Steering support

Abstract

This steering support provides a lightweight design while maintaining rigidity. [Solution] The steering support comprises a lower member and an upper member. The upper member is made of a plate material with a smaller plate thickness than the lower member. The lower member has a lower body portion, a front lower flange portion and a rear lower flange portion. The upper member has an upper body portion, a front upper flange portion and a rear upper flange portion. The front upper flange portion and the rear upper flange portion each have an extended portion and a folded portion. The folded portion of the front upper flange portion is welded to the extended portion and the front lower flange portion while in surface contact with at least one of the extended portion and the front lower flange portion of the front upper flange portion. The folded portion of the rear upper flange portion is welded to the extended portion and the rear lower flange portion while in surface contact with at least one of the extended portion and the rear lower flange portion of the rear upper flange portion.

Description

Technical Field

[0001] The present disclosure relates to a steering support that supports the steering of a vehicle from above.

Background Art

[0002] For example, Patent Document 1 describes a steering support that supports the steering of a vehicle from above. The steering support described in Patent Document 1 includes a main body portion. The main body portion has a lower member and an upper member made of a plate material. Each of the lower member and the upper member has a front flange portion and a rear flange portion. The front flange portions and the rear flange portions of the lower member and the upper member are welded to each other.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in recent years, carbon neutrality has been promoted. According to the present inventors, in order to achieve carbon neutrality for a vehicle, for example, weight reduction of components mounted on the vehicle is effective. Therefore, the present inventors considered weight reduction of the steering support as a component mounted on the vehicle. As a means for weight reduction of a component, it is conceivable to reduce the plate thickness of the plate material constituting the component. However, since the steering support is required to have high rigidity from the viewpoint of the collision safety performance of the vehicle, for example, it may be difficult to uniformly reduce the plate thickness of the plate material constituting the steering support.

[0005] One aspect of the present disclosure provides a steering support capable of achieving weight reduction while maintaining rigidity.

Means for Solving the Problems

[0006] One aspect of the present disclosure is a steering support mounted on a vehicle and configured to support the vehicle's steering from above, comprising a lower member and an upper member. The lower member is made of a plate material. The upper member is made of a plate material with a smaller plate thickness than the lower member and is positioned above the lower member. The lower member has a lower body portion, a front lower flange portion and a rear lower flange portion. The lower body portion is curved convexly downwards. The front lower flange portion and the rear lower flange portion extend from the front and rear edges of the lower body portion, respectively. The upper member has an upper body portion, a front upper flange portion and a rear upper flange portion. The upper body portion is curved convexly upwards and forms a space between it and the lower body portion. The front upper flange portion and the rear upper flange portion extend from the front and rear edges of the upper body portion, respectively. Each of the front upper flange portion and the rear upper flange portion has an extended portion and a folded portion. The extended portion extends from the upper body portion. The folded portion is formed by folding back the end of the extended portion opposite to the upper body portion. The folded portion of the front upper flange portion is welded to the extended portion and the front lower flange portion of the front upper flange portion while in surface contact with at least one of the extended portion and the front lower flange portion of the front upper flange portion. The folded portion of the rear upper flange portion is welded to the extended portion and the rear lower flange portion of the rear upper flange portion while in surface contact with at least one of the extended portion and the rear lower flange portion of the rear upper flange portion.

[0007] This configuration allows for weight reduction while maintaining the rigidity of the steering support.

[0008] In one aspect of this disclosure, the folded portion of the front upper flange and the rear upper flange may be in surface contact with at least the extended portion. The ratio of the total thickness of the front upper flange to the thickness of the front lower flange may be 0.5 or more and 2.0 or less. The ratio of the total thickness of the rear upper flange to the thickness of the rear lower flange may be 0.5 or more and 2.0 or less. Such a configuration makes it easier to maintain the rigidity of the steering support.

[0009] In one aspect of this disclosure, a separation portion and a contact portion may be provided. In the front upper flange portion and the rear upper flange portion, the separation portion is formed by folding back from the extended portion so as to form a space between it and the extended portion. The contact portion extends from the end of the separation portion opposite to the extended portion and is in surface contact with at least the extended portion. Such a configuration makes it easier to maintain the rigidity of the steering support.

[0010] In one aspect of this disclosure, the separation portion in both the front upper flange portion and the rear upper flange portion may be formed by folding it back to the side opposite to the lower member. Such a configuration makes it easier to maintain the rigidity of the steering support. [Brief explanation of the drawing]

[0011] [Figure 1] This is a view of the steering support and steering wheel of the first embodiment, seen from a diagonal rearward angle. [Figure 2] This is a view of the steering support of the first embodiment from the rear at an oblique angle. [Figure 3] This is a view of the steering support of the first embodiment from above. [Figure 4] This is a view of the steering support of the first embodiment from below. [Figure 5] This is a view of the steering support of the first embodiment from the front. [Figure 6]It is a view of the steering support of the first embodiment seen from the rear. [Figure 7] It is a view of the steering support of the first embodiment seen from the left side. [Figure 8] It is a view of the steering support of the first embodiment seen from the right side. [Figure 9] It is a cross-sectional view taken along line IX-IX of FIG. 3. [Figure 10] It is a cross-sectional view taken along line X-X of FIG. 6. [Figure 11] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the first embodiment. [Figure 12] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the second embodiment. [Figure 13] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the third embodiment. [Figure 14] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the fourth embodiment. [Figure 15] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the fifth embodiment. [Figure 16] It is a schematic cross-sectional view of the front lower flange portion and the front upper flange portion of the modification. [Mode for Carrying Out the Invention]

[0012] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. [1. First Embodiment] [1-1. Configuration] The steering support 1 shown in FIG. 1 is a member mounted on a vehicle. In the following description and the drawings, front and rear, up and down, and left and right respectively mean front and rear, up and down, and left and right as viewed from the driver's seat in a state where the steering support 1 is mounted on the vehicle. Note that the steering support 1 in the present embodiment is for a vehicle in which the driver's seat is provided on the left side, but the steering support may be formed, for example, for a vehicle in which the driver's seat is provided on the right side.

