Load transmission member

Abstract

Aspects of the present invention relate to a load transmission member for mounting in a channel of a body structure, the load transmission member comprising: an elongate body configured to transmit a load to the body structure along a non-linear load path, in use, wherein the elongate body comprises an upper surface, a lower surface and opposing first and second side surfaces extending therebetween; a recess extending at least partially along a length of one of the upper surface or the lower surface; a mounting formation located on the elongate body and configured to facilitate mounting of the load transmission member to the channel of the body structure.

Description

[0001] LOAD TRANSMISSION MEMBER

[0002] TECHNICAL FIELD

[0003] The present disclosure related to a load transmission member. Aspects of the invention relate to a load transmission member, a vehicle body assembly and to a vehicle.

[0004] BACKGROUND

[0005] Driven by environmental, economic and technological factors, vehicles, for example automotive vehicles, are transitioning from diesel and petrol internal combustion engines (ICEs) towards more sustainable alternatives, such as battery electric vehicles (BEV) or hybrid electric vehicles (HEV). In order to reduce the significant manufacturing costs associated with manufacturing new components for BEVs or HEVs, body structures from ICE vehicles may be used in BEVs or HEVs. This saves significantly on manufacturing costs, and may help to improve efficiency of the manufacturing process by using common components for the different types of vehicle.

[0006] It may be necessary to modify the components of the ICE vehicles for use in alternatively powered vehicles, for example BEVs and HEVs. These modifications may alter the structural strength of the vehicles’ body structure at particular locations, thereby providing locations of increased or decreased structural strength. In the event of a collision event, locations of decreased structural strength (or weak points) may fail prematurely compared to ICE vehicles.

[0007] It is an aim of the present invention to address one or more disadvantages associated with the prior art.

[0008] SUMMARY OF THE INVENTION

[0009] According to an aspect of the present invention there is provided a load transmission member for mounting in a channel of a body structure, the load transmission member comprising: an elongate body configured to transmit a load to the body structure, in use, wherein the elongate body comprises an upper surface, a lower surface and opposing first and second side surfaces extending therebetween; a recess extending at least partially along a length of one of the upper surface or the lower surface; a mounting formation located on the elongate body and configured to facilitate mounting of the load transmission member to the channel of the body structure.

[0010] Optionally, the load transmission member is configured to transmit a load to the body structure along a nonlinear load path.

[0011] Vehicles are moving away from diesel and petrol internal combustion engines and towards more sustainable alternatives, such as battery electric vehicles. In order to provide the space for the power source, for example a battery arrangement, dimensions of the body structure, for example a height of the channel, may have to be reduced. This reduces the structural strength of said body structure.

[0012] The load transmission member helps to bridge weak points located on the body structure along the non-linear load path, thereby transmitting the load in more than one direction to alternate components of the body structure with a greater structural strength. This helps to reinforce the body structure and helps to reduce the likelihood of the body structure failing prematurely, for example in the event of a crash.

[0013] Optionally, the mounting formation comprises at least one abutment formation configured to contact the channel, in use.

[0014] Optionally, the at least one abutment formation comprises a plurality of discrete abutment formations configured to each contact the channel at a discrete location.

[0015] The abutment formations provide contact surfaces between the load transmission member and the channel, without the need for the entirety of the load transmission member to be in abutment with the channel. This arrangement helps to increase the allowable manufacturing tolerances of the elongate body (aside from the abutment formations) because only the abutment formations needs to be machined accurately enough for abutment with the channel. Additionally, the abutment formations reduce the amount of material-on-material contact, thereby reducing surface damage.

[0016] Optionally, the at least one abutment formation is an abutment surface that protrudes from the first and / or second side surface of the elongate body, and / or wherein the at least one abutment formation is a foot protruding from the lower surface of the elongate body.

[0017] The protruded surfaces enable contact of the abutment formation and the channel, and are simple formations to manufacture and machine to the desired tolerances.

[0018] Optionally, the mounting formation comprises at least one mounting bore configured to receive a fastener, optionally wherein the mounting formation comprises a plurality of mounting bores located on the upper surface, lower surface, the first side surface and / or the second side surface.

[0019] The mounting bores help to securely mount the load transmission member to the channel, thereby improving the reinforcement provided to the body structure by the load transmission member along the non-linear load path.

[0020] Optionally, the mounting formation is configured to attach a deflector arrangement to the body structure via the load transmission member.

[0021] The load transmission member performs the secondary function of attaching the deflector arrangement. This helps to reduce the number of components used to assemble the body structure, and therefore the complexity of manufacture and assembly of the body structure.

[0022] Optionally, at least one of the plurality of mounting bores is configured to attach the deflector arrangement to the body structure via the load transmission member.

[0023] Using the mounting bores as attachment locations for the deflector arrangement helps to simplify the complexity of manufacture and assembly of the body structure. Additionally, the attachment of the deflector arrangement to the load transmission member provides additional securing of the load transmission member to the channel. Optionally, the elongate body comprises a substantially I-shaped cross-section extending at least partially along the length of the elongate body and / or wherein the elongate body comprises a substantially U-shaped cross-section extending at least partially along the length of the elongate body. I-shaped beams are widely known, having an I-shaped cross-section, wherein the bards of the serif-font letter “I” represent flanges of the I-shaped cross-section, sometimes called an I-beam. When rotated through 90 degrees such an I-beam may be considered to have a recess on the upper surface and a recess on the lower surface as described herein.

