Instrument panel reinforcement and manufacturing method for metal components

Abstract

To provide an instrument panel reinforcement and a method for manufacturing metal components that can improve torsional rigidity. [Solution] The instrument panel reinforcement 1 according to this disclosure comprises a steering hanger beam 11 having a convex structure 111 on its surface, and a steering support portion 12 fixed to the steering hanger beam 11 and holding the steering mechanism. The steering support portion 12 covers at least the area of ​​the surface of the steering hanger beam 11 that includes the convex structure 111.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing an in-panel reinforce and a metal member.

Background Art

[0002] Patent Document 1 describes an integrated structure of an in-panel reinforce. In the integrated structure of the in-panel reinforce described in Patent Document 1, the steering hanger beam is divided into a plurality of parts. Then, by casting a part of the divided parts with a light metal, the steering column mounting part is formed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, since the in-panel reinforce receives a torsional force from the steering mechanism, the in-panel reinforce needs to have torsional rigidity. Here, in the in-panel reinforce described in Patent Document 1, a torsional force may be applied to the cast part, but the torsional rigidity is not particularly mentioned. That is, in the prior art, there is a problem that means for improving the torsional rigidity of the in-panel reinforce have not been sufficiently studied.

[0005] The present disclosure has been made to solve such problems, and an object thereof is to provide an in-panel reinforce capable of improving torsional rigidity and a method for manufacturing a metal member.

Means for Solving the Problems

[0006] The instrument panel reinforcement according to this disclosure comprises a steering hanger beam having a convex structure on its surface, and a steering support portion fixed to the steering hanger beam and holding a steering mechanism. The steering support portion covers at least a region of the steering hanger beam surface that includes the convex structure.

[0007] With this configuration, the steering support portion according to the present disclosure receives a reaction force from the convex structure when subjected to a torsional force. As a result, the instrument panel reinforcement according to the present disclosure can improve torsional rigidity.

[0008] The method for manufacturing a metal member according to this disclosure comprises the following steps. Insert the jig into the hollow pipe. The inserted jig is expanded in diameter to form a convex structure on the hollow pipe. With the jig inserted, the hollow pipe is cast into place.

[0009] With this configuration, the method for manufacturing a metal member according to the present disclosure can perform casting while appropriately forming a convex structure on a hollow pipe. As a result, the method for forming a metal member according to the present disclosure can improve the torsional rigidity of the metal member.

[0010] The method for manufacturing a metal member according to this disclosure may further include a step of reducing the diameter of the inserted jig and removing it from the hollow pipe. With this configuration, metal components can be manufactured without leaving any jigs inside the metal components.

[0011] The method for manufacturing a metal member according to this disclosure may include a casting process which may be carried out by die casting. The method for manufacturing a metal component according to this disclosure is configured to perform the casting process with a jig inserted. With this configuration, the method for manufacturing a metal component according to this disclosure can suppress deformation of the molded convex structure even when the casting process is performed by die casting. In other words, the method for molding a metal component according to this disclosure is particularly effective when the casting process is performed by die casting.

[0012] The manufacturing method for a metal member according to this disclosure may involve the metal member being an instrument panel reinforcement and the hollow pipe being a steering hanger beam. Furthermore, in the casting process, a steering support portion that holds the steering mechanism may be cast. With this configuration, the method for manufacturing a metal member according to this disclosure can produce an instrument panel reinforcement capable of improving torsional rigidity. [Effects of the Invention]

[0013] This disclosure provides an instrument panel reinforcement and a method for manufacturing a metal component that can improve torsional rigidity. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic perspective view showing the configuration of the instrument panel information. [Figure 2] This is a schematic cross-sectional view showing the configuration of the instrument panel reinforcement. [Figure 3] This is a flowchart showing the manufacturing method of an instrument panel reinforcement. [Figure 4] This is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. [Figure 5] This is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. [Figure 6] This is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. [Modes for carrying out the invention]

[0015] <First Embodiment> (Configuration of Instrument Panel Reinforcement) Hereinafter, the first embodiment according to the present disclosure will be described in detail with reference to the drawings. First, the configuration of the instrument panel reinforcement according to this embodiment will be described in detail.