[0013] As shown in FIG. 1, the steering support 1 is configured to support the vehicle's steering 8 from above. The steering 8 has a steering wheel 81, a steering shaft 82, and a steering column 83. The steering wheel 81 is configured to be rotatable by a driver. The steering shaft 82 is a rod-shaped part connected to the steering wheel 81. The steering shaft 82 is configured to transmit the rotational operation of the steering wheel 81 by the driver to a steering mechanism (not shown). The steering column 83 is a cylindrical part. The steering column 83 covers the outer periphery of the steering shaft 82. The steering support 1 is configured to support the steering 8, specifically the steering column 83.

[0014] The steering support 1 is fixed to the vehicle body.

[0015] Specifically, the front end of the steering support 1 is fixed to the front part of the driver's seat on the vehicle body.

[0016] The left end of the steering support 1 is fixed to the driver's side pillar via a bracket 91. The pillar is part of the vehicle body.

[0017] The right end of the steering support 1 is fixed to the passenger side pillar via a steering member 92 and a bracket 93. The steering member 92 is a cylindrical member. The steering member 92 is arranged to extend in the left-right direction. The steering member 92 connects the right end of the steering support 1 and the bracket 93.

[0018] The lower surface of the steering support 1 is fixed to the part of the vehicle body that constitutes the floor via a floor brace 94. The floor brace 94 is a rod-shaped member. The floor brace 94 is arranged to extend from the vehicle body toward the upper steering support 1.

[0019] As shown in Figure 2, the steering support 1 comprises a main part 2 and a connecting part 3.

[0020] As shown in Figure 3, the main section 2 is generally trapezoidal in top view. The total dimensions of the main section 2 in the left-right direction are greater than the total dimensions in the front-back direction. The front-back dimensions of the main section 2 gradually decrease from near the center of the main section 2 in the left-right direction towards the left and right ends of the main section 2.

[0021] As shown in Figure 6, the main part 2 comprises a lower member 4 and an upper member 5. The lower member 4 and the upper member 5 are made of metal plates. The upper member 5 is made of a plate with a smaller thickness than the lower member 4. The lower member 4 and the upper member 5 are arranged to face each other in the vertical direction. As shown in Figure 10, an internal space S is formed between the lower member 4 and the upper member 5. The lower member 4 and the upper member 5 are welded to each other.

[0022] The lower member 4 is positioned below the upper member 5. As shown in Figure 4, the lower member 4 has a lower body portion 41, a front lower flange portion 42, and a rear lower flange portion 43.

[0023] The lower body portion 41 extends from the left end to the right end of the lower member 4. As shown in Figure 6, the lower body portion 41 as a whole is curved in a convex shape downwards. The lower body portion 41 has a central portion 411, a left fastening portion 412, a right fastening portion 413, a front portion 414, a left side portion 415, a right side portion 416, a left end portion 417, and a right end portion 418.

[0024] As shown in Figure 4, the central portion 411 is the part that extends to the center in the left-right direction of the lower body portion 41. The central portion 411 is flat. The central portion 411 is roughly rectangular in shape when viewed from below. The central portion 411 is surrounded on three sides, front, left, and right, by the front portion 414, the left fastening portion 412, and the right fastening portion 413. As shown in Figures 5 and 9, the central portion 411 is located above the front portion 414, the left fastening portion 412, and the right fastening portion 413.

[0025] As shown in Figure 4, the left fastening portion 412 is a continuous portion to the left of the central portion 411. The right fastening portion 413 is a continuous portion to the right of the central portion 411. In other words, the central portion 411 is sandwiched between the left fastening portion 412 and the right fastening portion 413. The left fastening portion 412 and the right fastening portion 413 are roughly rectangular in shape when viewed from below. As shown in Figure 6, the left fastening portion 412 and the right fastening portion 413 bulge downwards from the central portion 411. Through holes 419 are formed in each of the left fastening portion 412 and the right fastening portion 413.

[0026] As shown in Figure 4, the front portion 414 is a continuous part on the front side of the central portion 411, the left fastening portion 412, and the right fastening portion 413. The front portion 414 is roughly trapezoidal in a view from below. As shown in Figure 6, the front portion 414 bulges downwards compared to the central portion 411. The front portion 414 is fixed to the left wall portion 312 and the right wall portion 313 of the connecting portion 3, which will be described later.

[0027] As shown in Figure 4, the left side portion 415 is a continuous part to the left of the left fastening portion 412. The right side portion 416 is a continuous part to the right of the right fastening portion 413. The left side portion 415 and the right side portion 416 are roughly rectangular in shape when viewed from below. As shown in Figure 6, the left side portion 415 and the right side portion 416 bulge downwards. As shown in Figure 4, the front-to-back dimensions of the left side portion 415 and the right side portion 416 decrease as they move away from the left fastening portion 412 and the right fastening portion 413.

[0028] As shown in Figure 6, a floor brace 94 is positioned below the right-side portion 416. A through hole 4161 is formed in the right-side portion 416. A fastening member 4162 is inserted through the through hole 4161. The fastening member 4162 fastens the right-side portion 416 and the floor brace 94 together.

[0029] As shown in Figure 4, the left end portion 417 is a continuous part on the left side of the left lateral portion 415. The left end portion 417 constitutes the left end of the lower body portion 41. The right end portion 418 is a continuous part on the right side of the right lateral portion 416. The right end portion 418 constitutes the right end of the lower body portion 41. As shown in Figures 7 and 8, the left end portion 417 and the right end portion 418 bulge downwards. Specifically, the left end portion 417 and the right end portion 418 are roughly semi-cylindrical in shape, curved to bulge downwards.

[0030] As shown in Figure 4, the front lower flange portion 42 extends forward from the front edge of the lower body portion 41. Specifically, the front lower flange portion 42 extends from the entire front edge of the lower body portion 41. That is, the front lower flange portion 42 is continuously provided from the left end to the right end of the lower body portion 41. As shown in Figure 5, the front lower flange portion 42 has a shape in which multiple flat plate-like portions are connected along the edge of the lower body portion 41. The front lower flange portion 42 as a whole is inclined upward from the center in the left-right direction toward the left and right ends.