[0024] The I-shaped cross-section minimises the amount of material whilst achieving the desired load bearing capabilities of the load transmission member. The I-shaped cross-section is particularly useful as reinforcement of the body structure because it is capable of bending under stress as opposed to buckling. The U-shaped channel minimises material, whilst enabling abutment and mounting between the load transmission member and the channel.

[0025] Optionally, the cross-section of the elongate body transitions from a substantially I-shaped cross-section to a substantially U-shaped cross-section.

[0026] The transition of the cross-section minimises the amount of material and increases the load bearing capabilities of the load transmission member, whilst enabling abutment and mounting between the load transmission member and the channel.

[0027] Optionally, the load transmission member is manufactured using a forging process.

[0028] Forging has cost advantages, particularly in precision manufacturing in high volume productions. Additionally, forging may require fewer secondary manufacturing operations.

[0029] Optionally, the at least one abutment formation located on the lower surface of the elongate body comprises a first end abutment formation located at or towards a first end of the elongate body, a second end abutment formation located at or towards a second end of the elongate body and / or an intermediate abutment formation located between the first end and the second end.

[0030] Providing abutment formations at or towards the first and second ends helps to balance the load transmission member within the channel, and to distribute force exerted on the channel by the load transmission member. Providing the intermediate abutment formation helps to provide additional balancing and load distribution towards the centre of the load transmission member.

[0031] Optionally, the at least one mounting bore is located on the at least one abutment formation.

[0032] The mounting bores help to securely mount the load transmission member to the channel, thereby improving the reinforcement provided to the body structure by the load transmission member along the non-linear load path.

[0033] Optionally, the at least one mounting bore extends through the first or second side wall at an acute angle with respect to a central longitudinal axis of the elongate body. Providing angled mounting bores on the side walls helps to improve ease of manufacture of the channel in the body structure and the mounting bores, whilst improving ease of mounting of the load transmission member to the channel.

[0034] Optionally, the recess extends along a majority of the one of the upper surface or lower surface of the elongate body in a longitudinal direction.

[0035] The recess extending along a majority of the elongate body reduces the weight whilst meeting the desired resistance to bending of the load transmission member.

[0036] Optionally, the recess comprises an upper recess extending along the upper surface of the elongate body, and a lower recess extending along the lower surface of the elongate body to define the substantially I-shaped cross-section.

[0037] The I-shaped cross-section minimises the amount of material whilst achieving the desired load bearing capabilities of the load transmission member. The I-shaped cross-section is particularly useful as reinforcement of the body structure because it is capable of bending under stress as opposed to buckling.

[0038] Optionally, the load transmission member is configured to transmit load along at least two axis.

[0039] Optionally, the elongate body defines a height extending in a direction transverse to a central longitudinal axis of the elongate body, and wherein the height increases towards the second of the elongate body.

[0040] Optionally, the change in height is configured to facilitate transmission of the load along the non-linear load path to an elevated location of the body structure with respect to the first end of the elongate body.

[0041] Optionally, the load transmission member is manufactured from an aluminium alloy.

[0042] Aluminium is lightweight and has a high corrosion resistance.

[0043] According to a further aspect of the invention, there is provided a vehicle body assembly comprising: a body structure comprising a channel extending along the body structure; and a load transmission member as disclosed herein mounted to the channel to transmit a load to the body structure along a load path, in use.

[0044] Optionally, the load path is a non-linear load path.

[0045] Vehicles are moving away from diesel and petrol internal combustion engines and towards more sustainable alternatives, such as battery electric vehicles. In order to provide the space for the power source, for example a battery arrangement, dimensions of the body structure, for example a height of the channel, may have to be reduced. This reduces the structural strength of said body structure.

[0046] The load transmission member helps to bridge weak points located on the body structure along the non-linear load path, thereby transmitting the load in more than one direction to alternate components of the body structure with a greater structural strength. This helps to reinforce the body structure and helps to reduce the likelihood of the body structure failing prematurely, for example in the event of a crash.

[0047] Optionally, the vehicle body assembly comprises a deflector arrangement. Optionally, the deflector arrangement is attached to the body structure via the mounting formation of the load transmission member.

[0048] The deflector arrangement protects important components of the vehicle, for example the battery arrangement, in the event of a crash by deflecting debris away from the battery arrangement. Using the mounting formations as attachment locations for the deflector arrangement helps to simplify the complexity of manufacture and assembly of the body structure. Additionally, the attachment of the deflector arrangement to the load transmission member provides additional securing of the load transmission member to the channel.

[0049] Optionally, the load transmission member extends at an acute angle with respect to a central longitudinal axis of the vehicle body assembly.

[0050] The angle of the load transmission member helps to distribute the load along a non-linear load path, and to different locations of the vehicle body assembly with an increased load capacity.

[0051] Optionally, the mounting formation comprises at least one mounting bore and a corresponding fastener located in the mounting bore to mount the load transmission member to the channel, in use.

