Vehicle beam

Abstract

A vehicle beam (10) is provided with a cylindrical beam body (30) configured so as to be disposed extending in the vehicle width direction within an instrument panel, and a steering support unit (41). The steering support part (41) protrudes in the front-rear direction from the beam body (30). Reinforcing ribs (36, 44) protruding outward are integrally formed on the outer surface of the beam body (30) and the steering support part (41), respectively. The vehicle beam (10) is composed of two split bodies (21, 23) that divide the beam body (30) in the circumferential direction of the beam body (30). Each of the two divided bodies (21, 23) is integrally molded from a resin material.

Description

Vehicle beams

[0001] The present disclosure relates to a beam for a vehicle.

[0002] Patent Document 1 describes a steering support beam (hereinafter referred to as a beam). This beam has a beam body that extends in the left-right direction of the vehicle inside the instrument panel. The beam body has multiple metal brackets attached to it for connecting the beam body to a steering shaft, etc.

[0003] The beam body is formed into a generally rectangular cylindrical shape by assembling two resin divided members together. The outer peripheral surface of the beam body is formed with lattice-like ribs extending outward. The lattice-like ribs are molded integrally with each divided member.

[0004] In such a beam, the rib portion increases the section modulus of the beam body, thereby improving the rigidity and strength of the beam body.

[0005] Japanese Patent Application Laid-Open No. 2004-345396

[0006] Incidentally, it is desirable for such beams to be lightweight while also improving their rigidity and strength.

[0007] A vehicle beam according to one aspect of the present disclosure is a vehicle beam comprising a cylindrical beam body configured to be arranged to extend in the vehicle width direction within an instrument panel, and a connecting portion configured to connect peripheral members of the beam body to the beam body, wherein both ends of the beam body in the vehicle width direction are configured to be attached to the vehicle body, the connecting portion protrudes from the beam body in a direction intersecting the vehicle width direction, and a reinforcing rib protruding outward is integrally formed on the outer surfaces of each of the beam body and the connecting portion, and the vehicle beam is composed of a plurality of divided bodies that divide the beam body in the circumferential direction of the beam body, and each of the plurality of divided bodies is integrally molded from a resin material.

[0008] FIG. 1 is a perspective view showing one embodiment of a vehicle beam. FIG. 2 is a perspective view of the vehicle beam of FIG. 1 as seen from the opposite side. FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1. FIG. 4 is a cross-sectional view showing a portion of a vehicle beam according to one embodiment where a steering support portion protrudes from a beam main body. FIG. 5 is a cross-sectional view of the vehicle beam of FIG. 4, focusing on a reinforcing rib formed on the beam main body. FIG. 6 is a cross-sectional view of the vehicle beam of FIG. 4, focusing on a reinforcing rib formed on a steering support portion.

[0009] Hereinafter, a vehicle beam 10 (hereinafter referred to as the beam 10) according to one embodiment will be described with reference to Figures 1 to 6. Hereinafter, the longitudinal direction of the vehicle will be referred to as the longitudinal direction, and the front and rear of the longitudinal direction will be simply referred to as the front and rear. The width direction of the vehicle will be referred to as the vehicle width direction, and the right and left sides in the vehicle width direction when viewed from the rear of the vehicle to the front will be simply referred to as the right and left sides. The vertical direction of the vehicle when the vehicle is positioned on a horizontal plane will be referred to as the vertical direction, and the upper and lower sides in the vertical direction will be simply referred to as the upper and lower sides.

[0010] 1 to 4, the beam 10 supports a steering column 11 (see FIG. 4) and the like within the instrument panel. The beam 10 extends in the vehicle width direction as a whole, and both ends in the vehicle width direction are attached to the vehicle body.

[0011] The beam 10 has a beam main body 30 and a peripheral portion 40 as another component. <Beam main body 30> As shown in Figures 1 to 3, the beam main body 30 has a duct portion 31, an inlet 33, a plurality of outlets 34, and a plurality of mounting portions 35. The beam main body 30 has a substantially cylindrical shape as a whole.