[0031] As shown in Figure 4, the rear lower flange portion 43 extends rearward from the rear edge of the lower body portion 41. Specifically, the rear lower flange portion 43 extends from the entire rear edge of the lower body portion 41. That is, the rear lower flange portion 43 is continuously provided from the left end to the right end of the lower body portion 41. As shown in Figure 6, the rear lower flange portion 43 has a shape in which multiple flat plate-like portions are connected along the edge of the lower body portion 41. The rear lower flange portion 43 as a whole is inclined upward from the center in the left-right direction toward the left and right ends.

[0032] The upper member 5 is positioned above the lower member 4. As shown in Figure 3, the upper member 5 has an upper body portion 51, a front upper flange portion 52, and a rear upper flange portion 53.

[0033] The upper body portion 51 extends from the left end to the right end of the upper member 5. As shown in Figure 6, the upper body portion 51 as a whole is curved in an upward convex shape. As shown in Figure 3, the upper body portion 51 has a central portion 511, a left fastening portion 512, a right fastening portion 513, a front portion 514, a left side portion 515, a right side portion 516, a left end portion 517, and a right end portion 518.

[0034] The central portion 511 is the part that extends to the center in the left-right direction of the upper body portion 51. As shown in Figure 3, the central portion 511 is surrounded on three sides—front, left, and right—by the front portion 514, the left fastening portion 512, and the right fastening portion 513. As shown in Figure 9, the central portion 511 is flat. The central portion 511 is located below the left fastening portion 512 and the right fastening portion 513.

[0035] As shown in Figure 3, the left fastening portion 512 is a continuous portion to the left of the central portion 511. The right fastening portion 513 is a continuous portion to the right of the central portion 511. In other words, the central portion 511 is sandwiched between the left fastening portion 512 and the right fastening portion 513. The left fastening portion 512 and the right fastening portion 513 are roughly rectangular in shape when viewed from above. As shown in Figure 9, the left fastening portion 512 and the right fastening portion 513 bulge upwards from the central portion 511. Through holes 519 are formed in each of the left fastening portion 512 and the right fastening portion 513.

[0036] As shown in Figure 3, the front portion 514 is a continuous portion in front of the central portion 511, the left fastening portion 512, and the right fastening portion 513. As shown in Figure 5, the front portion 514 is located below the left fastening portion 512 and the right fastening portion 513.

[0037] As shown in Figure 3, the left side portion 515 is a continuous part to the left of the left fastening portion 512. The right side portion 516 is a continuous part to the right of the right fastening portion 513. The left side portion 515 and the right side portion 516 are roughly rectangular in shape when viewed from above. As shown in Figure 5, the left side portion 515 and the right side portion 516 bulge upwards. As shown in Figure 3, the front-to-back dimensions of the left side portion 515 and the right side portion 516 decrease as they move away from the left fastening portion 512 and the right fastening portion 513.

[0038] The left end portion 517 is a continuous part on the left side of the left lateral portion 515. The left end portion 517 constitutes the left end of the upper body portion 51. The right end portion 518 is a continuous part on the right side of the right lateral portion 516. The right end portion 518 constitutes the right end of the upper body portion 51. As shown in Figures 7 and 8, the left end portion 517 and the right end portion 518 bulge upwards. Specifically, the left end portion 517 and the right end portion 518 are roughly semi-cylindrical in shape, curved to bulge upwards.

[0039] As shown in Figure 3, the front upper flange portion 52 extends forward from the front edge of the upper body portion 51. Specifically, the front upper flange portion 52 extends from the entire front edge of the upper body portion 51. That is, the front upper flange portion 52 is continuously provided from the left end to the right end of the upper body portion 51. As shown in Figure 5, the front upper flange portion 52 has a shape in which multiple flat plate-like portions are connected along the edge of the upper body portion 51. The front upper flange portion 52 as a whole is inclined upward from the center in the left-right direction toward the left and right ends. The front upper flange portion 52 will be described in more detail later.

[0040] As shown in Figure 3, the rear upper flange portion 53 extends rearward from the rear edge of the upper body portion 51. Specifically, the rear upper flange portion 53 extends from the entire rear edge of the upper body portion 51. That is, the rear upper flange portion 53 is continuously provided from the left end to the right end of the upper body portion 51. As shown in Figure 6, the rear upper flange portion 53 has a shape in which multiple flat plate-like portions are connected along the edge of the upper body portion 51. The rear upper flange portion 53 as a whole is inclined upward from the center in the left-right direction toward the left and right ends. The rear upper flange portion 53 will be described in more detail later.

[0041] As mentioned above, the lower member 4 and the upper member 5 are arranged so that they face each other in the vertical direction. Specifically, the lower body portion 41 and the upper body portion 51, the front lower flange portion 42 and the front upper flange portion 52, and the rear lower flange portion 43 and the rear upper flange portion 53 are arranged so that they face each other in the vertical direction.

[0042] For the lower body portion 41 and the upper body portion 51, the central portions 411, 511 face each other, the left fastening portions 412, 512 face each other, the right fastening portions 413, 513 face each other, the front portions 414, 514 face each other, the left side portions 415, 515 face each other, the right side portions 416, 516 face each other, the left end portions 417, 517 face each other, and the right end portions 418, 518 face each other. As shown in Figure 9, the central portions 411, 511 of the lower member 4 and the upper member 5 are in contact with each other. The left fastening portions 412, 512 face each other, the right fastening portions 413, 513 face each other, the front portions 414, 514 face each other, the left side portions 415, 515 face each other, the right side portions 416, 516 face each other, the left end portions 417, 517 face each other, and the right end portions 418, 518 face each other.

[0043] As shown in Figures 5 and 7, the left end 417 of the lower body portion 41, together with the left end 517 of the upper body portion 51, constitutes the left end of the main portion 2 (and consequently, the left end of the steering support 1). The left end of the main portion 2 is cylindrical. The left end of the main portion 2 is inserted into an opening formed in the bracket 91. The outer circumferential surface of the left end of the main portion 2 is welded to the bracket 91 around its entire circumference, for example.