[0016] FIG. 1 is a schematic perspective view showing the configuration of the instrument panel reinforcement. More specifically, FIG. 1 is a schematic perspective view showing a part of the configuration of the instrument panel reinforcement according to this embodiment. Of course, the right-handed xyz orthogonal coordinates shown in FIG. 1 and other drawings are for convenience in explaining the positional relationship of the components and are common among the drawings.

[0017] The instrument panel reinforcement 1 according to this embodiment is a metal member constituting an automobile and is disposed in front of the driver's seat. The instrument panel reinforcement 1 according to this embodiment is arranged such that the x-axis in the figure is parallel to the steering mechanism, the y-axis is perpendicular to the forward and backward direction of the vehicle, and the z-axis is in the vertical direction. The instrument panel reinforcement 1 according to this embodiment includes a steering hanger beam 11 and a steering support portion 12.

[0018] The steering hanger beam 11 is a hollow pipe extending parallel to the y-axis, that is, perpendicular to the forward and backward direction. A steering support portion 12 is fixed to the steering hanger beam 11 by casting. Although details will be described later, the steering hanger beam 11 has a convex structure on its surface, and at least a region including the convex structure is covered by the steering support portion 12.

[0019] The steering hanger beam 11 is formed of, for example, iron, but any material may be used as long as it can achieve a predetermined strength or more. Furthermore, although the steering hanger beam 11 in this embodiment is a cylindrical hollow pipe, the shape of the steering hanger beam 11 is not limited to this, and for example, it may be configured as a rectangular prism-shaped hollow pipe.

[0020] The steering support section 12 holds a steering mechanism (not shown). More specifically, the steering support section 12 holds the steering mechanism such that the axis of rotation of the rotation input in the steering mechanism is parallel to the x-axis. The steering support portion 12 according to this embodiment receives a torsional force from the steering mechanism it holds, having a rotation axis parallel to the x-axis.

[0021] The steering support section 12 is formed from a different material than the steering hanger beam 11, and is made from materials such as aluminum, magnesium, copper, titanium, or resin. As will be described in detail later, the steering support section 12 is formed by die-casting, in which a part of the steering hanger beam 11 is cast into the steering support section 12.

[0022] The steering support portion 12 is fixed to the steering hanger beam 11. More specifically, the steering support portion 12 has a cast portion 121, and is fixed by covering a portion of the surface of the steering hanger beam 11 with the cast portion 121.

[0023] Figure 2 is a schematic cross-sectional view showing the configuration of the instrument panel reinforcement. More specifically, Figure 2(a) is a schematic cross-sectional view of the casting portion 121 and the steering hanger beam 11 when cut with a cutting plane parallel to the yz plane. Figure 2(b) is a schematic cross-sectional view of the casting portion 121 and the steering hanger beam 11 when cut with a cutting plane parallel to the zx plane.

[0024] As shown in Figures 2(a) and 2(b), a convex structure 111 is formed on the surface of the steering hanger beam 11. More specifically, the convex structure 111 according to this embodiment is a conical structure formed to extend along a plane parallel to the axis of rotation of the rotation input in the steering mechanism, i.e., the zx plane. Six convex structures 111 are arranged in a line along the circumference parallel to the zx plane.

[0025] In this embodiment, six convex structures 111 are formed on the surface of the steering hanger beam 11. However, the number of convex structures 111 formed on the surface of the steering hanger beam 11 is not limited to six. For example, only one convex structure 111 may be formed on the surface of the steering hanger beam 11 according to this embodiment. Furthermore, although the convex structure 111 according to this embodiment has a conical shape, the shape of the convex structure 111 may be, for example, a polygonal pyramidal shape.