[0012] The duct portion 31 extends in the vehicle width direction and mainly constitutes the beam body 30. The duct portion 31 has a hollow shape. Specifically, the duct portion 31 is cylindrical with both ends in the vehicle width direction closed. A flow path 32 is formed inside the duct portion 31, through which the conditioned air A from the air conditioning device 12 flows (see FIG. 3 ).

[0013] The inlet 33 is cylindrical and protrudes forward from the center of the duct portion 31 in the vehicle width direction. The cross-sectional shape of the inlet 33 along an imaginary plane perpendicular to the front-to-rear direction is a rectangle that is long in the vehicle width direction. The front end of the inlet 33 is connected to the air conditioning unit 12 (see FIG. 2 ). Thus, the inlet 33 functions to guide the air-conditioning air A from the air conditioning unit 12 to the flow path 32.

[0014] Each outlet 34 is cylindrical and protrudes rearward from the duct portion 31. The cross section of each outlet 34 along an imaginary plane perpendicular to the front-to-rear direction is square. The rear end of each outlet 34 is connected to an outlet 13 for air conditioning air A attached to the instrument panel (see FIG. 1). As a result, each outlet 34 functions to guide the air conditioning air A flowing through the flow path 32 toward the outlet 13. In this embodiment, two outlets 34 are provided in the center of the duct portion 31 in the vehicle width direction, and one outlet 34 is provided at each end of the duct portion 31 in the vehicle width direction, corresponding to the outlet 13.

[0015] The mounting portions 35 are provided on both ends of the duct portion 31 in the vehicle width direction. Each mounting portion 35 has an upper mounting portion 35a that protrudes upward from the outer surface of the duct portion 31 and a lower mounting portion 35b that protrudes downward from the outer surface. When each mounting portion 35 is fastened to a front pillar (not shown) of the vehicle body, the beam main body 30, and therefore the beam 10, is fixed to the vehicle body.

[0016] <Peripheral portion 40> The peripheral portion 40 protrudes from the beam main body 30 in a direction intersecting the vehicle width direction. The peripheral portion 40 includes a plurality of support portions for attaching various components to the beam main body 30, and a plurality of stay portions for connecting the beam main body 30 to the vehicle body.

[0017] As shown in Fig. 4, the multiple support parts include a steering support part 41 that supports and suspends from above the steering column 11, which is a peripheral member of the beam main body 30. Note that Fig. 4 shows a cross section of the part of the beam 10 where the steering support part 41 protrudes from the beam main body 30, taken along an imaginary plane perpendicular to the vehicle width direction.

[0018] The steering support portion 41 has a front support portion 42 that protrudes forward from the beam body 30 and a rear support portion 43 that protrudes rearward from the beam body 30. The front end 11a of the steering column 11 is fastened to the front support portion 42 via a bracket or the like (not shown). A portion 11b of the steering column 11 that is rearward of the front end 11a is fastened to the rear support portion 43 via a bracket or the like (not shown). In other words, the steering support portion 41 in this embodiment corresponds to the connecting portion according to the present disclosure. In this embodiment, the steering support portion 41 is provided integrally with the right portion of the beam body 30. In other words, the beam 10 is a vehicle beam configured to be applied to a right-hand drive vehicle.

[0019] The plurality of support parts include, in addition to the steering support part 41, an airbag support part that supports an airbag device for protecting an occupant seated in the passenger seat from an impact such as a frontal collision. The airbag support part is provided integrally with the left portion of the beam body 30.

[0020] The stay portions are, for example, integral with the right side portion of the beam body 30 and fastened to a cowl panel or dash panel of the vehicle body. For convenience, the peripheral portion 40 and the portion of the beam body 30 where the peripheral portion 40 is provided are not shown in Figures 1 and 2.

[0021] 1 to 4, the beam 10 is made up of a plurality of divided bodies. In this embodiment, the beam 10 is made up of two divided bodies: the upper divided body 21 that forms the upper part of the beam 10, and the lower divided body 23 that forms the lower part of the beam 10. The divided bodies 21 and 23 divide the beam main body 30 into two in the circumferential direction of the beam main body 30.