[0044] As shown in Figures 5 and 8, the right end portion 418 of the lower body portion 41, together with the right end portion 518 of the upper body portion 51, constitutes the right end portion of the main portion 2 (and consequently, the right end portion of the steering support 1). The right end portion of the main portion 2 is cylindrical. A steering member 92 is inserted into the right end portion of the main portion 2. The inner circumferential surface of the right end portion of the main portion 2 is welded to the steering member 92, for example, around its entire circumference.

[0045] As shown in Figure 9, the central part 321, left fastening part 322, and right fastening part 323 of the connecting part 3 (described later) are positioned above the central part 511, left fastening part 512, and right fastening part 513 of the upper body part 51. Through holes 325 are formed in the left fastening part 322 and right fastening part 323 of the connecting part 3, at positions opposite to the through hole 519 of the upper body part 51. A steering column 83 is positioned below the central part 411, left fastening part 412, and right fastening part 413 of the lower body part 41. A through hole 84 is formed in the steering column 83 at a position opposite to the through hole 419 of the lower body part 41. Fastening members 6 such as bolts are inserted through the through holes 325 of the connecting part 3, 419 of the lower body part 41, 519 of the upper body part 51, and 84 of the steering column 83. The fastening member 6 fastens together the left fastening portion 322 and the right fastening portion 323 of the connecting portion 3, the left fastening portions 412, 512 and the right fastening portions 413, 513 of the lower body portion 41 and the upper body portion 51 respectively, and the steering column 83.

[0046] As shown in Figure 5, the front lower flange portion 42 and the front upper flange portion 52 are in surface contact with each other. The front lower flange portion 42 and the front upper flange portion 52 are welded to each other. As shown in Figure 6, the rear lower flange portion 43 and the rear upper flange portion 53 are in surface contact with each other. The rear lower flange portion 43 and the rear upper flange portion 53 are welded to each other. As shown in Figure 9, the internal space S is the space formed between the left fastening portion 412, the right fastening portion 413, the front portion 414, the left side portion 415, and the right side portion 416 of the lower member 4, and the left fastening portion 512, the right fastening portion 513, the front portion 514, the left side portion 515, and the right side portion 516 of the upper member 5.

[0047] According to the inventors' diligent research, when an external force is applied to the main body 2 from the steering column 83, the external force is easily transmitted to the front lower flange portion 42 and the front upper flange portion 52, which are welded to each other, and to the rear lower flange portion 43 and the rear upper flange portion 53, which are also welded to each other. The external force transmitted through these flange portions 42, 43, 52, and 53 is distributed to the vehicle body from the left and right ends of the main body 2 and the connecting portion 3.

[0048] Here, as mentioned above, the upper member 5 is made of a plate material with a smaller plate thickness than the lower member 4. Therefore, the plate thickness of the plate material constituting the front upper flange portion 52 is smaller than the plate thickness of the plate material constituting the front lower flange portion 42. Also, the plate thickness of the plate material constituting the rear upper flange portion 53 is smaller than the plate thickness of the plate material constituting the rear lower flange portion 43. Therefore, from the viewpoint of the rigidity of the main portion 2 and by extension the steering support 1, the steering support 1 is configured such that the front upper flange portion 52 and the rear upper flange portion 53 include extended portions 521, 531 and folded portions 522, 532, as shown in Figure 10.

[0049] Specifically, as shown in Figure 11, the front upper flange portion 52 has an extended portion 521 and a folded portion 522.

[0050] The extension portion 521 is the part that extends from the upper main body portion 51. Specifically, the extension portion 521 is the part that extends forward from the entire front edge of the upper main body portion 51.

[0051] The folded portion 522 is formed by folding back the end of the extended portion 521 on the side opposite to the upper body portion 51. The folded portion 522 is in surface contact with at least one of the extended portion 521 and the front lower flange portion 42. The folded portion 522 is welded to the extended portion 521 and the front lower flange portion 42. The welding of the folded portion 522 to the extended portion 521 and the front lower flange portion 42 means that the extended portion 521, the folded portion 522 and the front lower flange portion 42 are overlap-welded. The order of the extended portion 521, the folded portion 522 and the front lower flange portion 42 in the thickness direction may differ depending on the embodiment.

[0052] In this embodiment, the folded portion 522 is folded upward. That is, the folded portion 522 is folded on the side opposite to the front lower flange portion 42. The folded portion 522 is in surface contact with the extended portion 521. Specifically, the entire area of ​​the folded portion 522 is in surface contact with the extended portion 521. In this case, it is preferable that the distance from the edge of the folded portion 522 on the side of the extended portion 521 to the edge on the opposite side of the extended portion 521 is 9 mm or more.

[0053] The extended portion 521 has a surface opposite to the folded portion 522 that is in surface contact with the front lower flange portion 42. That is, both sides of the extended portion 521 are in surface contact with the front lower flange portion 42 and the folded portion 522. With the extended portion 521 in surface contact with both the front lower flange portion 42 and the folded portion 522, the extended portion 521, the folded portion 522, and the front lower flange portion 42 are welded to each other. In this embodiment, the extended portion 521, the folded portion 522, and the rear lower flange portion 43 are welded to each other by laser welding.

[0054] The total thickness of the front upper flange portion 52 is greater than the thickness of the upper body portion 51. The total thickness of the front upper flange portion 52 is the sum of the dimensions in the thickness direction of the front upper flange portion 52 in the area where it is in surface contact with the front lower flange portion 42. In this embodiment, since the front upper flange portion 52 is composed of an extended portion 521 and a folded portion 522, the total thickness of the front upper flange portion 52 can be rephrased as the sum of the thickness of the extended portion 521 and the thickness of the folded portion 522. The ratio of the total thickness of the front upper flange portion 52 to the thickness of the front lower flange portion 42 is preferably 0.5 or more and 2.0 or less.

[0055] As shown in Figure 10, the rear upper flange portion 53 has an extended portion 531 and a folded portion 532.

