A cross car beam assembly

Abstract

The present disclosure envisages a cross car beam assembly (100) for a vehicle. The assembly comprises a cross car beam (CCB) tube (105) defining a straight section (102A) and a non-linear bent U-shaped section (102B); at least one bracket, configured on an operative base (103A) of said U-shaped section (102B); and a steering column (110) configured to be mounted on the bracket (115). The assembly is characterized such that the bracket (115) being configured to mount the steering column (115) in an operative upward direction to facilitate knee room (130) for the driver. Advantageously, the CCB assembly (100) facilitates maximum knee space as well as maximum space availability for mounting accessories of the vehicle.

Description

[0001] A CROSS CAR BEAM ASSEMBLY

[0002] FIELD

[0003] The present disclosure relates to the field of automobiles and more specifically, relates to a cross car beam assembly for a vehicle.

[0004] DEFINITION

[0005] “KNEE ROOM”; The term "knee room" refers to the space available between the driver's knees and the interior components of the vehicle, such as the dashboard, steering column, or center console. It is crucial for the driver's comfort and ability to operate the vehicle safely. Sufficient knee room allows the driver to comfortably adjust their seating position, maintain proper control of the vehicle, and avoid fatigue or discomfort during long drives. It is also essential for ensuring that the driver can easily access and use controls without restriction.

[0006] BACKGROUND

[0007] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0008] Generally, a cross car beam (CCB) assembly of the vehicles includes relatively straight elements with constant or variable cross-section bridging connections between the opposite side pillars of the vehicle. The CCB includes brackets for mounting different components which are configured to carry or hold functional components of the vehicle, providing structural stiffness to the overall system along with carrying certain loads of add-on items like steering column, airbags, an instrument panel, a glove box, infotainment, pedal arrester, and HVAC (Heating, Ventilation and Air Conditioning) & multiple electrical modules etc. The CCB is configured to absorb and resist the vibrations that are transmitted from a steering apparatus of the vehicle. In addition, the CCB is configured to increase the stiffness so as to enhance characteristics of resisting vibration transmitted from a steering wheel. However, on the other side, CCB should be robust enough to meet desired performance criteria of NVH (Noise, Vibration, and Harshness) and durability within limited inherent material weight & cost. In the modern era of vehicle technology, multiple electrical modules are being added on the passenger frontal area inside a body shell of the vehicle like HMI (Human-Machine Interface), HUD (head-up display), etc. to enhance passenger safety and comfort. The electrical modules occupy space over functional parts like HVAC, steering column, and utility spaces.

[0009] In the conventional CCB assembly, a steering column is mounted on the CCB from the downward direction, causing an inevitable loss of valuable space between the CCB and the vehicle floor.

[0010] There is, therefore felt a need for a cross car beam assembly that alleviates the aforementioned drawbacks.

[0011] OBJECTS

[0012] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

[0013] An object of the present disclosure is to provide a cross car beam assembly.

[0014] Another object of the present disclosure is to provide the cross car beam assembly that facilitates maximum space availability for the driver of the vehicle.

[0015] Another object of the present disclosure is to provide the cross car beam assembly that facilitates maximum space availability for mounting accessories of the vehicle.

[0016] Yet another object of the present disclosure is to provide the cross car beam assembly that increases the torsional stiffness of the cross car beam.

[0017] Still, yet another object of the present disclosure is to provide the cross car beam assembly that improves the vibration absorption ability of the vehicle.

[0018] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

[0019] SUMMARY

[0020] The present disclosure relates to a cross car beam assembly for a vehicle. The assembly is configured to mount the steering column to facilitate knee room for the driver. The assembly comprises a cross car beam (CCB) tube defining a straight section and a non-linear bent U- shaped section, the cross car beam tube is configured to be mounted on A-pillar of the vehicle; at least one bracket, configured on an operative base of the U-shaped section, the bracket is extending in an operative upward direction from the base and a steering column configured to be mounted on the bracket. The assembly is characterized such that said bracket being configured to mount the steering column in an operative upward direction to facilitate knee room for the driver

[0021] In an embodiment, the straight section is configured to be received in the U-shaped section to define a tube in tube configuration.

[0022] In an embodiment, diameter of the straight section is comparatively less than the diameter of the U-shaped section. The diameter of the straight section varies in the range of 32mm- 35mm, and the dimeter of the U-shaped section varies in the range of 38mm-54mm.

[0023] In an embodiment, an operative end of the straight section is joined to an operative end of the U-shaped section by means of welding forming a weld- zone.

[0024] In an embodiment, the weld-zone has a step configuration.

[0025] In an embodiment, the steering column is configured to be mounted on an operative base section of the non-linear bent U-shaped section.

[0026] In an embodiment, the cross car beam tube is configured to be mounted to A-pillar of the vehicle.