[0022] Each of the divided bodies 21, 23 is integrally molded from a resin material. From the viewpoint of improving rigidity and strength, it is preferable to use a fiber-reinforced resin as the resin material. In this embodiment, a polyamide resin containing glass fiber is used.

[0023] The upper segment 21 has an upper beam half 30a that constitutes the upper half of the beam main body 30, and an upper support segment 41a that constitutes the upper part of the steering support portion 41 (see FIG. 4).

[0024] As shown in Figures 1 to 3, the upper beam half 30a has a semi-cylindrical upper peripheral wall portion 31a, an upper inlet half 33a that is connected to the upper peripheral wall portion 31a and protrudes forward, and a plurality of upper outlet half portions 34a that are connected to the upper peripheral wall portion 31a and protrude rearward.

[0025] The upper peripheral wall portion 31a constitutes the upper half of the duct portion 31. The upper inlet half body 33a constitutes the upper half of the inlet 33. The upper outlet half body 34a constitutes the upper half of the outlet 34.

[0026] A flange-shaped upper connecting portion 22 is integrally provided on the peripheral edge of the upper peripheral wall portion 31a and on the lower end portions of the upper inlet half body 33a and the upper outlet half body 34a which are continuous with the peripheral edge.

[0027] As shown in FIG. 3, the upper connection portion 22 has an upper opposing surface 22a extending along the dividing surface of the beam body 30, and an upper welding rib 22b protruding downward from the upper opposing surface 22a.

[0028] 4, the portion of the upper support section segment 41a that forms the upper portion of the front support section 42 extends further forward from the front end of the upper connecting section 22. The portion of the upper support section segment 41a that forms the upper portion of the rear support section 43 extends further rearward from the rear end of the upper connecting section 22.

[0029] As shown in Figures 1 to 4, the lower split body 23 has a lower beam half body 30b that forms the lower half of the beam main body 30, and a lower support part split body 41b that forms the lower part of the steering support part 41 (see Figure 4).

[0030] As shown in Figures 1 to 3, the lower beam half body 30b has a semi-cylindrical lower peripheral wall portion 31b, a lower inlet half body 33b that is connected to the lower peripheral wall portion 31b and protrudes forward, and a plurality of lower outlet half bodies 34b that are connected to the lower peripheral wall portion 31b and protrude rearward.

[0031] The lower peripheral wall portion 31b constitutes the lower half of the duct portion 31. The lower inlet half body 33b constitutes the lower half of the inlet 33. The lower outlet half body 34b constitutes the lower half of the outlet 34.

[0032] A flange-shaped lower connecting portion 24 is integrally provided on the peripheral edge of the lower peripheral wall portion 31b and on the upper end portions of the lower inlet half body 33b and the lower outlet half body 34b that are continuous with the peripheral edge.

[0033] 3, the lower connection portion 24 has a lower opposing surface 24a extending along the dividing surface of the beam body 30 and a lower welding rib 24b protruding upward from the lower opposing surface 24a. The lower opposing surface 24a faces the upper opposing surface 22a in the vertical direction.

[0034] The upper welding rib 22b and the lower welding rib 24b are welded together using a well-known welding method such as vibration welding, thereby joining the upper connecting portion 22 and the lower connecting portion 24, and ultimately the upper division body 21 and the lower division body 23 together.

[0035] 4, the portion of the lower support section segment 41b that constitutes the lower part of the front support section 42 protrudes forward from the outer surface of the lower peripheral wall 31b that includes the lower connecting section 24. The portion of the lower support section segment 41b that constitutes the lower part of the rear support section 43 extends further rearward from the rear end of the lower connecting section 24.

[0036] <Reinforcing ribs 36, 44> As shown in Figures 1 to 4, the beam 10 has a first reinforcing rib 36 formed on the outer surface of the beam main body 30 and a second reinforcing rib 44 formed on the outer surface of the steering support portion 41.