[0056] The extension portion 531 is the part that extends from the upper main body portion 51. Specifically, the extension portion 531 is the part that extends rearward from the entire rear edge of the upper main body portion 51.

[0057] The folded portion 532 is formed by folding back the end of the extended portion 531 on the side opposite to the upper body portion 51. The folded portion 532 is in surface contact with at least one of the extended portion 531 and the rear lower flange portion 43. The folded portion 532 is welded to the extended portion 531 and the rear lower flange portion 43. The welding of the folded portion 532 to the extended portion 531 and the rear lower flange portion 43 means that the extended portion 531, the folded portion 532 and the rear lower flange portion 43 are overlap-welded. The order of the extended portion 531, the folded portion 532 and the rear lower flange portion 43 in the thickness direction may differ depending on the embodiment.

[0058] In this embodiment, the folded portion 532 is folded upward. That is, the folded portion 532 is folded on the side opposite to the rear lower flange portion 43. The folded portion 532 is in surface contact with the extended portion 531. Specifically, the entire area of ​​the folded portion 532 is in surface contact with the extended portion 531. In this case, it is preferable that the distance from the edge of the folded portion 532 on the side of the extended portion 531 to the edge on the opposite side of the extended portion 531 is 9 mm or more.

[0059] The extended portion 531 has surface contact with the rear lower flange portion 43 on the side opposite to the folded portion 532. That is, both sides of the extended portion 531 are in surface contact with the rear lower flange portion 43 and the folded portion 532. With the extended portion 531 in surface contact with both the rear lower flange portion 43 and the folded portion 532, the extended portion 531, the folded portion 532, and the rear lower flange portion 43 are welded to each other. In this embodiment, the extended portion 531, the folded portion 532, and the rear lower flange portion 43 are welded to each other by laser welding.

[0060] The total thickness of the rear upper flange portion 53 is greater than the thickness of the upper body portion 51. The total thickness of the rear upper flange portion 53 is the sum of the dimensions in the thickness direction of the rear upper flange portion 53 in the region where the rear upper flange portion 53 is in surface contact with the rear lower flange portion 43. In this embodiment, since the rear upper flange portion 53 is composed of an extended portion 531 and a folded portion 532, the total thickness of the rear upper flange portion 53 can be rephrased as the sum of the thickness of the extended portion 531 and the thickness of the folded portion 532. The ratio of the total thickness of the rear upper flange portion 53 to the thickness of the rear lower flange portion 43 is preferably 0.5 or more and 2.0 or less.

[0061] As shown in Figure 2, the connecting portion 3 is positioned to extend from the center of the main portion 2 in the left-right direction toward the front of the main portion 2. As shown in Figure 7, the connecting portion 3 is generally V-shaped in side view. The connecting portion 3 comprises a lower connecting portion 31 and an upper connecting portion 32.

[0062] As shown in Figure 4, the lower connecting portion 31 is a part that extends forward from a position facing the front portion 414 of the lower member 4 from below. The lower connecting portion 31 extends forward beyond the front end of the main portion 2. The cross-sectional shape of the lower connecting portion 31 perpendicular to the direction of extension is generally C-shaped with an opening at the top. The lower connecting portion 31 has a bottom wall portion 311, a left side wall portion 312, a right side wall portion 313, and a front end wall portion 314.

[0063] The bottom wall portion 311 is a plate-like part that constitutes the bottom surface of the lower connecting portion 31. As shown in Figure 7, the bottom wall portion 311 is inclined so that it is positioned higher towards the front.

[0064] The left side wall portion 312 is a plate-like portion that constitutes the left side surface of the lower connecting portion 31. The left side wall portion 312 extends upward from the left edge of the bottom wall portion 311.

[0065] As shown in Figure 8, the right side wall portion 313 is a plate-like portion that constitutes the right side of the lower connecting portion 31. The right side wall portion 313 extends upward from the right edge of the bottom wall portion 311. The right side wall portion 313 faces the left side wall portion 312 with a gap between them. As shown in Figures 7 and 8, through holes 315 are formed at the ends of the left side wall portion 312 and the right side wall portion 313 on the lower member 4 side.

[0066] As shown in Figure 5, the tip wall portion 314 is a plate-like portion that connects the front edges of the bottom wall portion 311, the left side wall portion 312, and the right side wall portion 313. A through hole 316 is formed in the tip wall portion 314.

[0067] As shown in Figure 3, the upper connecting portion 32 is a part that extends forward from a position facing the through hole 519 of the upper member 5 from above. The upper connecting portion 32 extends forward beyond the front end of the main portion 2. The upper connecting portion 32 has a central portion 321, a left fastening portion 322, a right fastening portion 323, and an extension portion 324.

[0068] The central portion 321 is the part of the upper member 5 located above the central portion 511. The central portion 321 is roughly trapezoidal in top view. As shown in Figure 9, the rear portion of the central portion 321 is formed in a flat plate shape. This portion contacts the central portion 511 from above. As shown in Figure 3, the central portion 321 is surrounded on three sides—front, left, and right—by the extension portion 324, the left fastening portion 322, and the right fastening portion 323.

[0069] The left fastening portion 322 is a continuous portion to the left of the central portion 321. The right fastening portion 323 is a continuous portion to the right of the central portion 321. In other words, the central portion 321 is sandwiched between the left fastening portion 322 and the right fastening portion 323. The left fastening portion 322 and the right fastening portion 323 are roughly rectangular in shape when viewed from above. Through holes 325 are formed in each of the left fastening portion 322 and the right fastening portion 323. As shown in Figure 9, a fastening member 6 is inserted through the through holes 325. As described above, the left fastening portion 322 and the right fastening portion 323 are fastened to the lower body portion 41, the upper body portion 51, and the steering column 83 by the fastening member 6.

[0070] As shown in Figure 3, the extension 324 is the portion that extends forward from the front side of the central portion 321. The extension 324 extends forward beyond the front end of the main portion 2. The extension 324 also extends above the lower connecting portion 31. The cross-sectional shape of the extension 324 perpendicular to its extension direction is roughly C-shaped with an opening at the bottom. As shown in Figure 7, the front end of the extension 324 is fixed to the front end of the lower connecting portion 31, for example, by welding.

