Support beam

Abstract

Aspects of the present invention relate to a support beam (100) for a vehicle (400). The support beam (100) is configured to structurally support the first suspension component (302) and the second suspension component (304). The support beam (100) includes: a first mounting member (102) configured for connection to a first suspension component (302) at a first side (402) of the vehicle (400); a second mounting member (104) configured for connection to a second suspension component (304) at a second side (404) of the vehicle (400); and a housing portion (106) configured to mount the high voltage electrical component (206) in the housing portion (106). The housing portion (106) of the support beam (100) is located between the first mounting member (102) of the support beam (100) and the second mounting member (104) of the support beam (100).

Description

Technical Field

[0001] This disclosure relates to support beams. Aspects of the invention relate to support beams for vehicles, vehicles including support beams, and methods of manufacturing support beams. Background Technology

[0002] It is known to provide a vehicle body designed to house the internal components of a vehicle, including structural elements that provide structural integrity for the vehicle, and powertrain components such as an electric drive unit for an electric vehicle.

[0003] The electric drive unit of an electric vehicle includes power electronics, a transmission, and an electric motor, all of which need to be housed within the vehicle body and protected from damage.

[0004] The aim is to improve the way space is used within the vehicle body in order to maximize functionality, reduce costs and weight, decrease manufacturing and assembly time, and improve the vehicle's noise, vibration, and ride comfort characteristics.

[0005] The purpose of this invention is to address one or more of the disadvantages associated with the prior art. Summary of the Invention

[0006] Various aspects and embodiments of the present invention provide a support beam for a vehicle and a vehicle including the support beam as claimed in the appended claims. Various aspects and embodiments of the present invention also provide a method for manufacturing the support beam.

[0007] According to one aspect of the invention, a support beam for a vehicle is provided, for example, a support beam configured to structurally support two structural support beams on opposite sides of a vehicle. The support beam may be configured to structurally support a first suspension component and a second suspension component of the vehicle. The support beam may include a first mounting member configured for connection to a first suspension component at a first side of the vehicle. The support beam may include a second mounting member configured for connection to a second suspension component at a second side of the vehicle. The support beam may include a housing portion. The housing portion may be configured to mount high-voltage electrical components therein. The housing portion may be located between the first mounting member and the second mounting member of the support beam.

[0008] According to another aspect of the invention, a support beam for a vehicle is provided, wherein the support beam is configured to structurally support a first suspension component and a second suspension component, the support beam comprising: a first mounting member configured for connection to the first suspension component at a first side of the vehicle; a second mounting member configured for connection to the second suspension component at a second side of the vehicle; and a housing portion configured to house high-voltage electrical components therein, wherein the housing portion of the support beam is located between the first mounting member and the second mounting member of the support beam.

[0009] Advantageously, the present invention enables the high-voltage electrical components and structural transverse members of a vehicle to be combined in a single component, which provides structural integrity to the vehicle and houses and protects the vehicle's electrical components. In this way, the functions of the structural transverse members and the housing for the electrical components can be combined in a single component, which occupies a small volume within the available space. In some examples, the single component can have a lower mass compared to having separate components for structural support and housing of electrical elements.

[0010] The support beam can be a lateral support beam. The support beam can extend across the vehicle in a direction perpendicular to the vehicle's (generally forward) direction of travel. The support beam can be arranged to resist relative lateral movement between the first suspension component and the second suspension component. The support beam can be configured to maintain the stability of the vehicle's suspension system. The support beam can be configured to ensure alignment between a first body panel on a first side of the vehicle and a second body panel on a second side of the vehicle. Advantageously, the support beam contributes to the local dynamic stiffness of the suspension components and provides structural integrity to the vehicle structure.

[0011] In this embodiment, the first mounting member, the second mounting member, and the housing portion are manufactured as a single unit. Compared to using separate components for structural support and housing of electrical components, manufacturing the first mounting member, the second mounting member, and the housing portion as a single unit allows for greater functionality within a smaller space and reduces weight.