[0027] In an embodiment, the legs of the U-shaped section is offset outward at an angle ranging between 89° to 99° relative to base of the U-shaped section.

[0028] In an embodiment, cross car beam (CCB) tube is selected from a group of material consisting of alloyed steel.

[0029] BRIEF DESCRIPTION OF ACCOMPANYING DRAWING

[0030] A cross car beam assembly of the present disclosure will now be described with the help of the accompanying drawing in which:

[0031] FIGURE 1A illustrates an isometric view of a conventional cross car beam assembly; FIGURE IB illustrates a front view of the conventional cross car beam assembly;

[0032] FIGURE 2A illustrates an isometric view of a cross car beam tube of the conventional cross car beam assembly;

[0033] FIGURE 2B illustrates a front view of the cross car beam tube of the conventional cross car beam assembly;

[0034] FIGURE 3 illustrates an isometric view of the conventional cross car beam assembly with a steering column mounted thereon;

[0035] FIGURE 4A illustrates an isometric view of a cross car beam assembly in accordance with the preferred embodiment of the present disclosure;

[0036] FIGURE 4B illustrates a front view of the cross car beam assembly in accordance with the preferred embodiment of the present disclosure;

[0037] FIGURE 5A illustrates an isometric view of a cross car beam tube of the cross car beam assembly in accordance with the preferred embodiment of the present disclosure;

[0038] FIGURE 5B illustrates front view of a cross car beam tube of the cross car beam assembly in accordance with the preferred embodiment of the present disclosure;

[0039] Figure 6 illustrates an enlarged view of the non-linear U-shaped section of the CCB assembly of the present disclosure;

[0040] FIGURE 7 illustrates an isometric view of the cross car beam assembly with a steering column mounted thereon in accordance with the preferred embodiment of the present disclosure;

[0041] Figure 8 A illustrates the available knee room between the driver knees ’s and the steering column in case of conventional cross car beam assembly, and Figure 8B illustrates the zero knee room when the vehicle met with an accident or collision in accordance with an embodiment; and

[0042] Figure 9A illustrates the available knee room between the driver knees’s and the steering column in case of the cross car beam assembly of the present disclosure, and Figure 9B illustrates the available knee room when the vehicle met with an accident or collision in case of the cross car beam assembly of the present disclosure. LIST OF REFERENCE NUMERALS

[0043] 50 - Conventional cross car bar (CCB) assembly

[0044] 100 - Cross car beam (CCB) assembly

[0045] 102 A - Straight section of CCB

[0046] 102B- U-shaped section of CCB

[0047] 103A- Base of U-shaped

[0048] 103B- leg of U-shaped

[0049] 105 - Cross car beam (CCB) tube of CCB assembly

[0050] 105' - Cross car beam (CCB) tube of the conventional CCB assembly

[0051] 110 - Steering column

[0052] 115’ - conventional mounting bracket for steering column

[0053] 115- present mounting bracket for steering column

[0054] 117- Dashboard bracket

[0055] 120- weld zone

[0056] 125 - knee room or driver knee space (Conventional)

[0057] 130 - knee room or driver knee space (Present)

[0058] 132- instrument cluster structure

[0059] 134- mounting provision

[0060] DETAILED DESCRIPTION

[0061] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0062] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and / or components, but do not forbid the presence or addition of one or more other features, elements, components, and / or groups thereof.

[0063] Generally, in a conventional cross bar assembly (50), the cross bar is a straight section from the operative left to the operative right end of the vehicle and has provision for a mounting bracket (115’) of the steering column (110). The mounting bracket (115’) is assembled from the downward side as shown in Figures 1A to 3 (i.e., the steering column (110) is located below the CCB tube). Therefore, the conventional cross bar assembly (50) causes a loss of space between the CCB assembly (50) and the floor of the vehicle.

[0064] A preferred embodiment of a cross car beam assembly (100) of the present disclosure will now be described with reference to Figures 4 to Figure 9. The preferred embodiment does not limit the scope and ambit of the present disclosure. FIGURE 4A illustrates an isometric view of a cross car beam assembly; FIGURE 4B illustrates a front view of the cross-car beam assembly.

[0065] The cross-car beam (CCB) assembly (100) comprises a cross car beam (CCB) tube (105), at least one bracket (115) and a steering column (110). The cross car beam tube is configured to be mounted on A-pillar of the vehicle. The cross car beam (CCB) tube (105) is defining a straight section (102A) and a non-linear bent “U” shaped section (102B) at the steering side or the driver side of the vehicle. The bracket (115) is configured on an operative base (103 A) of the U-shaped section (105). The bracket (115) is extending in an operative upward direction from the base (103A). The steering column (110) is mounted on the bracket (115) of the CCB tube (105) i.e. the steering column (110) is located on the operative top side of the CCB tube (105). Therefore, the proposed configuration of the CCB assembly (100) allows more vertical space above the steering column (110) to mount electrical units like HUD / AR- HUD within limited space in infront of a driver and BIW shell which is not feasible in the conventional type of design. The assembly is characterized such that the bracket (115) being configured to mount the steering column (115) in an operative upward direction to facilitate knee room (130) for the driver. FIGURE 5 A illustrates an isometric view of the cross car beam tube of the cross car beam assembly; FIGURE 5B illustrates front view of the cross car beam tube of the cross car beam assembly in accordance with the preferred embodiment of the present disclosure.