[0071] Although not shown in the diagram, the connecting portion 3 is fastened to the steering column 83 by inserting a fastening member through the through hole 315. The connecting portion 3 is also fastened to the vehicle body by inserting a fastening member through the through hole 316.

[0072] [1-2. Effects] According to the first embodiment described in detail above, the following effects can be obtained.

[0073] (1a) From a carbon neutrality perspective, it is desirable to reduce the weight of the steering support. On the other hand, from the perspective of the vehicle's crash safety performance, high rigidity is required for the steering support.

[0074] Therefore, in the steering support 1, the upper member 5 is made of a plate material with a smaller plate thickness than the lower member 4. With this configuration, weight reduction can be achieved while maintaining rigidity. This is because, since the steering support 1 is a member that supports the steering wheel 8 from above, the external force input from the steering wheel 8 tends to be greater on the lower member 4 than on the upper member 5. By making the lower member 4 out of a plate material with a relatively larger plate thickness, the overall rigidity of the steering support 1 can be maintained. By making the upper member 5 out of a plate material with a relatively smaller plate thickness, weight reduction of the steering support 1 can be achieved.

[0075] (1b) External forces input from the steering 8 to the steering support 1 are easily transmitted to the front lower flange portion 42 and the front upper flange portion 52, as well as the rear lower flange portion 43 and the rear upper flange portion 53. Therefore, in the steering support 1, the front upper flange portion 52 and the rear upper flange portion 53 have extended portions 521, 531 and folded portions 522, 532.

[0076] With this configuration, the total plate thickness of the front upper flange portion 52 and the total plate thickness of the rear upper flange portion 53 can be increased. Therefore, it becomes easier to maintain the rigidity of the steering support 1.

[0077] (1c) In the front upper flange portion 52 and the rear upper flange portion 53, the folded portions 522 and 532 are in surface contact with at least the extended portions 521 and 531. The ratio of the total thickness of the front upper flange portion 52 to the thickness of the front lower flange portion 42 is, for example, 0.5 or more and 2.0 or less. The ratio of the total thickness of the rear upper flange portion 53 to the thickness of the rear lower flange portion 43 is, for example, 0.5 or more and 2.0 or less.

[0078] With this configuration, when welding the front lower flange portion 42 to the front upper flange portion 52, and the rear lower flange portion 43 to the rear upper flange portion 53, it becomes easier to satisfy one of the welding conditions, which is the plate thickness ratio. Therefore, it becomes easier to weld the front lower flange portion 42 to the front upper flange portion 52, and the rear lower flange portion 43 to the rear upper flange portion 53 to each other. As a result, the rigidity of these flange portions 42, 43, 52, and 53 can be increased. In turn, it becomes easier to maintain the overall rigidity of the steering support 1. Furthermore, it becomes possible to increase the productivity of the steering support 1.

[0079] (1d) In each of the front upper flange portion 52 and the rear upper flange portion 53, the distance from the edge of the folded portion 522, 532 on the extended portion 521, 531 side to the edge on the opposite side of the extended portion 521, 531 side is, for example, 9 mm or more. With this configuration, the folded portions 522, 532 can be easily welded to the extended portions 521, 531 and the lower flange portions 42, 43. This increases the rigidity of the flange portions 42, 43, 52, 53. Consequently, it becomes easier to maintain the overall rigidity of the steering support 1. It also makes it possible to increase the productivity of the steering support 1.

[0080] [2. Second Embodiment] [2-1. Structure] The second embodiment has the same basic configuration as the first embodiment; therefore, the differences will be explained below. Note that the same reference numerals as in the first embodiment indicate the same components, and refer to the preceding description.

[0081] The steering support of the second embodiment shown in Figure 12 has an upper member 5A in place of the upper member 5 described above. The upper member 5A has a front upper flange portion 52A and a rear upper flange portion (not shown) in place of the front upper flange portion 52 and rear upper flange portion 53 described above. Since the front upper flange portion 52A and the rear upper flange portion have generally similar configurations, the front upper flange portion 52A will be described in detail below, and the explanation of the rear upper flange portion will be omitted.

[0082] The front upper flange portion 52A has a folded portion 522A instead of the folded portion 522 described above. The folded portion 522A is formed by folding back from the end of the extended portion 521 opposite to the upper body portion 51, similar to the folded portion 522 described above. However, the folded portion 522A has a separation portion 5221 and a contact portion 5222.

[0083] The separation portion 5221 is a portion formed by folding back from the extended portion 521 so as to form a space T between it and the extended portion 521. In this embodiment, the separation portion 5221 is formed by folding back on the side opposite to the lower member 4 side (more specifically, the front lower flange portion 42 side).

[0084] The contact portion 5222 is the portion of the separation portion 5221 that extends from the end opposite to the extension portion 521. The contact portion 5222 makes surface contact with at least the extension portion 521 of the extension portion 521 and the front lower flange portion 42. In this embodiment, since the separation portion 5221 is formed by folding back on the side opposite to the lower member 4, the contact portion 5222 makes surface contact with the extension portion 521.

[0085] [2-2. Effects] According to the second embodiment described in detail above, in addition to the same effects as the first embodiment, the following effects can be obtained.

[0086] (2a) In the front upper flange portion 52A, the folded portion 522A has a separation portion 5221 and a contact portion 5222. The separation portion 5221 is formed by folding back from the extended portion 521 so as to form a space T between it and the extended portion 521. With this configuration, the rigidity of the front upper flange portion 52A can be increased compared to a configuration in which, for example, the entire area of ​​the folded portion is in surface contact with the extended portion 521, because a space T is formed between the separation portion 5221 and the extended portion 521. The rear upper flange portion has the same configuration as the front upper flange portion 52A and therefore produces the same effect. Thus, it is possible to further maintain the rigidity of the steering support.

[0087] (2b) Furthermore, compared to the front upper flange portion 52 of the first embodiment, the radius of curvature for forming the folded portion 522A can be increased in the front upper flange portion 52A of this embodiment. The rear upper flange portion has the same configuration as the front upper flange portion 52A and therefore produces the same effect. Consequently, the front upper flange portion 52A and the rear upper flange portion can be formed more easily. This, in turn, makes it possible to increase the productivity of the steering support.