[0012] The first mounting member, the second mounting member, and the housing portion can be formed, for example, by forming (i.e., by reshaping metal parts through mechanical deformation without adding or removing material). The first mounting member, the second mounting member, and the housing portion can be pressed into a single integral part.

[0013] Alternatively, the first mounting member, the second mounting member, and the housing portion may be formed by casting. The first mounting member, the second mounting member, and the housing portion may also be formed by die casting, such as high-pressure die casting.

[0014] Advantageously, monolithic components can be manufactured and assembled more efficiently than individual components, and offer improved noise, vibration, and smoothness because there are fewer parts that might click when joined together. The mass of monolithic components is also reduced by eliminating the need for components that join individual parts together, compared to the combined mass of individual components used for structural support and housing of electrical components, as well as fixing components such as bolts or other mechanical fasteners.

[0015] The first mounting member of the supporting beam may include a first rib. Additionally or alternatively, the second mounting member of the supporting beam may include the first rib. At least one of the first mounting member and the second mounting member of the supporting beam includes the first rib.

[0016] The first rib, or each first rib, may extend longitudinally relative to the support beam. The first rib, or each first rib, may extend in a direction parallel to the longitudinal axis of the support beam. The longitudinal axis of the support beam may extend between the first mounting member and the second mounting member. The longitudinal axis of the support beam may be the lateral axis of the vehicle. The longitudinal axis of the support beam may be perpendicular to the vehicle's direction of travel.

[0017] The first rib, or each first rib, may extend from the outer wall of the shell portion. The first rib, or each first rib, may be continuous with the outer wall, such as the outer wall of the shell portion.

[0018] The first mounting member of the support beam may include a first rib extending from and / or continuous with the first outer wall of the housing portion. Additionally or alternatively, the first mounting member of the support beam may include a second rib extending from and / or continuous with the second outer wall of the housing portion. The first mounting member of the support beam may include a third rib. The third rib of the first mounting portion may be positioned between the first rib and the second rib of the first mounting portion.

[0019] The first rib and / or the second rib and / or the third rib of the first mounting member may extend longitudinally relative to the support beam. The first rib and / or the second rib and / or the third rib of the first mounting member may extend in a direction parallel to or in the direction of the longitudinal axis of the support beam. The longitudinal axis of the support beam may extend between the first mounting member and the second mounting member. The longitudinal axis of the support beam may be the transverse axis of the vehicle. The longitudinal axis of the support beam may be perpendicular to the direction of travel of the vehicle.

[0020] The second mounting member of the support beam may include a first rib extending from and / or continuous with the first outer wall of the housing portion. Additionally or alternatively, the second mounting member of the support beam may include a second rib extending from and / or continuous with the second outer wall of the housing portion. The second mounting member of the support beam may include a third rib. A third first rib of the second mounting portion may be positioned between the first and second ribs of the second mounting member.

[0021] The first rib of the second mounting member can be referred to as the fourth rib. The second rib of the second mounting member can be referred to as the fifth rib. The third rib of the second mounting member can be referred to as the sixth rib.

[0022] The first and / or second and / or third ribs of the second mounting member may extend longitudinally relative to the support beam. The first and / or second and / or third ribs of the second mounting member may extend in a direction parallel to or in the direction of the longitudinal axis of the support beam. The longitudinal axis of the support beam may extend between the first and second mounting members. The longitudinal axis of the support beam may be the lateral axis of the vehicle. The longitudinal axis of the support beam may be perpendicular to the vehicle's direction of travel.

[0023] One or more ribs advantageously improve the vehicle’s dynamic stiffness and / or torsional strength.

