u-shaped cross section 450 (not shown) and is arranged adjacent to the first main body 110. The lateral openings of the u-shaped cross sections 150, 450 are facing each other.

[0091] Further the second main body 410 also extends from a first end 411 to a second end 412 and follows the longitudinal direction.

[0092] As with the first main body 110, the u-shaped cross section 450 of the second main body 410 follows the mentioned longitudinal direction.

[0093] In a middle section, the second main body 410 includes a first opening 420 and a second opening 430. The first opening 420 and the second opening 430 divide the second main body 410 into an upper part 421 a middle part 422 and a lower part 423. Also, the upper part 421, the middle part 422 and the lower part 423 have each a u-shaped cross section 450 for reasons of rigidity. Additionally, each u-shaped cross section 450 includes inner ribs 158 to further increase the stiffness of the second main body 410.

[0094] In a condition in which the first main body 110 and the second main body 410 are welded together, the first openings 120, 420 and the second openings 130, 430 are aligned to correspond to each other.

[0095] In contrast to the first main body 110, the second main body 410 does not have any first upper fixing points 131, second upper fixing points 133, first lower fixing points 132, and second lower fixing points 134.

[0096] The second main body 410 is formed integrally by at least one fiber reinforced polymer.

[0097] FIG. 4 shows a view of a further cross car beam 100 from a front side view.

[0098] The cross car beam 100 includes the first main body 110 and corresponds almost identically to the first main body 110 described in FIG. 1. A repeated description of identical features is thus dispensed with. In the following the description is therefore restricted to the additional features shown in FIG. 4.

[0099] The first main body 110 extends from a first end 111 to a second end 112 in a longitudinal direction. The longitudinal direction describes the connection from a left hand door to a right hand door of a vehicle in whose passenger compartment the cross car beam 100 is provided for. For reasons of rigidity, the first main body 110 includes a u-shaped cross section 150 following the longitudinal direction of the first main body 110 from the first end 111 to the second end 112. Further stiffness is reached by inner ribs 158 inside the u-shaped cross section 150.

[0100] Between the first end 111 and the steering column carrier 170 several collapsible guiding elements 300 are shown. Adjacent to the second end 112 a glove box housing 160 is attached to the first main body 110. Again, the complete cross car beam 100 from the first end 111 to the second end 112 including the first sub body 220, the second sub body 230, the steering column carrier 170 and the glove box housing 160 is formed integrally by at least one fiber reinforced polymer.

[0101] FIG. 5 shows a cross section view of a cross car beam 100.

[0102] The cross car beam 100 includes a deformable crash pad 200 that is adapted to absorb impact energy. Inside the deformable crash pad 200 there is a foam core to distribute the force acting on the deformable crash pad 200. The deformable crash pad 200 is placed on the first main body 110 and is covered by a cover element 330. The cover element 330 is facing the passenger compartment such that an impact from a passenger sitting in the passenger compartment on the cover element 330 can be transferred to the deformable crash pad 200.

[0103] Additionally, a collapsible guiding element 300 is placed parallel to the deformable crash pad 200 and is adapted to guide the deformable crash pad 200 during deformation by the cover element 330. The cover element 330 also covers the collapsible guiding element 300 such that the cover element 330 can collapse the collapsible guiding element 300 in the event of an energy impact.

[0104] To collapse the collapsible guiding element 300 a threshold of a predetermined breaking location 310 has to be exceeded.

[0105] So, if the impact on the cover element 330 is large enough, the deformable crash pad 200 is deformed first. If the impact energy absorbed is not sufficient, the cover element 330 comes into contact with the impact unit 302 of the collapsible guiding element 300. If a threshold is exceeded, a predetermined breaking location 310 fails and the impact unit 302 is displaced by the cover element 330 into an internal space 304. The predetermined breaking location 310 is placed between the collapsible guiding element 300 and the impact unit 302. In a cross section view the predetermined breaking location 310 includes a reduced cross section and extends into a peripheral direction of the collapsible guiding element 300. Thus, the predetermined breaking location is arranged in a ring around the collapsible guiding element 300.

[0106] As a consequence, the deformable crash pad 200 can be further deformed to absorb impact energy. During the entire deformation process, a guiding surface 320 on the lateral outer shaft of the collapsible guiding element 300 provides that the deformation of the deformable crash pad 200 takes place in an orderly and straight line.

[0107] Above the collapsible guiding element 300 is the u-shaped cross section 150 of the first main body 110 extending in the longitudinal direction.

[0108] Again, the complete cross car beam 100 comprising the u-shaped cross section 150 extending from the first end 111 to the second end 112 including the collapsible guiding element 300 and the impact unit 302 is formed integrally by at least one fiber reinforced polymer.

[0109] FIG. 6 shows a detailed view the excerpt of FIG. 5.

[0110] The deformable crash pad 200 is located between first main body 110 and cover element 330. Additionally, the predetermined breaking location 310 is located between the collapsible guiding element 300 and the impact unit 302. The predetermined breaking location 310 is placed between the collapsible guiding element 300 and the impact unit 302. In a cross section view the predetermined breaking location 310 includes a reduced cross section and extends into a peripheral direction of the collapsible guiding element 300.

[0111] FIG. 7 shows a deformable crash pad 200 in a front view. Next to the deformable crash pad 200 is a first collapsible guiding element 300 including the impact unit 302 and the predetermined breaking location 310. A guiding surface 320 is placed at the lateral outer side of the collapsible guiding element 300 facing the deformable crash pad 200 to provide a guided deformation of the deformable crash pad 200. Below the deformable crash pad 200 is a second collapsible guiding element 300 including the impact unit 302 and the predetermined breaking location 310. Also, the second collapsible guiding element 300 includes a guiding surface 320 that is placed at a lateral outer side of the second collapsible guiding element 300 facing the deformable crash pad 200.

[0112] FIG. 8 shows a further cross section view of a cross car beam 100.

[0113] The first main body 110 has a u-shaped cross section 150 and a u-shaped additional cross section 154. Both u-shaped cross section 150 and the u-shaped additional cross section 154 are following parallel to each other and follow the longitudinal direction. Within the u-shaped cross section 150 and the u-shaped additional cross section 154 there are inner ribs 158 for reinforcement.

[0114] The u-shaped additional cross-section 154 is arranged offset, whereby the u-shaped cross section 150 and the u-shaped additional cross section 154 together define a stepped cross section structure. The resulting protrusion area 159 is suitable for laying cable harnesses 502.

[0115] Although the present disclosure has been explained in detail with reference to one aspect, it goes without saying that the present disclosure is not limited to this form, but rather that modifications and changes are possible within the scope of the following claims.

[0116] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word about or approximately in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

[0117] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean at least one of A, at least one of B, and at least one of C.

[0118] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.