[0052] The mounting bores and fasteners help to securely mount the load transmission member to the channel, thereby improving the reinforcement provided to the body structure by the load transmission member along the non-linear load path.

[0053] According to a further aspect of the invention, there is provided a vehicle comprising a vehicle body assembly as disclosed herein.

[0054] Optionally, the channel of the bodywork structure is located towards a front of the vehicle with respect to a principal direction of travel of the vehicle.

[0055] Such a vehicle body assembly and vehicle benefit from the advantages of the load transmission member outlined above.

[0056] Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.

[0057] BRIEF DESCRIPTION OF THE DRAWINGS

[0058] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0059] Figure 1 shows a schematic plan view of a vehicle in accordance with an embodiment of the invention;

[0060] Figure 2 shows a perspective view of a vehicle body assembly for the vehicle of Figure 1 ; Figure 3 shows a perspective view of an underside of a portion of a right side of the vehicle body assembly of Figure 2;

[0061] Figure 4 shows a perspective view of a topside of a portion ofthe right side of the vehicle body assembly of Figure 2;

[0062] Figure 5 shows a perspective view of a topside of a connecting member located on the right side of the vehicle body assembly of Figure 2;

[0063] Figure 6 shows a plan view of the connecting member of Figure 5 located on the right side ofthe vehicle body assembly of Figure 2;

[0064] Figure 7 shows a cross-sectional front view across the cross-section x-x of the vehicle body assembly of Figure 6;

[0065] Figure 8 shows a perspective view of a load insert member of the vehicle body assembly of Figures 2 to 7;

[0066] Figure 9 shows a left side view of the load insert member of Figure 8;

[0067] Figure 10 shows a right side view of the load insert member of Figure 8;

[0068] Figure 11 shows a top plan view of the load insert member of Figure 8; and Figure 12 shows a base plan view of the load insert member of Figure 8.

[0069] DETAILED DESCRIPTION

[0070] A load transmission member 30 in accordance with an embodiment ofthe present invention is described herein with reference to accompanying Figures 1 to 12. As shown in Figures 2 to 7, the load transmission member 30 is mounted to a vehicle body assembly 12 of a vehicle 10.

[0071] In Figure 1 , the vehicle 10 defines a central longitudinal axis a-a, a left side 10a and a right side 10b with respect to the central longitudinal axis a-a, and a front 10c and a rear 10d with respect to a principal direction of travel of the vehicle 10. The left side 10a is taken to mean the side which is closest to the viewer when the vehicle 10 is viewed from the left, and the right side 10b is taken to mean the side which is closest to the viewer when the vehicle 10 is viewed from the right. It shall be appreciated that the left side 10a and right side 10b of the vehicle 10 are the same as the left side 10a and right side 10b of the vehicle body assembly 12. It shall be understood that the principal direction of travel corresponds to when the vehicle 10 is driving substantially forwards under normal operating conditions. The vehicle 10 includes a drive arrangement configured for providing motive power to the wheels of the vehicle 10. The drive arrangement includes a power source 16 and a prime mover (not shown) configured to provide motive power to the wheels, as well as power to auxiliary components of the vehicle 10. In the embodiment of Figures 1 to 12, the vehicle 10 is a battery electric vehicle (BEV) 10. The prime mover is therefore an electric motor, and the power source 16 is a battery arrangement 16. It shall be appreciated that in alternative embodiments, the prime mover may be an internal combustion engine (ICE), and / or the vehicle 10 may be a hybrid electric vehicle (HEV) 10.

[0072] A front portion of the vehicle body assembly 12 is illustrated in Figures 2 and 3. Figure 2 shows a topside of the front portion of the vehicle body assembly 12, and Figure 3 shows an underside of a portion of the right side 10b of the vehicle body assembly 12. The vehicle body assembly 12 supports and holds together the components of the vehicle 10, for example the battery arrangement 16, and provides structural integrity, strength and protection to the vehicle 10 in the event of a frontal impact arising from a collision. The vehicle body assembly 12 includes a body structure 14 comprising a front structure 18 located at the front 10c of the vehicle 10, a rear structure (not shown) located at the rear l Od of the vehicle 10. The body structure 14 further includes axial runners 20 (see Figure 4) located on the left side 10a and right side 10b respectively and extending parallel to the central longitudinal axis a-a. As well as providing support for components of the vehicle 10, the front structure 18 of the body structure 14 absorbs and dissipates energy generated during a collision event, thereby helping to protect the vehicle’s occupants in a cabin of the vehicle.

[0073] The vehicle body assembly 12 includes a deflector arrangement 26, illustrated in Figures 3 and 7, configured to protect the battery arrangement 16. The deflector arrangement 26 may be made up of a plurality of deflector plates fastened together to form the deflector arrangement 26. The deflector arrangement 26 protects the battery arrangement 16 in the event of a collision event by deflecting debris away from the battery arrangement 26. The deflector arrangement 26 is mounted to the body structure 14. This enables the deflector arrangement 26 to transmit load exerted on the deflector arrangement 26 to the body structure 14, which may have a greater structural strength than the deflector arrangement 26. This helps to reduce the load on the fasteners of the deflector arrangement 26 in the event of a collision, and reduces the likelihood of the plates of the deflector arrangement 26 detaching upon impact.