[0024] The support beam may include a housing portion protrusion. The housing portion protrusion may be configured to mount high-voltage electrical components therein. The housing portion protrusion may be a first housing portion protrusion. The support beam may include another, for example a second housing portion protrusion. The other, for example a second housing portion protrusion may be configured to mount high-voltage electrical components therein. The housing portion protrusion, or each housing portion protrusion, may extend outward from the housing portion in a direction parallel to the vehicle's direction of travel. The housing portion protrusion, or each housing portion protrusion, may extend towards the front of the vehicle. Alternatively, the housing portion protrusion, or each housing portion protrusion, may extend towards the rear of the vehicle. The first housing portion protrusion may extend towards the front of the vehicle, and the other housing portion protrusion may extend towards the rear of the vehicle. Alternatively, the first housing portion protrusion may extend towards the rear of the vehicle, and the other housing portion protrusion may extend towards the front of the vehicle.

[0025] The protruding portion of the housing provides additional space for electrical components, such as high-voltage electrical components.

[0026] The housing portion may include openings. The housing portion may include any number of openings. The openings, or each opening, may be configured to receive an electrical connector.

[0027] Advantageously, the orifice, or each orifice, enables the maintenance of the structural integrity of the supporting beam while simultaneously enabling electrical functionality.

[0028] The support beam may include a cover. The cover may be configured to close openings in the housing portion during use.

[0029] Advantageously, the opening provides access to the high-voltage electrical components within the housing portion, and the cover protects the high-voltage electrical components during use.

[0030] The opening in the housing section can be on the lower surface of the support beam. In use, the opening in the housing section can be located below the support beam.

[0031] The location of the opening provides further protection for components within the housing portion of the supporting beam, such as high-voltage electrical components.

[0032] The support beam provides the vehicle with improved stiffness and torsional strength by contributing to the local dynamic stiffness of the first and / or second suspension components.

[0033] The support beam may also include high-voltage electrical components. These high-voltage electrical components may be installed within the housing section.

[0034] The support beam may comprise aluminum or an aluminum alloy. The first mounting member, the second mounting member, and the housing portion may comprise aluminum or, for example, the same aluminum alloy.

[0035] The aluminum alloy forming the support beam, such as the aluminum alloy forming the first mounting member and / or the second mounting member and / or the housing portion of the support beam, may include one or more of silicon, manganese, and magnesium. The aluminum alloy may, for example, include alloys from the AlSi7MnMg group. The aluminum alloy may include C611 aluminum alloy, for example, C611 aluminum alloy sold under the name EZCast.

[0036] Aluminum alloys can include cast aluminum alloys. Cast aluminum alloys can be, for example, heat-treatable cast aluminum alloys.

[0037] The first suspension component and the second suspension component may include aluminum or aluminum alloy.

[0038] For example, the aluminum alloy forming the first suspension component and / or the second suspension component may include one or more of silicon, manganese, and magnesium. The aluminum alloy may, for example, include alloys from the AlSi7MnMg group. The aluminum alloy may include C611 aluminum alloy, for example, C611 aluminum alloy sold under the name EZCast.

[0039] Aluminum alloys can include cast aluminum alloys. Cast aluminum alloys can be, for example, heat-treatable cast aluminum alloys.

[0040] The same material can be selected for the support beam, the first suspension component, and the second suspension component to reduce the risk of galvanic corrosion. Galvanic corrosion refers to corrosion damage that occurs when two different materials, such as two different metals, come into contact in a humid environment.

[0041] According to another aspect of the invention, a vehicle is provided. This vehicle may include the support beams of any of the foregoing aspects of the invention.

[0042] The support beam can be located in front of the vehicle's A-pillar.

[0043] The location of the support beam allows electrical components to be housed in the front section of the vehicle. This is advantageous for vehicles with a "rear-mounted cab" layout, as it allows the battery and associated components to move forward within an effective front-end impact logic system, where crumple zone and energy absorption capacity are maximized.