[0026] As shown in Figures 2(a) and 2(b), the casting portion 121 encases the steering hanger beam 11 so as to cover the region including the convex structure 111. With this configuration, the steering support section 12 receives a reaction force from the convex structure 111 when subjected to a torsional force having a rotation center parallel to the x-axis. As a result, the instrument panel reinforcement 1 according to this embodiment can improve torsional rigidity.

[0027] (Method of manufacturing instrument panel reinforcement) Next, the method for manufacturing the instrument panel reinforcement according to this embodiment will be described in detail. Figure 3 is a flowchart showing the method for manufacturing the instrument panel reinforcement according to the first embodiment. In the following description, Figures 1 and 2 will be referred to as appropriate.

[0028] In the manufacturing method of the instrument panel reinforcement according to this embodiment, first, a jig is inserted into the hollow pipe (step ST1). That is, in step ST1, a jig is inserted into the hollow pipe that functions as the steering hanger beam 11 in the instrument panel reinforcement 1 after manufacturing.

[0029] Figure 4 is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. More specifically, Figure 4(a) is a schematic cross-sectional view of the hollow pipe, i.e., the steering hanger beam 11, after step ST1 has been performed, when cut with a cutting plane parallel to the yz plane. Figure 4(b) is a schematic cross-sectional view of the steering hanger beam 11, after step ST1 has been performed, when cut with a cutting plane parallel to the zx plane.

[0030] As shown in Figures 4(a) and 4(b), after step ST1 is performed, the jig 2 is positioned inside the steering hanger beam 11. The jig 2 has a shape corresponding to the convex structure 111 described above and is configured to be able to freely expand and contract in diameter inside the steering hanger beam 11.

[0031] In the manufacturing method of the instrument panel reinforcement according to this embodiment, the inserted jig is then expanded in diameter to form a convex structure on the hollow pipe (step ST2). In other words, in step ST2, the jig 2 is enlarged inside the steering hanger beam 11, and the jig 2, which has a shape corresponding to the convex structure 111, is pressed against the inner side surface of the steering hanger beam 11.

[0032] Figure 5 is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. More specifically, Figure 5(a) is a schematic cross-sectional view of the steering hanger beam 11 after step ST2 has been performed, when cut with a cutting plane parallel to the yz plane. Figure 5(b) is a schematic cross-sectional view of the steering hanger beam 11 after step ST2 has been performed, when cut with a cutting plane parallel to the zx plane.

[0033] As shown in Figures 5(a) and 5(b), after step ST2 is performed, the jig 2 is pressed against the inner side surface of the steering hanger beam 11, and as a result, the convex structure 111 is formed.

[0034] In the manufacturing method of the instrument panel reinforcement according to this embodiment, the hollow pipe is then cast with the jig inserted (step ST3). In other words, in step ST3, the casting process is performed on the steering hanger beam 11 with the jig 2 still positioned inside the steering hanger beam 11, thereby casting the steering support portion 12.

[0035] With this configuration, the casting is performed with the convex structure 111 supported by the jig 2, thus suppressing deformation of the convex structure 111 caused by the casting. In other words, with this configuration, the method for manufacturing the instrument panel reinforcement according to this embodiment can perform casting while appropriately forming the convex structure on the steering hanger beam 11.

[0036] In the manufacturing method of the instrument panel reinforcement according to this embodiment, step ST3 may be performed by die casting. As described above, in the manufacturing method of the instrument panel reinforcement according to this embodiment, the casting process is performed with the jig 2 inserted. With this configuration, even when casting is performed using die casting, which is prone to deformation of the object to be cast due to the pressure applied to the molten metal, deformation of the convex structure 111 can be suppressed. In other words, the method for manufacturing the instrument panel reinforcement according to this embodiment is particularly effective when step ST3 is performed by die casting.