[0074] The body structure 14 includes a connecting member 22 configured to secure the front structure 18 to the axial runner 20. In vehicles 10 where the deflector arrangement 26 is present, the deflector arrangement 26 may be mounted to the connecting member 22. It shall be appreciated that BEVs, HEVs and vehicles with an ICE may include common components in order to reduce manufacturing costs. The connecting member 22 may be one such common component. The connecting member 22 may be modified, for example the dimensions of the connecting member 22 may be modified, to suit the type of vehicle 10. However, due to the similarities in the design of connecting members 22 for the different types of vehicle, the connecting members 22 for each type of vehicle may be manufactured using substantially the same manufacturing line, thereby significantly reducing manufacturing costs.

[0075] As illustrated in Figure 2, a first connecting member 22 is provided on the left side 10a to connect the front structure 18 to the left side axial runner 20, and a second connecting member 22 is provided on the right side 10b to connect the front structure 18 to the right side axial runner 20. The first and second connecting members 22 are provided in substantially symmetrical positions about the central longitudinal axis a-a of the vehicle 10, and towards the front 10c of the vehicle 10 so as to connect the front structure 18 to the axial runners 20. Although the left and right of the body structure 14 are of substantially the same configuration, the right side of the body structure 14, illustrated in Figures 3 to 7 (i.e. including the right side connecting member 22 and right side axial runner 20) will be described hereafter for reasons of clarity and brevity. The second connecting member 22 will be referred to hereafter generally as the connecting member 22. The connecting member 22 may be manufactured using a casting process. The connecting member 22 defines an inboard side 23a located towards the central longitudinal axis a-a of the vehicle 10, and an outboard side 23b located towards the right hand side 10b of the vehicle 10 . Figure 5 shows a topside of the connecting member 22 of the right side 10b of the vehicle 10 (or vehicle body assembly 12). As illustrated in Figure 5, the connecting member 22 is non-linear. In particular, the connecting member 22 may be a “swan neck” casting 22, meaning that the casting includes an elevation in plane. The elevation in plane is an elevation from a first horizontal plane to a second horizontal plane located above the first horizontal plane, in use. The elevation in plane extends from the outboard side 23b towards the inboard side 23a. Put another way, the inboard side 23a is located higher than the outboard side 23b relative to a ground surface, in use. This shape of connecting member 22 is particularly advantageous for distributing load in more than one direction to the rest of the body structure 14 in the event of a collision to the front structure 18 of the vehicle 10, as will be described in more detail below. The load L imparted on the connecting member 22 by the front structure 18 is illustrated schematically in Figure 6 as a linear load L extending parallel to the central longitudinal axis a-a, however it shall be appreciated that the load may be non-linear, and / or may be transmitted in more than one direction. Figure 6 shows the topside (i.e. a plan view) of the connecting member 22 of the right side 10b of the vehicle 10.

[0076] The connecting member 22 includes a first branch 22a and a second branch 22b extending rearward, in use. The first branch 22a is located on the inboard side 23a, and the second branch 22b is located on the outboard side 23b. The first branch 22a is used to connect to the axial runner 20 of the body structure 14 to the connecting member 22, and the second branch 22b extends along the right side 10b ofthe vehicle 10 outboard of the axial runner 20 to connect to the right side of the vehicle body assembly 12, i.e. the sill of the body structure 14.

[0077] As illustrated in Figure 6, the first branch 22a extends at an acute angle relative to the central longitudinal axis a-a, and the second branch 22b extends at an acute angle in an opposite direction relative to the central longitudinal axis a-a. The first branch 22a is partially spaced apart from the second branch 22b. Put another way, the connecting member 22 is forked in a rearward direction to form the first branch 22a and the second branch 22b. The first branch 22a is located on an elevated plane compared to the second branch 22b, so as to define the “swan neck” shape. Put anotherway, in use, the first branch 22a is higherthan the second branch 22b relative to the ground surface. As such, the axial runner 20 is higher than the second branch 22b of the connecting member 22 when the vehicle 10 is assembled. The first and second branches 22a, 22b are therefore intended to transmit some of the load L imparted by the front structure 18 along the axial runner 20, and some of the load along the second branch 22b outboard to the right side 10b of the vehicle 10 and to the underneath of the vehicle 10. This is advantageous because the right side 10b of the vehicle 10 and the axial runner 20 have increased structural strength, and the right side 10b of the vehicle 10 is located away from occupants and important components of the vehicle 10, such as the battery arrangement 16. Accordingly, the purpose of the swan neck connecting member 22 of the body structure 14 is to transmit the load L in a nonlinear manner and in more than one direction. In particular, the purpose of the swan neck section 22 of the body structure 14 is to transmit the load L to the body structure 14 along more than one plane. The body structure 14 includes a channel 28, illustrated in Figure 7. In particular, the channel 28 is located on the connecting member 22, for example on the first branch 22a of the connecting member 22. It shall be appreciated that the channel 28 may be present on the connecting member 22 of ICE vehicles, as well as the connecting members 22 of BEVs 10 or HEVs. In embodiments where the connecting member 22 is of a BEV 10, in orderto provide space underneath the body assembly 14 forthe battery arrangement 16, a height of the connecting member 20, including a depth of the channel 28, may be reduced. This reduces the structural strength of the connecting member 22, particularly along the first branch 22a between the front structure 18 and the axial runner 20. In the BEV 10 of Figure 1 , the connecting member 22 of the body structure 14 is therefore a weaker point of the body structure 14 compared to connecting members 22 with a greater channel depth (and therefore greater structural strength). The connecting member 22 is therefore more likely to buckle or fail in the event of a collision.