[0044] A first mounting member of the support beam can be connected to a first suspension component on a first side of the vehicle. A second mounting member of the support beam can be connected to a second suspension component on a second side of the vehicle. The support beam can be a lateral support beam. The support beam can extend across the vehicle in a direction perpendicular to the vehicle's direction of travel. The support beam can be arranged to resist relative lateral movement between the first and second suspension components. The support beam can be configured to maintain the stability of the vehicle's suspension system. The support beam can be configured to ensure alignment between a first body panel on a first side of the vehicle and a second body panel on a second side of the vehicle.

[0045] Support beams advantageously provide improved stiffness and torsional strength for vehicle components, as well as more efficient manufacturing and assembly.

[0046] According to another aspect of the invention, a method for manufacturing a support beam according to the foregoing aspects of the invention is provided. The method may include forming a support beam having a first mounting member, a second mounting member, and a housing portion. The first mounting member may be configured for connection to a first suspension component at a first side of a vehicle. The second mounting member may be configured for connection to a second suspension component at a second side of the vehicle. The housing portion may be positioned between the first mounting member and the second mounting member of the support beam. The housing portion may be configured to accommodate high-voltage electrical components.

[0047] According to one aspect of the invention, a method of manufacturing a support beam according to the foregoing aspect of the invention is provided, the method comprising forming a support beam having: a first mounting member configured for connection to a first suspension component at a first side of a vehicle; a second mounting member configured for connection to a second suspension component at a second side of the vehicle; and a housing portion located between the first mounting member and the second mounting member of the support beam; wherein the housing portion is configured to accommodate high-voltage electrical components.

[0048] This method enables efficient manufacturing and assembly because a component provides (at least) two functions.

[0049] In this embodiment, the first mounting member, the second mounting member, and the housing portion are manufactured as a single integrated component.

[0050] This method enables the manufacture of components that offer more functionality in a smaller space and have fewer clicking parts (thus providing improved noise, vibration, and smoothness).

[0051] One-piece components can be manufactured using forming methods. The first mounting component, the second mounting component, and the housing portion can be manufactured using compression molding.

[0052] One-piece components can be manufactured using casting methods. The first mounting component, the second mounting component, and the housing portion can be manufactured using die casting, such as high-pressure die casting.

[0053] High-pressure die casting is a cost-effective method that enables the production of parts with the required stiffness and wall thickness.

[0054] After forming or casting, the integral part can be heat treated.

[0055] The cast integral component can be heat-treated, for example, by tempering. The cast integral component can be tempered. It can be heated in an oven, for example, at temperatures above 300°C, or above 350°C, or above 400°C, or above 450°C, or above 500°C. The cast integral component can be quenched, for example, in water. It can be aged, for example, by heating to temperatures of at least 60°C, at least 90°C, or at least 100°C, or at least 125°C, or at least 150°C. The tempering process can be, for example, a T6 tempering process.

[0056] Heating to a temperature of at least 60°C, at least 90°C, or at least 100°C, or at least 125°C, or at least 150°C may be the first aging process.

[0057] The method may include a second aging process. The cast monolithic part may be heated to a temperature of at least 100°C, at least 150°C, or at least 175°C, or at least 200°C, or at least 225°C. The tempering process may be, for example, a T7 tempering process.

[0058] Within the scope of this application, it is expressly intended that all aspects, embodiments, examples, and alternatives set forth in the preceding paragraphs, claims, and / or the following description and drawings, and in particular their various features, may be adopted independently or in any combination. That is, all embodiments and / or features of any embodiment may be combined in any manner and / or combination, unless such features are incompatible. The applicant reserves the right to amend any originally filed claim or accordingly file any new claim, including the right to modify any originally filed claim to derive from and / or incorporate any feature of any other claim, even if not originally claimed in this manner. Attached Figure Description

[0059] One or more embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 A top view of a support beam according to an embodiment of the present invention is shown; Figure 2 It shows Figure 1 A bottom view of the supporting beam; Figure 3 The mounting to the first suspension component and the second suspension component is shown. Figure 1 Front view cross-section of the supporting beam; Figure 4 The illustration shows a method for manufacturing a support beam according to one embodiment of the present invention; Figure 5 A plan view of a vehicle including a support beam according to an embodiment of the present invention is shown; and Figure 6 It shows Figure 5 A side view of the vehicle. Detailed Implementation

[0060] This article refers to the attached document. Figures 1 to 3 A support beam 100 according to an embodiment of the present invention is described. (Refer to...) Figure 4 The method for manufacturing the support beam 100 is described. For example... Figure 5 and Figure 6 As shown, the support beam 100 is installed in the vehicle 400.