[0037] The first reinforcing rib 36 includes an upper first reinforcing rib 36a and a lower first reinforcing rib 36b. The upper first reinforcing rib 36a is integrally formed with the upper beam half 30a. The upper first reinforcing rib 36a protrudes upward from the outer surface of the upper peripheral wall portion 31a and extends in a mesh-like pattern along the outer surface. The protruding height of the upper first reinforcing rib 36a in the vertical direction is constant throughout the entire extension direction.

[0038] The lower first reinforcing ribs 36b are formed integrally with the lower beam half 30b. The lower first reinforcing ribs 36b protrude downward from the outer surface of the lower peripheral wall 31b and extend in a mesh pattern along the outer surface. The protruding height of the lower first reinforcing ribs 36b in the up-down direction is constant throughout the entire extension direction.

[0039] 5 schematically shows the orientation of the glass fibers 50 in the upper first reinforcing rib 36a of the first reinforcing rib 36. As shown in Fig. 5, the glass fibers 50 in the first reinforcing rib 36 include a plurality of glass fibers 50a aligned along the extension direction of the first reinforcing rib 36 and a plurality of glass fibers 50b intersecting the extension direction of the first reinforcing rib 36.

[0040] In the first reinforcing rib 36 , the proportion of the glass fibers 50 a in the glass fibers 50 is greater than the proportion of the glass fibers 50 b in the glass fibers 50 at any point in the extending direction of the first reinforcing rib 36 .

[0041] As shown in Figure 4, the second reinforcing rib 44 has an upper second reinforcing rib 44a and a lower second reinforcing rib 44b. The upper second reinforcing rib 44a is integrally formed with the upper support section segment 41a. The upper second reinforcing rib 44a protrudes upward from the outer surface of the upper support section segment 41a. Although not shown, similar to the first reinforcing rib 36, the upper second reinforcing rib 44a extends in a mesh pattern along the outer surface of the upper support section segment 41a.

[0042] The lower second reinforcing ribs 44b are integral with the lower support section segment 41b. The lower second reinforcing ribs 44b protrude downward from the outer surface of the lower support section segment 41b. Although not shown, similar to the first reinforcing ribs 36, the lower second reinforcing ribs 44b extend in a mesh pattern along the outer surface of the lower support section segment 41b.

[0043] 4, the protruding height in the vertical direction of the second reinforcing rib 44 is greater than the protruding height in the vertical direction of the first reinforcing rib 36. Furthermore, the width of the second reinforcing rib 44 (the length in the direction perpendicular to the extension direction of the second reinforcing rib 44) is approximately the same as the width of the first reinforcing rib 36 (the length in the direction perpendicular to the extension direction of the first reinforcing rib 36).

[0044] 6 schematically shows the orientation of the glass fibers 50 in the upper second reinforcing rib 44a of the second reinforcing rib 44. As shown in FIG. 6, the orientation of the glass fibers 50 in the second reinforcing rib 44 is aligned in the extension direction of the second reinforcing rib 44. In the second reinforcing rib 44, the orientation of the glass fibers 50 is aligned in the same extension direction at any point in the extension direction of the second reinforcing rib 44. Note that in the second reinforcing rib 44, the proportion of glass fibers (not shown) that intersect with the extension direction of the second reinforcing rib 44 is smaller than the proportion of glass fibers 50b that intersect with the extension direction of the second reinforcing rib 44 in the glass fibers 50 in the first reinforcing rib 36.

[0045] <Operation of the Present Embodiment> Next, the operation of the present embodiment will be described. When the two segments 21, 23 are integrally molded from fiber-reinforced resin, the orientation of the glass fibers 50 in the resin of the first reinforcing rib 36 and the second reinforcing rib 44 protruding from the outer surfaces tends to be aligned in the extension direction of the reinforcing ribs 36, 44. Furthermore, this tendency becomes stronger as the protruding height of the reinforcing ribs 36, 44 in the vertical direction increases. The fiber-reinforced resin exhibits increased rigidity and strength in the direction in which the orientation of the glass fibers 50 is aligned, but decreased rigidity and strength in the direction perpendicular to the direction in which the orientation of the glass fibers 50 is aligned. Therefore, in the segments 21, 23, deformation along the extension direction during molding shrinkage is suppressed by the reinforcing ribs 36, 44, but deformation along the orthogonal direction perpendicular to the extension direction is less suppressed by the reinforcing ribs 36, 44.