[0078] The channel 28 extends at an acute angle with respect to the central longitudinal axis a-a of the vehicle 10. In particular, as illustrated in Figure 6, the channel 28 may extend substantially parallel to the first branch 22a. As illustrated in Figure 7, the channel 28 includes a substantially planar base wall 28c and opposing first and second side walls 28a, 28b extending therefrom. A least one of the opposing side walls 28a, 28b extends at a non-perpendicular angle from the base wall 28c. The first side wall 28a may extend at a greater acute angle from the base wall 28c than the second side wall 28b. This helps to improve ease of manufacturing of the channel 28, for example compared to a channel with side walls which extend perpendicular to the base wall. Additionally, the angled walls 28a, 28b conform with a profile of the axial runner 20, thereby simplifying assembly and manufacture.

[0079] As illustrated in Figures 2 to 7, a load transmission member 30 is mounted in the channel 28 of the body structure 14, for example in the channel 28 of the connecting member 22, to form the vehicle body assembly 12. As illustrated in Figure 6, the load transmission member 30 extends substantially coaxially with the channel 28. As such, the load transmission member 30 extends at an acute angle with respect to the central longitudinal axis a-a of the vehicle 10. This enables the load transmission member 30 to distribute load along a non-linear path, and along more than one axis. The load transmission member 30 helps to bridge the weaker point of the body structure 14, for example at the connecting member 22, thereby helping to transmit the load L to the outboard side 23a and to the axial runner 20 of the body structure 14. Additionally, the load transmission member 30 helps to reinforce the connecting member 22 so that the force exerted on the connecting member 22 by the deflector arrangement 26 in the event of a collision is distributed to the body structure 14. Accordingly, the structural strength of the body structure 14, particularly of the connecting member 22, is increased.

[0080] It shall be appreciated that although the load transmission member 30 has been described in relation to the body structure 14 of the BEV 10, the load transmission member 30 may also be used to reinforce body structures of alternate vehicles, for example vehicles with an ICE or a HEVs. Furthermore, it shall be appreciated that the load transmission member 30 may be mounted in an alternative channel of the body structure 14 to provide reinforcement to alternative parts of the body structure 14. The load transmission member 30 is illustrated in Figures 8 to 12. The load transmission member 30 is manufactured using a forging process. It shall be appreciated that in alternative embodiments, the load transmission member 30 may be manufactured using an alternative process, for example casting. The load transmission member 30 is manufactured from an aluminium alloy, however alternative materials, for example alternative metal alloys, may be used. The load transmission member 30 includes an elongate body 32 configured to transmit the load L to the body structure 14 along the non-linear load path, in use. The load transmission member 30 is configured to transmit load to more than one location on the body structure 14. The elongate body 32 includes an upper surface 32a, a lower surface 32b and opposing first and second side surfaces 32c, 32d extending therebetween. In addition, the elongate body 32 defines a first end 33a, or front end 33a, when assembled in the channel 28, a second end 33b, or rear end 33b, opposing the first end 33a and located rear of the front end 33b, and a neck portion 33c located between the first end 33a and the second end 33b. In particular, the neck portion 33c is located towards a centre of the elongate body 32. It shall be appreciated that the neck portion 33c may be omitted. The load transmission member 30 includes a recess 36a, 36b extending at least partially along a length of one of the upper surface 32a and / or the lower surface 32b. In particular, the recess 36a, 36b extends along a majority of the upper surface 32a and / or lower surface 32b of the elongate body 32 in a longitudinal direction.

[0081] The elongate body 32 is substantially non-linear. In addition to the extension of the load transmission member 30 at the acute angle with respect to the longitudinal axis a-a, the non-linear elongate body 32 facilitates the non-linear transmission of load to the body structure 14 along more than one axis. As illustrated in Figures 9 and 10, a height of the elongate body 32 increases from the first end 33a to a location at ortowards the second end 33b. As such, the elongate body 32 defines an elevation from the first end 33a to the second end 33b. In particular, the upper surface 32a is substantially non-planar and defines the elevation in height. The lower surface 32b is substantially planar. The upper surface 32a extends substantially parallel to the base wall 28c from the first end 33a towards the neck portion 33c, and curves upward relative to the base wall 28c from the neck portion 33c to define the increase in height toward the second end 33b. The upper surface 32a may then include a deviation in height towards the base wall 28c at the second end 33b, however this deviation in height may be omitted. This helps to “fill” as much of the channel 28 as possible, whilst providing space to mount alternative components of the body structure 14. The change in height of the elongate body 32 helps to facilitate transmission of the load along the non-linear load path to an elevated location of the body structure 14 with respect to the first end 33a of the elongate body 32.