[0066] In an embodiment, the CCB is configured with an instrument panel cluster (132) as shown in figure 4 A and 4B, extending in an operative downward direction from the CCB. The instrument panel structure (132) facilitate the mounting of the instrument panel on the structure (132).

[0067] Further, the legs (103B) of the U-shaped section (102B) of the cross car beam (CCB) tube (105) are configured to be offset in an outward direction at a specific angle. Figure 6 illustrates an enlarged view of the non-linear U-shaped section of the CCB assembly of the present disclosure. Further, figure 6 also illustrates a plurality of dashboard brackets (117), configured on the U-shaped section. The dashboard brackets are configured to mount the CCB assembly (100) to the dashboard of the vehicle. The outward offset of the legs (103B) of the U-shaped tube section (102B) provides significant geometrical stiffness to the CCB assembly (100). As a result, the structure of the CCB assembly (100) offers following advantages:

[0068] • Noise, Vibration, and Harshness (NVH) Improvement: The geometrical stiffness helps in reducing noise and vibration levels, enhancing the overall driving experience by minimizing disturbances or vibration inside the vehicle.

[0069] • Impact Absorption: The increased stiffness allows the structure to better absorb impacts during collisions, contributing to improved crash performance and safety. Optimal Weight: The configuration achieves these improvements while maintaining an optimal weight for the structure, which is crucial for vehicle efficiency and performance.

[0070] Additionally, the CCB assembly (100) is configured to comply with safety regulations, ensuring that the vehicle meets necessary safety standards in the event of a crash. The overall performance of the vehicle is enhanced due to the improved NVH characteristics, better impact absorption, and adherence to safety requirements.In an embodiment, the steering column is mounted to a bracket (115) provided on the non-linear bent U-shaped section (102B) of the CCB tube (105).

[0071] In an embodiment, the U-shaped section (102B) is configured with at least one or more mounting provisions (134), such as hole. The mounting provisions facilitates the mounting of different electronic componets or wire routing on the CCB.

[0072] In an embodiment, the legs (103B) of the U-shaped section (102B) is offset outward at an angle ranging between 89° to 99° relative to the base (103A) of the U-shaped section (102B).

[0073] In a preffered embodiment, the legs (103B) of the U-shaped section (102B) is offset outward at 95°.

[0074] In an embodiment, the vertical distance between the center axis of the base (103 A) of the U- shaped section (102B) and the center axis of the CCB tube ranges from 205mm to 220mm, depending on the type of vehicle. For larger vehicles, such as lorries, buses, or SUVs, this proposed distance may exceed the specified range, contingent upon the strength and design requirements specific to these vehicles.In an embodiment, the steering column (110) is configured to be mounted on an operative base section of the U-shaped section (102B).

[0075] In an embodiment, the CCB (105) features a tube-in-tube configuration, where the diameter of the straight section (102A) ranges from 32 mm to 35 mm, and the diameter of the U- shaped section ranges from 38 mm to 54 mm.

[0076] In an embodiment, the operative ends of the straight section (102A) and the U-shaped section (102B) are joined together by means of welding. An operative end of the straight section (102A) is joined to an operative end of the U-shaped section (102B) by means of welding forming a weld-zone (120). The weld-zone (120) has the step configuration which provides suitable robustness and stiffness to the CCB. FIGURE 7 illustrates an isometric view of the cross car beam assembly with the steering column mounted thereon.

[0077] In an embodiment, the diameter of the straight section (102 A) is comparatively less than the diameter of the U-shaped section (102B). In an embodiment, the cross car beam (CCB) tube (105) is selected from a group of material consisting of alloyed steel.

[0078] As per the virtual simulation results of the CCB assembly (100), all the above parameters are meeting the desired criteria. Additionally, the configuration of the CCB assembly (100) yields weight saving as well as cost savings. The CCB tube (105) diameter and thickness matrix of the CCB:

[0079] The diameter and thickness ranges of the CCB tube in vehicles: In accordance with Figure 8A, the conventional method of mounting the steering column involves securing the steering column (110) to the conventional cross car beam (CCB) (50) from an operative downward direction. This traditional setup leads to a reduction in knee room (125) or driver knee space between the CCB (50) and the vehicle floor. The limited space becomes a significant concern during a vehicle collision or accident. Due to the restricted knee room (125), the driver’s knee can suffer severe injury and may get trapped between the steering column (110) and the floor space during collision. Figure 8B illustrates the scenario of zero knee room when a vehicle collision occurs, highlighting the increased risk of injury to the driver’s knee.