[0061] Reference Figure 1 , Figure 2 and Figure 3The illustration shows a support beam 100 for a vehicle 400. The support beam 100 includes a first mounting member 102, a second mounting member 104, and a housing portion 106.

[0062] The support beam 100 has a longitudinal axis 110 extending between the first mounting member 102 and the second mounting member 104.

[0063] As will refer to Figure 4 In more detail, the first mounting member 102, the second mounting member 104, and the housing portion 106 are manufactured as a single, integral component 108 made of aluminum alloy. In other words, the first mounting member 102, the second mounting member 104, and the housing portion 106 are integral.

[0064] A first mounting member 102 is disposed at one end of the support beam 100 and has a flat first mounting portion 112 through which three holes 114 extend. A first rib 116, a second rib 118 and a third rib 120 extend upward from the surface of the first mounting portion 112.

[0065] The second mounting member 104 is disposed at the end of the support beam 100 opposite to the first mounting member 102. The second mounting member 104 has a flat second mounting portion 122 through which three holes 114 extend. A fourth rib 124, a fifth rib 126, and a sixth rib 128 extend upward from the second mounting portion 122.

[0066] The housing portion 106 is positioned between the first mounting member 102 and the second mounting member 104. The housing portion 106 includes a plate portion 130, from which an outer wall 132 extends. The plate portion 130 includes two openings 148 and 150. The outer wall 132 includes a first longitudinal outer wall portion 134, a second longitudinal outer wall portion 136, a first transverse outer wall portion 138, and a second transverse outer wall portion 140. The outer wall 132 also includes a flange 142 extending around the periphery of the housing portion 106. The housing portion 106 includes two housing portion protrusions 144 and 146 extending outwardly from the first longitudinal outer wall portion 134.

[0067] Special reference Figure 2 The plate portion 130 and the outer wall 132 of the housing portion 106 define a cavity 202 having an opening 204. The cavity 202 is configured to receive or accommodate the high-voltage electrical component 206 of the support beam 100. In other words, the housing portion 106 of the support beam 100 is configured to house the high-voltage electrical component 206 within the housing portion 106.

[0068] Now refer to Figure 3The cover 306 is mounted to the flange 142 of the outer wall 132 to protect the high-voltage electrical components 206 inside the housing portion 106 from debris and other environmental contaminants.

[0069] Now, special reference will be made Figure 4 Describe the method for manufacturing the support beam 100.

[0070] The method includes manufacturing a support beam 100, the support beam 100 including: a first mounting member 102 configured for connection to a first suspension component 302 at a first side 402 of a vehicle 400; a second mounting member 104 configured for connection to a second suspension component 304 at a second side 404 of the vehicle 400; and a housing portion 106 located between the first mounting member 102 and the second mounting member 104 of the support beam 100; wherein the housing portion 106 is configured to accommodate a high-voltage electrical component 206.

[0071] The method may also include producing the first mounting member 102, the second mounting member 104, and the housing portion 106 as a single, integral component. The production of the support beam 100 as an integral component makes it possible to manufacture components that provide more functionality in a smaller space and have fewer clicking parts (thus providing improved noise, vibration, and smoothness).

[0072] In an example of the present invention, the method may be a casting method, such as high-pressure die casting method 600.