[0082] In addition to being non-linear in an axial plane (or in side view), the load transmission member 30 may be non-linear in plan view, as illustrated in Figures 11 and 12. A width of the first end 33a extending between the first and second side surfaces 32c, 32d is less than a width of the second end 33b extending between the first and second side surfaces 32c, 32d. The first side surface 32c curves outwardly with respect to an elongate axis b-b of the elongate body 32, for example outwardly from the neck portion 33c. In addition, the first and second side surfaces 32a, 32b taper inward from the first end towards the neck portion 33c of the elongate body 32. The non-linear elongate body 32 (in both the side view and plan view) of the load transmission member helps to facilitate the distribution of load along the non-linear load path, and along more than one axis and more than one plane. The first and second side surfaces 32c, 32d include a continuously recessed portion 40a, illustrated in Figure 8. The recessed portion 40a extends from the neck portion 33c and around the second end 33b. The recessed portion 40a extends from the lower surface 32b and terminates before the upper surface 32a. The recessed portion 40a on the first side surface 32c extends at an acute angle from the lower surface 32b, as illustrated in Figures 8 and 12. The recessed portion 40a is defined by a protruded upper edge 40b located above the recessed portion and extending from the upper surface 32a. The protruded upper edge 40b is an extension of the first and second side walls 32c, 32d that extends from the first end 33a (i.e. where no recessed portion 40a is present).

[0083] It shall be appreciated that the shape of the elongate body 32 described above is one possible example of an elongate body 32. In alternative embodiments, the specific configuration of the elongate body 32 may vary, for example the first and second side surfaces 32c, 32d may be substantially planar.

[0084] In the embodiment of the Figures, the recess 36a, 36b includes an upper recess 36a, illustrated in Figures 8 and 1 1 , extending along the upper surface 32a of the elongate body 32, and a lower recess 36b, illustrated in Figure 12, extending along the lower surface 32b of the elongate body 32. The upper and lower recesses 36a, 36b extend discontinuously along the upper surface 32a and the lower surface 32b respectively. As such, the elongate body 32 body defines a substantially I-shaped cross-section extending at least partially along the length of the elongate body 32, and a substantially U-shaped cross-section extending at least partially along the length of the elongate body 32, as will be described in more detail below.

[0085] The load transmission member 30 includes a mounting formation located on the elongate body 32 and configured to facilitate mounting of the load transmission member 30 to the channel 28 of the body structure 14. In addition to facilitating mounting of the load transmission member 30 to the channel 28, the mounting formation is configured to attach the deflector arrangement 26 to the body structure 14 via the load transmission member 30, as illustrated in Figures 3 and 7.

[0086] The mounting formation includes at least one mounting bore 34a-g configured to receive a corresponding fastener 35a, 35f, 35g. The mounting formation may include a plurality of mounting bores 34a-g located on the upper surface 32a, the lower surface 32b, the first side surface 32c and / or the second side surface 32d. Although only fasteners 35a, 35f, 35g are illustrated in Figures 3 and 7 for reasons of clarity, it shall be appreciated there may be a fastener 35a, 35f, 35g located in each of the mounting bores 34a-g. In particular, the mounting formation includes a plurality of mounting bores 34a-g located on all of the upper surface 32a (Figure 10), the lower surface 32b (Figure 11), the first side surface 32c (Figure 8) and the second side surface 32d (Figure 9). Some of the mounting bores 34a-g are through-holes 34a-e, and some of the mounting bores 34a-g are blind holes 34f, 34g, as will be described in more detail below. As such, some of the fasteners 35a, 35f, 35g may be nuts and bolts, and some of the fasteners 35a, 35f, 35g may be screws.

[0087] At least one of the mounting bores, for example mounting bores 34f, 34g, may extend through the first side wall 32c at an acute angle with respect to the central longitudinal axis b-b of the elongate body 32 (as illustrated in Figure 7 in relation to bore 34f). Providing angled mounting bores on the first side wall 32c helps to improve ease of mounting of the load transmission member 30 to the channel 28.

[0088] The mounting formation includes at least one abutment formation 38a-g configured to contact the channel 28, in use. The at least one abutment formation 38a-g includes a plurality of discrete abutment formations 38a-g configured to each contact the channel 28 at a discrete location. The abutment formations 38a-g are machined during manufacturing once the load transmission member 30 has been manufactured using the forging process. The abutment formations 38a-g provide contact surfaces between the load transmission member 30 and the channel 28, without the need for the entirety of the load transmission member 30 to be in abutment with the channel 28. This arrangement helps to increase the allowable manufacturing tolerances of the elongate body 32 (aside from the abutment formations 38a-g) because only the abutment formations 38a-g need to be machined accurately enough for abutment with the channel 28. Additionally, the abutment formations 38a-g reduce the amount of material-on-material contact, thereby reducing surface damage.

[0089] The abutment formations 38a-g may be located on the lower surface 32b, first side surface 32c and / or the second side surface 32d. In the embodiment of the Figures, the abutment formations 38a-g are located on the lower surface 32b, as illustrated in Figure 12, and the first side surface 32c, as illustrated in Figure 9.

