Instrument panel reinforcement for vehicle

Abstract

To provide a structure capable of easily preventing circumferential or axial displacement of a cast member 4 on an instrument panel reinforcement when the cast member 4 is formed on the instrument panel reinforcement 1 by a casting-envelopment method.SOLUTION: An instrument panel reinforcement 1 has a substantially cylindrical outer shape and configured such that a cast member 4 is molded to surround a part of the substantially cylindrical outer shape by the casting-envelopment method, wherein a convex part (or a concave part) is formed on a surface of a portion of the instrument panel reinforcement that is surrounded by the cast member, and the structure is configured to prevent circumferential and axial displacement of the cast member on the substantially cylindrical outer shape.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to the structure of an instrument panel reinforcement, which is a substantially round pipe-shaped member that extends in the width direction of the vehicle body inside the instrument panel and dashboard in front of the front seats of a vehicle such as an automobile, and supports a steering device, air conditioning system, audio equipment, etc., and more specifically, to a structure that enables a member that supports a steering column, etc. to be stably fixed in the instrument panel reinforcement. [Background technology]

[0002] Various methods have been proposed for fixing a member that supports a steering column or the like to an instrument panel reinforcement. For example, Patent Document 1 proposes a structure for fixing a fixed member to an instrument panel reinforcement, which is a pipe member fixed to a vehicle in a state extending in the width direction of the vehicle, in which a through hole is formed in the fixed member so as to be joined to the outer circumferential surface of the pipe member, both end faces of the through hole are shaped so as not to be perpendicular to the pipe member, and the diameter of the pipe member outside both end faces of the through hole is formed larger than the inner diameter of the through hole, so that the fixed member is crimped to the pipe member. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2019-18608 Summary of the Invention [Problem to be solved by the invention]

[0004] An instrument panel reinforcement is typically formed by rolling a steel plate into a round pipe shape, and a cast member, such as a member for supporting a steering column or the like, manufactured by a die-casting method or the like, is attached to this round pipe-shaped structure. One method for attaching such a cast member to a round pipe-shaped instrument panel reinforcement is to mold the cast member directly on the instrument panel reinforcement by placing the instrument panel reinforcement in a mold of a casting machine, pouring molten metal into the mold in that state, and allowing it to harden (a method known as a cast-insertion method). This cast-insertion method is advantageous in that it can avoid deformation and wear of the cast member when attaching it to the instrument panel reinforcement, as occurs when a separately molded cast member is fitted onto the instrument panel reinforcement.

[0005] In this regard, when a cast member is formed on an instrument panel reinforcement by the above-described cast-insertion method, since the instrument panel reinforcement is in the shape of a round pipe, the cast member after hardening may be displaced in the circumferential or axial direction on the instrument panel reinforcement.

[0006] In view of the above circumstances, a main object of the present invention is to provide a structure that can easily prevent circumferential or axial displacement of a cast member on an instrument panel reinforcement when the cast member is formed on the instrument panel reinforcement by a cast-in insert method. [Means for solving the problem]

[0007] According to one aspect of the present invention, the above-mentioned object is achieved by an instrument panel reinforcement having a substantially cylindrical outer shape, in which a cast member is formed by a cast-insertion method so as to surround a part of the substantially cylindrical outer shape, and in which a convex portion or a concave portion is formed on the surface of the part surrounded by the cast member, and which is configured to prevent circumferential and axial displacement of the cast member on the substantially cylindrical outer shape.

[0008] In the above configuration, the "instrument panel reinforcement" having a substantially cylindrical outer shape may be a substantially round pipe-shaped steel plate member that extends in the width direction of the vehicle body inside the instrument panel and dashboard in front of the front seats of a vehicle such as an automobile, as described above, and supports a steering system, air conditioning system, audio equipment, etc. The "cast member" that surrounds part of the outer shape of the instrument panel reinforcement may be a member that supports a steering column, air conditioning system, audio equipment, etc., or may be a member that is cast by a die-casting method or the like. In the "cast-in-place method," as already mentioned, the instrument panel reinforcement is placed in a mold, and molten metal is poured around the outer shape of the instrument panel reinforcement and hardened.

[0009] In the instrument panel reinforcement of the present invention, convex or concave portions are formed on the surface of the outer shape of the cast member to be molded. When such convex or concave portions are placed in a mold, molten metal contacts the periphery of the convex or concave portion and hardens in a shape complementary to the shape of the convex or concave portion. Thus, the hardened cast member forms a portion that fits into the convex or concave portion on the instrument panel reinforcement, thereby preventing circumferential and axial displacement of the cast member on its substantially cylindrical outer shape.

