Cross-Car Beam Ventilation Duct Nesting for Compact Assembly

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Solution Overview

Problem

Existing cross-car beams in motor vehicles occupy a large space and are difficult and costly to manufacture, particularly when integrating ventilation ducts.

Innovation Solution

A cross-car beam assembly with a hollow channel that integrates ventilation ducts, allowing for compact design and simplified manufacturing by partially receiving the ducts within the beam, using fixing members for stabilization and support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ventilation ducts are supported by the cross-car beam using known solutions, then ventilation function is provided, but space occupancy increases and manufacturing complexity increases

Engineering Contradiction:

Improveventilation functionVSAvoidspace occupancy

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The ventilation duct is nested within the hollow channel of the cross-car beam, with the duct positioned inside the beam's internal cavity. This nesting arrangement allows the ventilation function to be integrated within the beam structure itself, reducing the overall space required compared to external duct arrangements while maintaining reliable ventilation performance.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If ventilation ducts are supported by the cross-car beam using known solutions, then ventilation function is provided, but manufacturing difficulty and cost increase

Engineering Contradiction:

Improveventilation functionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cross-car beam and ventilation duct are merged into a single integrated assembly. The duct is positioned within the hollow channel of the beam and secured using fixing members that are part of the beam structure. This merging eliminates the need for separate mounting structures and complex assembly procedures, thereby reducing manufacturing complexity and cost while ensuring reliable ventilation function.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of stationary object

If ventilation ducts are integrated into the cross-car beam, then space occupancy is reduced, but duct stability may be compromised

Engineering Contradiction:

Improvespace occupancyVSAvoidduct stability

Core Design Contradiction:

Volume of stationary objectVSStability of the object's composition

Solution Approach 1:

Fixing members are introduced as intermediary elements between the ventilation duct and the cross-car beam. These fixing members are positioned within the hollow channel and engage both the duct and the beam structure, providing secure mechanical attachment. This intermediary mechanism ensures duct stability while maintaining the compact integrated design, preventing the duct from dislodging or shifting during vehicle operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4433315B1A cross-car beam assembly with an inner ventilation duct

Publication Date: 2025.10.01 WUHAN LOTUS CARS CO LTD

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AI summary

The invention concerns a cross-car beam assembly (12) for a motor vehicle, with: a cross-car beam (10) having a first end portion (13) and a second end portion (14) that are spaced apart from one another along a longitudinal axis (L) of the cross-car beam (10), a first fixing member (32) connected to the first end portion (13); a second fixing member (32) connected to the second end portion (14); a hollow channel (16) extending through the cross-car beam (10) from the first end portion (13) to the second end portion (14); a first ventilation duct (22) that extends through a first section of the hollow channel (16) towards the first end portion (13).