[0090] Referring to Figure 12, four abutment formations 38a-d are provided on the lower surface 32b. In particular, the abutment formations 38a-d are feet protruding from the lower surface 32b of the elongate body 32. As such, the feet 38a-d contact the channel 28 (i.e. the base wall 28c of the channel 28), whilst the remainder of the lowersurface 32b is spaced apart from the base wall 26c of the channel 28. The abutment formations 38a- d located on the lower surface 32b of the elongate body 32 include a first end abutment formation 38a located at or towards the first end 33a of the elongate body 32, a second end abutment formation 38c, 38d located at or towards the second end 33b of the elongate body 32, and an intermediate abutment formation 38b located between the first end 33a and the second end 33b, for example at the neck portion 33c. As illustrated in Figure 12, the intermediate abutment formation 38b may be located at a central location between the first end 33a and the second end 33b.

[0091] As illustrated in Figure 12, the first end abutment formation 38a and the intermediate abutment formation 38b extend between the first and second side surfaces 32c, 32d of the elongate body 32, for example along an entirety of a distance extending between the first and second side surfaces 32c, 32d. As such, the first end abutment formation 38a and the intermediate abutment formation 38b separate the lower recess 36b into two lower recess portions 36b. It shall be appreciated that the number of lower recess portions 36b may depend on the number of abutment formations 38a, 38b that extend entirely or partially between the first and second side surfaces 32a, 32b. The first abutment formation 38a and the intermediate abutment formation 38 define the substantially U-shaped cross section. This is because, at these locations, there is no lower recess 36b to define the I-shaped cross-section (due to the abutment between the lower surface 32b and the base wall 28c), only the upper recess 36a. The abutment formations 38a, 38b therefore help to define the transition of the cross-section of the elongate body 32 between the substantially I-shaped cross-section shown in Figure 7 and the substantially U-shaped cross-section at the location of the first and intermediate abutment formations 38a, 38b. The first and intermediate abutment formations 38a, 38b form substantially rectangular and planar abutment surfaces 38a, 38d for contacting the channel 28.

[0092] The second end abutment formations 38c, 38d are a pair of feet 38a, 38da spaced apart and located towards the first side surface 32c and the second side surface 32d respectively. As such, a portion of the lower surface 32b extending between the second abutment formations 38b, 38c does not contact the base wall 28c of the channel 28. Providing abutment formations 38a-d at or towards the first and second ends 33a, 33b helps to balance the load transmission member 30 within the channel 28, and to distribute force exerted on the channel 28 by the load transmission member 30. Providing the intermediate abutment formation 38b helps to provide additional balancing and load distribution towards the centre, or neck portion 33c, of the load transmission member 30.

[0093] Three abutment formations 38e-g are provided on the first side surface 32c. In particular, the abutment formations 38e-f protrude from the first side surface 32c. As such, the abutment formations 38e-g contact the channel 28 (i.e. the first side 28a of the channel 28), whilst the remainder of the first side surface 32c is spaced apart from the side wall 28a of the channel 28. The abutment formations 38e-g located on the first side surface 32c of the elongate body 32 include a first abutment formation 38e located closer to the first end 33a than the second end 33b, and second and third abutment formations 38f, 38g located closer to the second end 33b than the first end 33a. The second and third abutment formations 38f, 38g are located on the recessed portion 40a, i.e. below the protruded upper edge 40b of the first side surface 32c. The second and third abutment formations 38f, 38g extend at a non-perpendicular angle from the lower surface 32b. As such, the angle of the second and third abutment formations 38f, 38g corresponds to the angle of the first wall 26a. The first abutment formation 38e may extend at an angle from the lower surface 32b. As illustrated in Figure 8, the first abutment formation 38e may extend from the first side surface 32c and through to the second side surface 32d so as to separate the upper surface 36a into two section. The cross-section of the elongate body 32 through the first abutment formation 38e is therefore substantially U-shaped, with the U-shape being defined by the lower recess 36b.

[0094] It shall be appreciated that in alternative embodiments, any suitable number and / or arrangement of abutment formations 38a-g may be used. For example, abutment formations may be provided on the second side surface 32d. Additionally or alternatively, any suitable number of abutment formations 38a-g may be provided at any location on the lower surface 32a, first side surface 32c and / or second side surface 32d.

[0095] The at least one mounting bore 34a-g is located on the at least one abutment formation 38a-g. In particular, in the embodiment of the Figures, there are mounting bores 34e-g located on each of the three abutment formations 38e-g provided on the first side surface 32c, and mounting bores 34a, 34b located on the first end abutment formation 38a and the intermediate abutment formation 38b located on the lower surface 32b. Locating the mounting bores 34a, 34b, 34e-g on the abutment formations 38a, 38b, 38e-g helps to reduce the number of surfaces that need machining, and provides a more secure mounting by attaching the surfaces 38a- g in contact with the channel 28 to the channel 28. This may also help to reduce the likelihood of misalignment of the mounting bore 34a, 34b, 34e-g, and therefore of the associated fastener 35a, 35f, 35g loosening, in use. The at least one mounting bore 34a-g may extend transversely into the abutment formation 38a-g. The abutment formations 38a, 38b, 38f, 38g are axially spaced apart from one another along the central longitudinal axis b-b of the elongate body 32. This enables the fasteners to extend through the mounting bores 34a, 34b, 34f, 34g without obstructing the other of the mounting bores 34a, 34b, 34f, 34g. Additionally, the provision of distributed mounting locations helps to improve distribution of load exerted on the load transmission member 30 by the deflector arrangement 26.