[0010] The convex or concave portion on the instrument panel reinforcement may be formed by any method. In one embodiment, the convex or concave portion may be formed by forming a weld bead, i.e., a convex portion formed by piling up molten metal by arc welding or the like, on the surface of a substantially cylindrical outer shape. Such a weld bead is advantageous in that it can be easily formed on the surface of the instrument panel reinforcement. In this embodiment, the convex or concave portion may be formed to any length in the axial or circumferential direction of the instrument panel reinforcement.

[0011] As described above, when a convex portion is formed on an instrument panel reinforcement using a weld bead, the surface rigidity and strength of the outer shape of the instrument panel reinforcement can be increased, and crushing of the instrument panel reinforcement during casting by the cast-insertion method can be suppressed. Furthermore, by applying a weld bead to compensate for distortion of the instrument panel reinforcement during casting by the cast-insertion method, it is also possible to correct eccentricity of the instrument panel reinforcement during casting. Furthermore, since the size, shape, and position of the weld bead can be easily adjusted, it is also advantageous in that the convex portion can be formed to match the engagement position and shape of the cast member for each individual vehicle. [Effects of the Invention]

[0012] Thus, according to the present invention, when a cast member is formed on an instrument panel reinforcement by a cast-in insert method, it is possible to prevent the cast member from being displaced in the circumferential or axial direction on the instrument panel reinforcement. The configuration of the present invention may be applied to various instrument panel reinforcements as long as the cast-in insert method is applicable.

[0013] Other objects and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention. [Brief explanation of the drawings]

[0014] [Figure 1] Fig. 1(A) is a schematic perspective view of an instrument panel reinforcement to which this embodiment is applied, Fig. 1(B) is an enlarged view of a portion where a convex portion is arranged, and Fig. 1(C) is a schematic perspective view of a cast member formed by a cast-in-insertion method on the instrument panel reinforcement to which this embodiment is applied. [Figure 2] 2(A) to 2(D) are schematic cross-sectional views taken from a direction perpendicular to the axial direction of the instrument panel reinforcement, illustrating a process of forming a cast member on the instrument panel reinforcement by a cast-in-insertion method, to which this embodiment is applied. Fig. 2(E) is a schematic cross-sectional view taken along line (E)-(E) in Fig. 2(D). [Figure 3] FIG. 3 is a schematic perspective view showing a state in which a cast member is formed on an instrument panel reinforcement to which this embodiment is applied by the cast-in-place method. [Explanation of symbols]

[0015] 1...Instrument panel reinforcement, 2...Convex portion (weld bead), 3...Mold, 4...Molten metal and cast member BEST MODE FOR CARRYING OUT THE INVENTION

[0016] Instrument panel reinforcement and cast parts configuration As shown in FIG. 1(A), the instrument panel reinforcement according to this embodiment has a generally cylindrical shape, extends in the width direction of the vehicle body inside the instrument panel and dashboard in front of the front seats of the vehicle, and is fixed to the vehicle body so as to support a steering system, an air conditioning system, audio equipment, etc. The instrument panel reinforcement is typically manufactured by rolling a steel plate into a round pipe shape, but may also be made of aluminum, magnesium alloy, resin, etc., as long as it is usable for a casting process using the insert casting method described below. Furthermore, the instrument panel reinforcement may typically be provided with a link mechanism for fixing the instrument panel reinforcement to the vehicle body, holes for fixing various devices, etc., as shown in the figure.

[0017] A cast member 4, as shown in FIG. 1(C) , is formed directly on the instrument panel reinforcement 1 by a casting process using a cast-in insert method, as described below, so as to surround a portion of the instrument panel reinforcement 1, as shown in FIG. 3 . The cast member 4 may typically be an aluminum casting formed by pouring molten aluminum into a mold using a die casting method or the like. In this regard, if the cast member 4 is formed separately and then fitted to the instrument panel reinforcement 1 without using the cast-in insert method, friction, deformation, or cracks may occur in the cast member 4 during the fitting process of the cast member 4 to the intended portion of the instrument panel reinforcement 1. On the other hand, forming the cast member 4 directly on the instrument panel reinforcement 1 using the cast-in insert method is advantageous in that friction, deformation, or cracks do not occur in the cast member 4 during the fitting process.