[0073] In the first step 602 of the high-pressure die-casting method 600, a mold defining the overall shape of the support beam 100 is provided and prepared. In the subsequent step 604, molten aluminum alloy is injected into the mold at high speed and high pressure. The mold is closed and sealed to ensure that the pressure inside the mold is maintained, for example, from about 10 MPa to about 180 MPa, until the molten aluminum alloy has cooled and solidified. In step 606, the cast support beam 100 is discharged from the mold. Then, in step 608, the cast support beam 100 is heat-treated.

[0074] Advantageously, the high-pressure die-casting method 600 can produce the support beam 100 as a one-piece component 108, which has high precision and improved mechanical properties, especially the bending moment and torsional strength required for use in the vehicle 400.

[0075] Step 602 may also include applying a lubricant to the inner surface of the mold that forms the outer wall 132 and the plate portion 130. This advantageously helps to regulate the temperature of the mold while also creating a film between the molten metal and the mold, thereby facilitating the removal of the casting from the mold.

[0076] After step 606, any scrap metal remaining in the mold can be removed in order to prepare the mold for the next casting.

[0077] Heat treatment step 608 may include tempering the cast support beam 100. The cast support beam may be heated, for example, in an oven, at a temperature above 300°C. The cast support beam may be quenched, for example, in water. The cast support beam may also be aged, for example, by heating to a temperature of at least 60°C. The tempering process may be, for example, a T6 tempering process.

[0078] In some examples of the invention, heating to a temperature of at least 60°C is the first aging process. The method may include a second aging process. In the second aging process, the cast support beam may be heated to a temperature of at least 100°C. In other words, the tempering process may be a T7 tempering process.

[0079] The installation of the support beam 100 on the vehicle will now be described. (Refer to...) Figure 5 and Figure 6 The vehicle 400 has a first side portion 402, a second side portion 404, a longitudinal axis 406, and a transverse axis 408. The vehicle 400 also has a first A-pillar 410 at the first side portion 402 and a second A-pillar at the second side portion 404. The first A-pillar 410 and the second A-pillar 412 form an upright structure that supports the windshield 414 toward the front portion 416 of the vehicle 400.

[0080] Now refer to Figure 1 , Figure 2 and Figure 3 The high-voltage electrical component 206 is housed within the cavity 202 of the housing portion 106. The electrical connector of the high-voltage electrical component 206 is aligned with the openings 148 and 150 in the housing portion 106. The cover 306 is secured to the flange 142 by fasteners to secure the high-voltage electrical component 206 and protect it from debris and other environmental contaminants.

[0081] like Figure 3As shown, a first mounting member 102 of the support beam 100 is connected to a first suspension component 302 at a first side 402 of the vehicle 400. A first mounting portion 112 is aligned with the first suspension component 302, and fasteners 308 pass through each hole in the holes 114 to secure the first mounting portion 112 to the first suspension component 302. Similarly, a second mounting member 104 of the support beam 100 is connected to a second suspension component 304 at a second side 404 of the vehicle 400. A second mounting portion 122 is aligned with the second suspension component 304, and fasteners 308 pass through each hole in the holes 114 to secure the second mounting portion 122 to the second suspension component 304.

[0082] Refer again Figure 5 The support beam 100 therefore spans the vehicle 400, extending from the first side 402 of the vehicle 400 to the second side 404 of the vehicle 400. Therefore, the longitudinal axis 110 of the support beam (as shown) Figure 1 and Figure 2 (As shown) Parallel to the vehicle's lateral axis 408. In other words, the longitudinal axis 110 of the support beam is perpendicular to the direction of movement of the vehicle 400 or the vehicle's longitudinal axis 406. The bending and / or torsional strength of the support beam 100 supports the panels at the first side 402 and the second side 404 of the vehicle 400. The support beam 100 contributes to the local dynamic stiffness of the first suspension component 302 and the second suspension component 304. The support beam 100 may, for example, contribute to the local dynamic stiffness of the springs and upper control arm mounts of the first suspension component 302 and the springs and upper control arm mounts of the second suspension component 304 (neither suspension component is shown). The housing portion 106 of the support beam 100 provides space for storing high-voltage electrical components 206.