[0096] It shall be appreciated that some of the abutment formations 38c, 38d do not include a mounting bore 34a-g provided thereon. Further, some of the mounting bores 34c, 34d are not located on the abutment formations 38a-g. For example, in the embodiment illustrated in Figures 11 and 12, two mounting bores 34c, 34d are provided on the lower recess 36b. The mounting bores 34a-g are through holes which extend through to the upper recess 36a. It shall be appreciated that the mounting bores 34c, 34d located on the abutment formations 38 may have the primary function of securely mounting the deflector arrangement 26 and / or load transmission member 30 to the channel 28, and the mounting bores 34c, 34d which are not located on the abutment formations 38 may have the primary function of locating the load transmission member 30 relative to the channel 28 and the deflector arrangement 26.

[0097] As described above, the mounting formation is configured to attach a deflector arrangement 26 to the body structure 14 via the load transmission member 30, as illustrated in Figures 3 and 7. The deflector arrangement 26 is mounted closer to the first end 33a than the second end 33b. In the embodiment of the Figures, the abutment formation 38f and associated mounting bore 34f located on the first side surface 32c is used for attachment of the deflector arrangement 26, and the abutment formations 38a, 38b and associated mounting bores 34a, 34b located on the lower surface 32b are used for attachment of the deflector arrangement 26. In addition, the mounting bore 34c (which is not located on an abutment formation 38a-g) is used to mount the deflector arrangement 26. The mounting bores 34f, 34g are blind bores 34f, 34g, as illustrated in Figure 7 in relation to blind bore 34f. The blind bores 34f, 34g are of substantially the same configuration, however the mounting bore 34g is not used to attach the deflector arrangement 26. The mounting bores 34a-d are through bores, however through bore 34d is not used to attach the deflector arrangement 26 in the embodiment of the Figures.

[0098] It shall be appreciated that the embodiment of the Figures in one possible arrangement of abutment formations 38 and mounting bores 34. The number of and location of abutment formations 38a-g and mounting bores 34a-g may vary, as may the number of mounting bores 34a-g located on abutment formations 38a-g, and the number of mounting bores 34a-g and abutment formations 38a-g used to attach the deflector arrangement 26.

[0099] It is also conceivable that the load transmission member 30 may be used to support alternative auxiliary components of the body structure, for example an alternative bracket or plate of the battery arrangement.

Claims

CLAIMS1 . A load transmission member for mounting in a channel of a body structure, the load transmission member comprising: an elongate body configured to transmit a load to the body structure along a non-linear load path, in use, wherein the elongate body comprises an upper surface, a lower surface and opposing first and second side surfaces extending therebetween; a recess extending at least partially along a length of one of the upper surface or the lower surface; a mounting formation located on the elongate body and configured to facilitate mounting of the load transmission member to the channel of the body structure.

2. The load transmission member according to claim 1 , wherein the mounting formation comprises at least one abutment formation configured to contact the channel, in use.

3. The load transmission member according to claim 2, wherein the at least one abutment formation comprises a plurality of discrete abutment formations configured to each contact the channel at a discrete location.

4. The load transmission member according to claim 2 or claim 3, wherein the at least one abutment formation is an abutment surface that protrudes from the first and / or second side surface of the elongate body, and / or wherein the at least one abutment formation is a foot protruding from the lower surface of the elongate body.

5. The load transmission member according to any preceding claim, wherein the mounting formation comprises at least one mounting bore configured to receive a fastener, optionally wherein the mounting formation comprises a plurality of mounting bores located on the upper surface, lower surface, the first side surface and / or the second side surface.

6. The load transmission member according to any preceding claim, wherein the mounting formation is configured to attach a deflector arrangement to the body structure via the load transmission member.

7. The load transmission member according to claim 6 when dependent on claim 5, wherein at least one of the plurality of mounting bores is configured to attach the deflector arrangement to the body structure via the load transmission member.

8. The load transmission member according to any preceding claim, wherein the elongate body comprises a substantially I-shaped cross-section extending at least partially along the length of the elongate body and / or wherein the elongate body comprises a substantially U-shaped cross-section extending at least partially along the length of the elongate body.

9. The load transmission member according to claim 8, wherein the cross-section of the elongate body transitions from a substantially I-shaped cross-section to a substantially U-shaped cross-section.

10. The load transmission member according to any preceding claim, wherein the load transmission member comprises a forging11 . A vehicle body assembly comprising: a body structure comprising a channel extending along the body structure; and a load transmission member according to any preceding claim mounted to the channel to transmit a load to the body structure along a non-linear load path, in use.

12. The vehicle body assembly according to claim 11 , comprising a deflector arrangement, wherein the deflector arrangement is attached to the body structure via the mounting formation of the load transmission member.

13. The vehicle body assembly according to claim 11 or claim 12, wherein the load transmission member extends at an acute angle with respect to a central longitudinal axis of the vehicle body assembly.

14. The vehicle body assembly according to any one of claim 11 to claim 13, wherein the mounting formation comprises at least one mounting bore and a corresponding fastener located in the mounting bore to mount the load transmission member to the channel, in use.

15. A vehicle comprising a vehicle body assembly according to any one of claim 11 to claim 14.

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