[0018] Incidentally, after a cast member 4 is formed on the above-mentioned instrument panel reinforcement 1 by the cast-insertion method so as to surround a portion of the instrument panel reinforcement 1, it has been observed that when the shape of the portion surrounded by the instrument panel reinforcement 1 is cylindrical, the cast member 4 may be displaced in the axial or circumferential direction on the instrument panel reinforcement 1. Therefore, in this embodiment, in order to prevent the formed cast member 4 from being displaced in the axial or circumferential direction on the instrument panel reinforcement 1, a convex portion 2 is formed on the surface of the portion of the instrument panel reinforcement 1 where the cast member 4 is formed, as schematically illustrated in FIGS. 1(A) and 1(B). The presence of such convex portion 2 on instrument panel reinforcement 1 causes the molten metal to harden around convex portion 2 in a shape complementary to that of the convex portion, as will be described later, and the portion of the complementary shape fits securely into convex portion 2, thereby preventing axial and circumferential displacement of cast member 4 on instrument panel reinforcement 1.

[0019] The convex portion 2 of the instrument panel reinforcement 1 described above may be formed in any shape on the surface of the instrument panel reinforcement 1 by any method. The simplest and most advantageous typical method is to form the convex portion 2 as a weld bead, i.e., by adhering molten metal by arc welding or the like in a convex shape to the surface of the instrument panel reinforcement 1. Forming the convex portion 2 using a weld bead allows the convex portion 2 to be formed in any size on the instrument panel reinforcement 1 to match its dimensions, which is advantageous in that the size and shape of the convex portion 2 can be adjusted to suit various dimensions of the instrument panel reinforcement 1 and the cast member 4 formed thereon. Furthermore, forming the convex portion 2 as a weld bead in the axial or circumferential direction of the instrument panel reinforcement 1, as shown in FIG. 1(B), improves the surface rigidity and strength of the instrument panel reinforcement 1 and makes it possible to suppress crushing of the instrument panel reinforcement 1 during the formation of the cast member 4, etc. Furthermore, by forming the convex portion 2, which is a weld bead, to compensate for distortion of the instrument panel reinforcement 1 during the formation of the cast member 4, it is also possible to correct eccentricity of the instrument panel reinforcement 1.

[0020] The weld bead of the convex portion 2 may be formed by any welding method capable of forming a convex portion (laser welding, spot welding) other than arc welding. The convex portion 2 may also be formed by screw fastening or the like. Furthermore, a concave portion may be formed on the surface of the instrument panel reinforcement 1 as a configuration for preventing axial and circumferential displacement of the formed cast member 4 on the instrument panel reinforcement 1.

[0021] Casting components by insert casting 2, in the process of forming a cast member on the instrument panel reinforcement 1 according to this embodiment, first, as shown in FIG. 2(A), a convex portion 2, which may be a weld bead, is formed on the surface of a portion of the instrument panel reinforcement 1 where a cast member 4 is to be formed. Then, as shown in FIG. 2(B), the portion of the instrument panel reinforcement 1 where the convex portion 2 is formed is enclosed in a mold 3 of a casting machine, which may be a die-casting machine. Thereafter, as shown in FIG. 2(C), a molten metal material 4 is poured into the mold 3. When the metal material 4 hardens, it hardens into a shape complementary to the convex portion 2. When the instrument panel reinforcement 1 is removed from the mold 3 as shown in FIG. 2(D), the cast member 4 formed by the hardened metal material is attached to the instrument panel reinforcement 1 as shown in FIG. At this time, as shown in FIG. 2(E), the convex portion 2 is in a state of biting into the cast member 4, so that the cast member 4 on the instrument panel reinforcement 1 is prevented from being displaced in the circumferential and axial directions.

[0022] Thus, as taught by this embodiment, with an instrument panel reinforcement 1 in which a convex portion 2 (or a concave portion) is formed at a location where a cast member is formed by the cast-insertion method, it is possible to prevent circumferential and axial displacement of the cast member 4 formed on the instrument panel reinforcement 1 by a simple method.

[0023] The above description has been made in relation to the embodiments of the present invention, but it will be apparent that many modifications and changes will be readily apparent to those skilled in the art, and the present invention is not limited to the above-described exemplary embodiments, but can be applied to various devices without departing from the concept of the present invention.

Claims

[Claim 1] An instrument panel reinforcement having a generally cylindrical outer shape, in which a cast member is formed by a cast-insertion method so as to surround a portion of the generally cylindrical outer shape, wherein a convex portion or a concave portion is formed on the surface of the portion surrounded by the cast member, and the instrument panel reinforcement is configured to prevent circumferential and axial displacement of the cast member on the generally cylindrical outer shape.

Images