[0046] However, if deformation occurs in the beam half bodies 30a, 30b, which are parts of the segments 21, 23 that make up the beam main body 30, misalignment of the connecting parts 22, 24 between the multiple segments 21, 23 may occur when forming the beam 10, making it difficult to assemble the segments 21, 23. For this reason, measures are desired to prevent deformation along the orthogonal direction, particularly in the beam half bodies 30a, 30b of the segments 21, 23.

[0047] In this regard, according to the beam 10 of this embodiment, the protruding height in the vertical direction of the first reinforcing rib 36 formed on the beam main body 30 is smaller than the protruding height in the vertical direction of the second reinforcing rib 44 formed on the steering support portion 41. Therefore, in the first reinforcing rib 36 of the beam main body 30, the orientation of the glass fibers 50 in the resin is less likely to be aligned in the extension direction than in the second reinforcing rib 44 of the steering support portion 41. This increases the rigidity and strength of the beam main body 30 in the orthogonal direction compared to when the protruding height of the first reinforcing rib 36 is equal to or greater than the protruding height of the second reinforcing rib 44. Furthermore, by appropriately setting the protruding height in the vertical direction of the first reinforcing rib 36 of the beam main body 30, the rigidity and strength of the beam main body 30 in the orthogonal direction can be increased while maintaining the necessary rigidity and strength in the extension direction.

[0048] <Advantages of the Present Embodiment> Next, advantages of the present embodiment will be described. (1) The beam 10 includes a cylindrical beam main body 30 configured to extend in the vehicle width direction within the instrument panel, and a steering support portion 41 serving as a connecting portion configured to connect the beam main body 30 to the steering column 11, which is a peripheral member of the beam main body 30. Both ends of the beam main body 30 in the vehicle width direction are configured to be attached to the vehicle body. The steering support portion 41 protrudes in the front-rear direction from the beam main body 30. Reinforcing ribs 36, 44 protruding upward and downward are integrally formed on the outer surfaces of the beam main body 30 and the steering support portion 41, respectively. The beam 10 is configured from two divided bodies 21, 23 that divide the beam main body 30 in the circumferential direction of the beam main body 30. Each of the two divided bodies 21, 23 is integrally molded from a resin material.

[0049] According to this configuration, by assembling together two divided bodies 21, 23 integrally molded from a resin material, the beam 10 is formed in which the steering support portion 41 protrudes from the beam main body 30. Therefore, the weight of the beam 10 can be reduced compared to conventional vehicle beams in which the steering support portion is made of a metal material.

[0050] Furthermore, according to the above-described configuration, the reinforcing ribs 36, 44 are formed on the beam main body 30 and the steering support portion 41. Therefore, the section modulus of the steering support portion 41 is increased in addition to the beam main body 30. This improves the rigidity and strength of the steering support portion 41.

[0051] Therefore, it is possible to achieve both weight reduction and improved rigidity and strength of the beam 10. (2) The resin material is a glass fiber-reinforced polyamide resin. The protruding height in the vertical direction of the first reinforcing rib 36 formed on the beam body 30 is smaller than the protruding height in the vertical direction of the second reinforcing rib 44 formed on the steering support portion 41.

[0052] This configuration achieves the effects described in the operation of this embodiment, thereby further improving the rigidity and strength of the beam body 30 and, ultimately, the beam 10. (3) The beam body 30 has a duct portion 31 that extends in the vehicle width direction and forms a flow path 32 through which the air-conditioning air A from the air conditioning unit 12 flows.