[0080] However, the proposed configuration of the CCB (100) as per the present disclosure, as depicted in Figure 9A, addresses this issue by modifying the structure of the cross car beam on the driver’s side. The CCB (100) is bent downward to create the non-linear U-shaped tube section (102B). The proposed configuration of the CCB (100) provides vertical lateral space that allows the steering column to be mounted on the bracket (115) extending in an upward direction. As a result, the steering column (110) is positioned on top of the bracket (115), following the operative direction of the CCB (100). The propsed configuration of CCB (100) results in significantly more knee room (130) or driver knee space on the driver’s side. Additionally, it allows for the packaging of elements such as a Heads-Up Display (HUD) within a compact boundary.

[0081] Furthermore, the U-shaped tube section (102B) of the present disclosure is configured with sufficient stiffness in its legs section (103B) by offsetting each of the legs (103B) at a desired angle, and thus enhancing torsional stiffness and minimizing steering column vibrations. Therefore, in the event of a collision, the increased knee space (130) delays the impact’s travel time to the driver’s knee, and provide more room (130) for the knee to absorb the impact. Thus the non-liner bent U shaped section (102B) of the CCB (100) reduces the risk of severe knee injury and the likelihood of the driver’s knee becoming stuck. Figure 9B demonstrates the available knee room (130) in the event of a collision, showcasing the benefits of the improved CCB design.

[0082] Thus, the conventional CCB (50) configuration compromises the driver knee space (125), which lead to increased injury risk during collisions. The improved CCB (100) configuration with the non-linear bent U-shaped tube section (102B) enhances the knee room (130) and safety by allowing better impact absorption and reducing the chances of knee entrapment.

[0083] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

[0084] TECHNICAL ADVANCEMENTS

[0085] The present disclosure described hereinabove has several technical advantages including, but not limited to, the cross car beam assembly, that:

[0086] • facilitates maximum knee space for the driver of the vehicle;

[0087] • facilitates maximum space availability for mounting accessories of the vehicle;

[0088] • increases the torsional stiffness of the cross car beam;

[0089] • optimises the weight by 1.6%; and

[0090] • improves the vibration absorption ability of the vehicle.

[0091] The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

[0092] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description.

[0093] Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0094] The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0095] Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[0096] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A cross car beam assembly (100) for a vehicle, said assembly configured to mount the steering column to facilitate knee room for the driver, said assembly (100) comprising:• a cross car beam (CCB) tube (105) defining a straight section (102A) and a non-linear bent U-shaped section (102B), said cross car beam tube (105) configured to be mounted on A-pillar of the vehicle;• at least one bracket (115) configured on an operative base (103 A) of said U- shaped section (102B), said bracket (115) extending in an operative upward direction from said base (103A); and• a steering column (110) configured to be mounted on said bracket (115), wherein said assembly is characterized such that said bracket (115) being configured to mount the steering column (115) in an operative upward direction to facilitate knee room (130) for the driver.

2. The assembly (100) as claimed in claim 1, wherein said straight section (102A) configured to be received on an operative end of said non-linear bent U-shaped section (102B) to define a tube in tube configuration.

3. The assembly (100) as claimed in claim 1, wherein the diameter of said straight section (102A) is comparatively less than the diameter of said non-linear bent U- shaped section (102B).

4. The assembly (100) as claimed in claim 3, wherein the diameter of said straight section (102 A) varies in the range of 32mm-35mm, and the diameter of said said nonlinear bent U-shaped section (102B) varies in the range of 38mm-54mm.

5. The assembly (100) as claimed in claim 1, wherein an operative end of said straight section (102A) is joined to an operative end of said non-linear bent U-shaped section (102B) by means of welding forming a weld-zone (120).

6. The assembly (100) as claimed in claim 5, wherein said weld-zone (120) has a step configuration.

7. The assembly (100) as claimed in claim 1, wherein said steering column (110) is configured to be mounted on an operative base section of said non-linear bent U- shaped section (102B).

8. The assembly (100) as claimed in claim 1, wherein said cross car beam tube (105) is configured to be mounted to A-pillar of the vehicle.

9. The assembly (100) as claimed in claim 1, wherein legs (103B) of said U-shaped section (102B) is offset outward at an angle ranging between 89° to 99° relative to base of said U-shaped section (105).

10. The assembly (100) as claimed in claim 1, wherein cross car beam (CCB) tube (105) is selected from a group of material consisting of alloyed steel.

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