[0088] (2c) In the front upper flange portion 52A, the separation portion 5221 is formed by folding it back to the side opposite to the lower member 4. With this configuration, it is possible to make the extended portion 521, the contact portion 5222 and the front lower flange portion 42 into surface contact with each other, compared to the case where the separation portion 5221 is formed by folding it back to the lower member 4 side. Consequently, it is possible to weld the extended portion 521, the contact portion 5222 and the front lower flange portion 42 to each other. The rear upper flange portion has the same configuration as the front upper flange portion 52A and therefore produces the same effect. As a result, the rigidity of the flange portions 42, 43, and 52A can be further increased. This makes it easier to maintain the rigidity of the steering support. It is also possible to increase the productivity of the steering support.

[0089] [3. Third Embodiment] [3-1. Structure] The third embodiment has the same basic configuration as the first embodiment, so the differences will be explained below. Note that the same reference numerals as in the first embodiment indicate the same components, and refer to the preceding description.

[0090] The steering support of the third embodiment shown in Figure 13 has an upper member 5B in place of the upper member 5 described above. The upper member 5B has a front upper flange portion 52B and a rear upper flange portion (not shown) in place of the front upper flange portion 52 and rear upper flange portion 53 described above. Since the front upper flange portion 52B and the rear upper flange portion have generally similar configurations, the front upper flange portion 52B will be described in detail below, and the explanation of the rear upper flange portion will be omitted.

[0091] The front upper flange portion 52B has a folded portion 522B instead of the folded portion 522 described above. The folded portion 522B is formed by folding back from the end of the extended portion 521 opposite to the upper body portion 51, similar to the folded portion 522 described above. Specifically, the folded portion 522B is formed by folding back from the end opposite to the upper body portion 51 towards the front lower flange portion 42, similar to the folded portion 522 described above.

[0092] However, the folded portion 522B is folded back together with the extended portion 521 so as to sandwich the front lower flange portion 42. That is, the folded portion 522B is in surface contact with the front lower flange portion 42, but not with the extended portion 521. The folded portion 522B is welded to the extended portion 521 and the front lower flange portion 42. The front lower flange portion 42 has surface contact with the extended portion 521 on the side opposite to the folded portion 522B. That is, both sides of the front lower flange portion 42 are in surface contact with the extended portion 521 and the folded portion 522B.

[0093] [3-2. Effects] According to the third embodiment described in detail above, in addition to the same effects as (1a), (1b), and (1d) above, the following effects can be obtained.

[0094] In the front upper flange portion 52B, the folded portion 522B is folded back together with the extended portion 521 so as to sandwich the front lower flange portion 42. That is, the folded portion 522B is in surface contact with the front lower flange portion 42. With this configuration, compared to the front upper flange portion 52 of the first embodiment, the radius of curvature for forming the folded portion 522B can be increased in the front upper flange portion 52B of this embodiment. The rear upper flange portion has the same configuration as the front upper flange portion 52B and therefore produces the same effect. Consequently, the front upper flange portion 52B and the rear upper flange portion can be formed more easily. In turn, it becomes possible to increase the productivity of the steering support.

[0095] [4. Fourth Embodiment] [4-1. Structure] The fourth embodiment has the same basic configuration as the first embodiment, so the differences will be explained below. Note that the same reference numerals as in the first embodiment indicate the same components, and refer to the preceding description.

[0096] The styling support of the fourth embodiment shown in Figure 14 has an upper member 5C instead of the upper member 5 described above. The upper member 5C has a front upper flange portion 52C and a rear upper flange portion (not shown) instead of the front upper flange portion 52 and rear upper flange portion 53 described above. Since the front upper flange portion 52C and the rear upper flange portion have generally similar configurations, the front upper flange portion 52C will be described in detail below, and the explanation of the rear upper flange portion will be omitted.

[0097] The front upper flange portion 52C has a folded portion 523 in addition to the extended portion 521 and folded portion 522 described above. To distinguish between the two folded portions 522 and 523, they will be referred to as the first folded portion 522 and the second folded portion 523 below.

[0098] The second folded portion 523 is formed by folding back the end of the first folded portion 522 on the side opposite to the extended portion 521. The second folded portion 523 is formed by folding back on the side opposite to the extended portion 521. In this embodiment, since the first folded portion 522 is formed by folding back on the side opposite to the lower member 4 (more specifically, the front lower flange portion 42), it can also be said that the second folded portion 523 is formed by folding back on the side opposite to the lower member 4. The second folded portion 523 is in surface contact with the first folded portion 522. The second folded portion 523 is welded to the extended portion 521, the first folded portion 522, and the front lower flange portion 42.

[0099] The first folded portion 522 has surface contact with the extended portion 521 on the side opposite to the second folded portion 523. That is, both sides of the first folded portion 522 are in surface contact with the extended portion 521 and the second folded portion 523. Also, the extended portion 521 has surface contact with the front lower flange portion 42 on the side opposite to the first folded portion 522. That is, both sides of the extended portion 521 are in surface contact with the first folded portion 522 and the front lower flange portion 42. With each of these parts in surface contact, the extended portion 521, the first folded portion 522, the second folded portion 523, and the front lower flange portion 42 are welded to each other. [4-2. Effects] According to the fourth embodiment described in detail above, in addition to the same effects as the first embodiment, the following effects can be obtained.

[0100] The front upper flange portion 52C further has a second folded portion 523. The second folded portion 523 is formed by folding back from the end of the first folded portion 522 opposite to the extended portion 521 side. The second folded portion 523 is welded to the extended portion 521, the first folded portion 522 and the front lower flange portion 42 while in surface contact with the first folded portion 522. With this configuration, the total plate thickness of the front upper flange portion 52C can be increased by having the second folded portion 523 in the front upper flange portion 52C. The rear upper flange portion has the same configuration as the front upper flange portion 52C and therefore produces the same effect. Thus, the rigidity of the steering support as a whole can be further increased.