[0083] In the above embodiment, each of the first mounting portion 112 and the second mounting portion 122 includes three holes 114 through which fasteners 308 are inserted to secure the support beam 100 to the first suspension component 302 and the second suspension component 304. It will be understood that in other embodiments of the invention, the first mounting portion and / or the second mounting portion may include one, two, three, or any number of holes. It will also be understood that any suitable means for securing the first and second mounting members of the support beam 100 to the first suspension component 302 and the second suspension component 304 can be used. Such means may include, for example, screws, bolts, rivets, structural adhesives, etc.

[0084] In the above embodiments, the first mounting member and the second mounting member of the support beam are respectively fixed to the first suspension component and the second suspension component. It will be understood that in other embodiments of the invention, the first mounting member and the second mounting member may be fixed to any component at the first side and the second side of the vehicle, respectively.

[0085] In the above embodiment, the integral component 108 of the support beam 100, comprising the first mounting member 102, the second mounting member 104, and the housing portion 106, is produced by high-pressure die casting. It will be understood that in other embodiments of the invention, the integral component 108 of the support beam 100 can be produced by any suitable method for creating an integral structure. The integral component 108 of the support beam 100 can be produced, for example, by compression molding.

[0086] It will be understood that various modifications and alterations can be made to the invention without departing from the scope of this application.

Claims

1. A support beam for a vehicle, wherein, The support beam is configured to structurally support a first suspension component and a second suspension component, the support beam comprising: a first mounting member configured for connection to the first suspension component at a first side of a vehicle; a second mounting member configured for connection to the second suspension component at a second side of a vehicle; and a housing portion configured for mounting a high voltage electrical component in the housing portion; wherein the housing portion of the support beam is located between the first mounting member of the support beam and the second mounting member of the support beam.

2. The support beam of claim 1, wherein, The first mounting member, the second mounting member and the housing portion are manufactured as an integral component.

3. The support beam of claim 2, wherein, The integral component comprising the first mounting member, the second mounting member and the housing portion is formed by shaping.

4. The support beam of claim 2, wherein, The integral component comprising the first mounting member, the second mounting member and the housing portion is formed by casting.

5. The support beam of any one of claims 1 to 4, wherein, At least one of the first mounting member of the support beam and the second mounting member of the support beam comprises a first rib.

6. The support beam of any one of claims 1 to 5, comprising a housing portion protrusion configured for mounting a high voltage electrical component in the housing portion protrusion.

7. The support beam of any one of claims 1 to 6, wherein, The housing portion comprises an aperture configured to receive an electrical connector.

8. The support beam of any one of claims 1 to 7, comprising high voltage electrical components, wherein, The high voltage electrical component is mounted within the housing portion.

9. The support beam of any one of claims 1 to 8, comprising aluminium or an aluminium alloy.

10. The support beam of claim 9, wherein, The first suspension component and the second suspension component comprise aluminium or the aluminium alloy.

11. A vehicle comprising the support beam of any one of claims 1 to 10.

12. The vehicle of claim 11, wherein, The support beam is located forward of an A-pillar of the vehicle.

13. The vehicle of claim 11 or 12, wherein, the first mounting member of the support beam is connected to the first suspension component on a first side of the vehicle; and the second mounting member of the support beam is connected to the second suspension component on a second side of the vehicle.

14. A method of manufacturing the support beam of any one of claims 1 to 10, the method comprising: manufacturing a support beam, the support beam comprising: a first mounting member configured for connection to the first suspension component at a first side of a vehicle; a second mounting member configured for connection to the second suspension component at a second side of a vehicle; and a housing portion located between the first mounting member of the support beam and the second mounting member of the support beam; wherein the housing portion is configured for housing a high voltage electrical component.

15. The method of claim 14, wherein, The first mounting member, the second mounting member and the housing portion are manufactured as an integral component.

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