[0053] With this configuration, the beam 10 functions as an air conditioning duct, eliminating the need to provide a separate air conditioning duct within the instrument panel, thereby reducing the number of components within the instrument panel.

[0054] <Modifications> This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

[0055] The inlet 33 is not limited to one that protrudes forward from the duct portion 31. For example, the inlet 33 may extend at an angle from the duct portion 31 so as to be positioned higher toward the front, or may extend at an angle from the duct portion 31 so as to be positioned lower toward the front.

[0056] The cross-sectional shapes of the inlet 33 and the outlet 34 are not limited to the shapes exemplified in this embodiment and may be, for example, an oval shape that is long in the vehicle width direction. The beam 10 does not need to function as a so-called air conditioning duct in which the beam main body 30 guides the air-conditioning air A from the air conditioning unit 12 to the air outlet 13. In this case, the inlet 33 and the outlet 34 can be omitted from the beam main body 30.

[0057] The protruding height of the first reinforcing rib 36 does not have to be constant throughout the entire extension direction, as long as it is smaller than the protruding height of the second reinforcing rib 44. The connecting portion according to the present disclosure is not limited to the steering support portion 41 exemplified in this embodiment. The connecting portion may be any portion that protrudes from the beam main body 30 in a direction intersecting the vehicle width direction, is configured to connect the beam main body 30 to a peripheral member of the beam main body 30, and has the second reinforcing rib 44 protruding from its outer surface. For example, the stay portion exemplified as the peripheral portion 40 may also be embodied as the connecting portion. In this case, the cowl panel or dash panel of the vehicle body would correspond to the peripheral member according to the present disclosure.

[0058] The connecting portion according to the present disclosure is not limited to being divided into an upper support portion segment 41 a and a lower support portion segment 41 b like the steering support portion 41 exemplified in this embodiment, and may be an undivided portion. In this case, the connecting portion may protrude from only one of the beam half bodies 30 a, 30 b.

[0059] In the present embodiment, the upper divisional body 21 and the lower divisional body 23 are joined by welding the upper welding rib 22b and the lower welding rib 24b, but the method for joining the upper divisional body 21 and the lower divisional body 23 is not limited to this. Any joining method can be used as long as it defines the flow path 32. For example, the upper divisional body 21 and the lower divisional body 23 may be joined by fastening the upper connecting portion 22 and the lower connecting portion 24 together using a plurality of bolts.

[0060] The beam 10 is not limited to being divided into the upper segment 21 and the lower segment 23 as exemplified in this embodiment. For example, the beam 10 may be divided into a front segment and a rear segment. Furthermore, the beam 10 is not limited to being divided into two segments in the circumferential direction of the beam main body 30, but may be divided into three or more segments in the circumferential direction.

[0061] The vehicle beam according to the present disclosure is not limited to the beam 10 configured to be applied to a right-hand drive vehicle, but may be configured to be applied to a left-hand drive vehicle. That is, the vehicle beam may be one in which the steering support portion 41 is provided on the left side of the beam body 30.

Claims

1. A vehicle beam comprising: a cylindrical beam body configured to be arranged so as to extend in the vehicle width direction within an instrument panel; and a connecting portion configured to connect peripheral members of the beam body to the beam body, wherein both ends of the beam body in the vehicle width direction are configured to be attached to the vehicle body, the connecting portion protrudes from the beam body in a direction intersecting the vehicle width direction, and reinforcing ribs that protrude outward are integrally formed on the outer surfaces of each of the beam body and the connecting portion, and the vehicle beam is composed of a plurality of divided bodies that divide the beam body in the circumferential direction of the beam body, and each of the plurality of divided bodies is integrally molded from a resin material.

2. A vehicle beam as described in claim 1, wherein the resin material is fiber-reinforced resin, and the protruding height of the reinforcing ribs formed on the beam body is smaller than the protruding height of the reinforcing ribs formed on the connecting portion.

3. A vehicle beam as set forth in claim 1 or claim 2, wherein the beam body has a duct portion extending in the vehicle width direction and forming a flow path through which conditioned air from an air conditioning device flows.

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