[0037] Figure 6 is a schematic cross-sectional view illustrating the manufacturing method of an instrument panel reinforcement. More specifically, Figure 6(a) is a schematic cross-sectional view of the casting portion 121 and steering hanger beam 11 after step ST3 has been performed, when cut with a cutting plane parallel to the yz plane. Figure 6(b) is a schematic cross-sectional view of the casting portion 121 and steering hanger beam 11 after step ST3 has been performed, when cut with a cutting plane parallel to the zx plane.

[0038] As shown in Figures 6(a) and 6(b), after step ST3, the steering support portion 12 is cast. Also, after step ST3, at least the area of ​​the surface of the steering hanger beam 11 that includes the convex structure 111 is covered by the casting portion 121.

[0039] In the manufacturing method of the instrument panel reinforcement according to this embodiment, the last step is to reduce the diameter of the inserted jig and remove it from the hollow pipe (step ST4). In other words, in step ST4, the jig 2 is removed from inside the steering hanger beam 11. By performing the steps from step ST1 to step ST4 described above, the instrument panel reinforcement 1 according to this embodiment can be manufactured.

[0040] As described above, in this embodiment, the instrument panel reinforcement 1 has a steering hanger beam 11 with a convex structure 111 on its surface, and the steering support portion 12 covers the convex structure 111.

[0041] With this configuration, the steering support section 12 receives a reaction force from the convex structure 111 when subjected to a torsional force. As a result, the instrument panel reinforcement 1 according to this embodiment can improve torsional rigidity.

[0042] Furthermore, in the manufacturing method of the instrument panel reinforcement according to this embodiment, a jig 2 is used to form a convex structure 111 on the surface of the steering hanger beam 11, and the casting process is performed with the jig 2 inserted into the steering hanger beam 11.

[0043] With this configuration, the method for manufacturing the instrument panel reinforcement according to this embodiment can suppress deformation of the convex structure 111 during the casting process. In other words, with this configuration, the method for manufacturing the instrument panel reinforcement according to this embodiment can perform casting while appropriately forming the convex structure. As a result, the method for manufacturing the instrument panel reinforcement according to this embodiment can appropriately manufacture the instrument panel reinforcement 1.

[0044] <Other Embodiments> The method for manufacturing an instrument panel reinforcement according to the first embodiment can also be applied when manufacturing metal components other than instrument panel reinforcements. The method for manufacturing a metal member according to this disclosure only needs to include the steps of: inserting a jig into a hollow pipe; expanding the diameter of the inserted jig to form a convex structure on the hollow pipe; and casting the hollow pipe with the jig inserted. Therefore, the metal member manufactured by the manufacturing method of the metal member according to this disclosure may be any metal member as long as it has a hollow pipe and a structure that covers a part of the hollow pipe.

[0045] Although the present invention has been described above in reference to the embodiments described above, the present invention is not limited to the configuration of the embodiments described above, and of course includes various modifications, alterations, and combinations that can be made by a person skilled in the art within the scope of the claims of the present patent application. [Explanation of Symbols]

[0046] 1. Instrument Panel Inforcement 11. Steering hanger beam 111 Convex structure 12. Steering support section 121 Casting part 2. Jig

Claims

1. A steering hanger beam having a convex structure on its surface, It comprises a steering support section fixed to the steering hanger beam and holding the steering mechanism, The steering support portion covers at least the area of ​​the surface of the steering hanger beam that includes the convex structure. Instrument panel information.

2. The process of inserting a jig into a hollow pipe, The process involves expanding the diameter of the inserted jig to form a convex structure on the hollow pipe, The process includes the step of casting a hollow pipe with the jig inserted. A method for manufacturing metal components.

3. The process further includes reducing the diameter of the inserted jig and removing it from the hollow pipe. The method for manufacturing a metal member according to claim 2.

4. The aforementioned casting process is carried out by die casting. A method for manufacturing a metal member according to claim 2 or 3.

5. The aforementioned metal member is an instrument panel reinforcement, The aforementioned hollow pipe is a steering hanger beam. In the casting process described above, the steering support portion that holds the steering mechanism is cast. A method for manufacturing a metal member according to claim 2 or 3.

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