[0101] [5. Fifth Embodiment] [5-1. Structure] The fifth embodiment has the same basic configuration as the first embodiment, so the differences will be explained below. Note that the same reference numerals as in the first embodiment indicate the same components, and refer to the preceding description.

[0102] The steering support of the fifth embodiment shown in Figure 15 has an upper member 5D in place of the upper member 5 described above. The upper member 5D has a front upper flange portion 52D and a rear upper flange portion (not shown) in place of the front upper flange portion 52 and rear upper flange portion 53 described above. Since the front upper flange portion 52D and the rear upper flange portion have generally similar configurations, the front upper flange portion 52D will be described in detail below, and the explanation of the rear upper flange portion will be omitted.

[0103] The front upper flange portion 52D has a bent tip portion 524 in addition to the extended portion 521 and folded portion 522 described above. The bent tip portion 524 extends from the end of the folded portion 522 opposite to the extended portion 521, in a direction intersecting the folded portion 522. The bent tip portion 524 extends away from the extended portion 521. The bent tip portion 524 faces the upper body portion 51.

[0104] [5-2. Effects] According to the fifth embodiment described in detail above, in addition to the same effects as the first embodiment, the following effects can be obtained.

[0105] The front upper flange portion 52D further has a bent portion 524. The bent portion 524 extends from the end of the folded portion 522 opposite to the extended portion 521, in a direction intersecting the folded portion 522. With this configuration, the rigidity of the front upper flange portion 52D can be further increased by having the bent portion 524. The rear upper flange portion has the same configuration as the front upper flange portion 52D, and therefore produces the same effect. Thus, the rigidity of the steering support as a whole can be further increased.

[0106] [6. Other Embodiments] While embodiments of this disclosure have been described above, it goes without saying that this disclosure is not limited to the embodiments described above and can take various forms.

[0107] (6a) In the first, second, fourth, and fifth embodiments described above, the folded portions 522, 522A, 522B, 523, and 532 were formed by folding upward (i.e., toward the opposite side from the lower member 4). However, the direction in which the folded portions are folded is not particularly limited. For example, as in the folded portion 522B of the third embodiment described above, and the folded portion 522E of the modified example shown in Figure 16, the folded portion may be formed by folding downward (i.e., toward the lower member 4). As shown in Figure 16, the folded portion 522E of the modified example is a portion included in the front upper flange portion 52E of the upper member 5E. The folded portion 522E of the modified example is welded to the extended portion 521 and the front lower flange portion 42 in a state of surface contact with both of them. In the modified example shown in Figure 16, the rear upper flange portion may be configured similarly to, for example, the front upper flange portion 52E.

[0108] (6b) In the first embodiment described above, laser welding was exemplified as the welding method for the front lower flange portion 42 and the front upper flange portion 52, and the rear lower flange portion 43 and the front upper flange portion 53. However, the welding method for the front lower flange portion and the front upper flange portion, and the rear lower flange portion and the rear upper flange portion are not particularly limited. For example, the welding method may be arc welding, spot welding, etc.

[0109] (6c) The functions of one component in the above embodiment may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Also, some parts of the configuration of the above embodiment may be omitted. Also, at least some parts of the configuration of the above embodiment may be added to, replaced with, or otherwise adapted to the configuration of other above embodiments. [Explanation of Symbols]

[0110] 1...Steering support, 2...Main part, 3...Connecting part, 4...Lower member, 5, 5A, 5B, 5C, 5D, 5E...Upper member, 31...Lower connecting part, 32...Upper connecting part, 41...Lower main body part, 42...Front lower flange part, 43...Rear lower flange part, 51...Upper main body part, 52, 52A, 52B, 52C, 52D, 52E...Front upper flange part, 53...Rear upper flange part, 521, 531...Extended part, 522, 522A, 522B, 522E, 523, 532...Folded part, 524...Front bent part, 5221...Separation part, 5222...Contact part, S...Internal space, T...Space.

Claims

1. A steering support mounted on a vehicle and configured to support the vehicle's steering from above, A lower member made of plate material, An upper member is made of a plate material with a thickness smaller than that of the lower member and is positioned above the lower member, Equipped with, The lower member has a lower body portion that is curved in a convex shape downward, and a front lower flange portion and a rear lower flange portion that extend from the front and rear edges of the lower body portion of the vehicle, respectively. The upper member has an upper body portion that is curved upward in a convex shape and forms a space between it and the lower body portion, and a front upper flange portion and a rear upper flange portion that extend from the front and rear edges of the upper body portion, respectively. Each of the front upper flange portion and the rear upper flange portion has an extended portion extending from the upper body portion and a folded portion formed by folding back from the end of the extended portion opposite to the upper body portion side. The folded portion of the front upper flange portion is welded to the extended portion and the front lower flange portion of the front upper flange portion while in surface contact with at least one of the extended portion and the front lower flange portion of the front upper flange portion. A steering support in which the folded portion of the rear upper flange portion is welded to the extended portion and the rear lower flange portion of the rear upper flange portion while in surface contact with at least one of the extended portion and the rear lower flange portion of the rear upper flange portion.

2. A steering support according to claim 1, In each of the aforementioned front upper flange portion and the aforementioned rear upper flange portion, the folded portion is in surface contact with at least the extended portion. The ratio of the total thickness of the front upper flange portion to the thickness of the front lower flange portion is 0.5 or more and 2.0 or less. A steering support in which the ratio of the total plate thickness of the rear upper flange portion to the plate thickness of the rear lower flange portion is 0.5 or more and 2.0 or less.

3. A steering support according to claim 1 or claim 2, A steering support in which, in each of the front upper flange portion and the rear upper flange portion, the folded portion has a separation portion formed by folding back from the extension portion so as to form a space between it and the extension portion, and a contact portion extending from the end of the separation portion opposite to the extension portion side and making surface contact with at least the extension portion.

4. A steering support according to claim 3, A steering support in which, in each of the front upper flange portion and the rear upper flange portion, the separation portion is formed by folding back to the side opposite to the lower member side.

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