GB2535764A

GB2535764A - Structural cross-member

Info

Publication number: GB2535764A
Application number: GB1503272.5A
Authority: GB
Inventors: Gwinnutt Nicholas
Original assignee: Aston Martin Lagonda Ltd
Current assignee: Aston Martin Lagonda Ltd
Priority date: 2015-02-26
Filing date: 2015-02-26
Publication date: 2016-08-31
Also published as: GB201503272D0

Abstract

A structural cross-member 1 spans between opposing sides 2a, 2b of a vehicle interior, and comprises integrated air ducts (13, 14, 15, 16, Figure 4B) for the supply of air to the interior of a vehicle, typically with a coupling to a heating, ventilation and air-conditioning (HVAC) unit 8. Cross-member 1 may be monolithic or integrally formed and may comprise carbon-fibre reinforced plastic. Outlets 3a, 3b may be provided to at ends of duct 1 to provide air to side windows, while outlets 4a, 4b, typically at ends of tubular portions 5a, 5b providing a steering column support structure, may provide air to vents in A-pillars and outlets 7a, 7b may provide air for demisting a windscreen.

Description

Structural Cross-Member The present application relates to the structural cross-member, a vehicle interior comprising a structural cross-member and a vehicle comprising a structural cross-5 member.

Conventional vehicle interiors include a ventilation system comprising a number of air outlets. Typically a plurality of separate duct components are required to serve all the outlets. Vehicle assembly can therefore be complicated due to the number of components which need to be assembled. Furthermore, the tolerances of individual components need to be kept within well-defined limits to avoid problems during assembly. This can result in increased manufacturing cost.

The present invention seeks to alleviate at least to a certain extent, the problems and/or 15 address at least to a certain extent the difficulties associated with the prior art.

According to a first aspect of the disclosure, there is provided a structural cross-member for spanning between opposing sides of a vehicle interior, said cross-member comprising integrated air ducts for the supply of air to the interior of a vehicle.

By providing the air ducts integrally within the cross-member, the assembly of a vehicle can be facilitated due to reduced part count for example. The structural cross-member can be formed as a strut to provide reinforcement and resist longitudinal compression. The cross-member can be coupled to a vehicle structure to improve resistance to torsion.

Optionally, the cross-member is formed as a monolithic or integral component. The cross-member can be formed as a single part with all internal air-ducts formed integrally. A single component can be easier to handle during assembly.

Optionally, the cross-member is formed of carbon-fibre reinforced plastic. This can allow the component to be relatively lightweight and strong compared with conventional manufacturing materials.

Optionally, the cross-member comprises a plurality of internally formed air ducts. This can 35 seek to ensure ducts are not damaged during assembly.

Optionally, the cross-member is formed with a coupling for coupling the air ducts directly or indirectly to a heating, ventilation and air-conditioning, HVAC, unit. This allows for ready installation and connecting within a vehicle.

Optionally, air ducts are provided within the cross-member with outlets being provided arranged at opposing ends of the cross-member for providing air flow to vehicle door ventilation units.

Optionally, air ducts are provided within the cross-member with outlets being provided 10 arranged along the upper surface of the cross-member for providing air flow to a vehicle windscreen.

Optionally, air ducts are provided within the cross-member with outlets being provided arranged along the lower surface of the cross-member for providing air flow to a vehicle 15 footwell.

Optionally, air ducts are provided within the cross-member with outlets being provided arranged along the upper surface of the cross-member for providing air flow to ventilation units in the A-pillars of a vehicle.

Optionally, the air ducts are provided within the cross-member include with outlets provided along the front face of the cross-member for providing air flow to a face of a vehicle occupant.

By including multiple air ducts within the cross-member, additional necessary steps can be avoided during assembly of the vehicle. The cross-member may be provided with all necessary air-ducts to serve all dashboard air vents.

Optionally, at least four distinct individual air ducts are provided within the cross-member.

Optionally, at least eight distinct individual air ducts are provided within the cross-member.

Optionally, the cross-member includes a steering column mounting. By providing a steering column mounting, further additional components and manufacturing steps can be 35 avoiding during vehicle assembly.

Optionally, the cross-member includes coupling points for coupling the cross-member to a vehicle frame component. The couplings can be apertures for coupling using bolts or other fastening means. Reinforced coupling points may be provided on the cross-member.

Optionally, the cross-member has a generally curved profile over its longitudinal extent. This allows the cross-member to follow the dashboard profile and impede as little as possible into the vehicle interior space.

Optionally, the cross-member includes one or more laterally extending connection members for coupling to a vehicle transmission tunnel and/or a vehicle frame in the region of a vehicle windshield. This can provide additional loading paths and increase the structural rigidity to the vehicle frame when the cross-member is installed. Two coupling points may be provided for coupling to a vehicle frame in the region of a vehicle dashboard.

Optionally, one of the laterally extending connection members is formed as a closed frame. This can provide a more rigid structure.

Optionally, the laterally extending connection members have a generally curved profile in 20 the fore and aft direction. This allows the cross-member to conform to the dashboard profile. This shape can also can also improve the rigidity of the cross-member.

According to a further aspect of the disclosure, there is provided a vehicle interior, comprising a structural cross-member as claimed in any one of the preceding claims, the 25 cross-member being coupled to opposing sides of the vehicle interior.

Optionally, the interior includes one or more fascia panels and dash board panels arranged over or connected to said structural cross-member, the cross-member being at least partially exposed to provide an interior A-surface. In this way, the cross-member 30 need not be covered once installed in a vehicle.

Optionally, the structural cross-member is coupled to a transmission tunnel of the vehicle or to a floor of the vehicle at a location substantially equidistant between the longitudinal ends of the structural cross-member. This can provide improved rigidity.

Optionally, the structural member is coupled to the vehicle frame in the region below the vehicle windshield.

According to a further aspect of the disclosure, there is provided a vehicle comprising a cross-member or a vehicle interior according to any preceding aspect.

According to a further aspect of the disclosure, there is provided a method of manufacturing a structural cross-member as claimed in any one of the preceding claims, comprising the steps of: a. laying fibre-reinforced resin sheets or prepregs into a mould or mould parts; b. arranging one or more bladders within the mould to define said air ducts; c. applying a vacuum to said mould while expanding said bladders; d. heating the mould to cure said composite part.

The present invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 shows a structural cross-member positioned within a vehicle interior; Figure 2 shows the airflow through the structural cross-member shown in figure 1; Figure 3 shows an underside view of the cross-member shown in figure 2; Figure 4 shows a rear view of part of the cross-member of figure 1; Figure 4A shows a cross-section through a-a in figure 4; Figure 4B shows a cross-section through b-b in figure 4; Figure 5 shows an underside view of the cross-member of figure 1 showing airflow from the underside of the cross-member; Figure 6 shows the coupling of the cross-member with a vehicle frame: Figure 7 shows a front view of the coupling shown in figure 6; Figure 7A shows a cross section through b-b of figure 7; Figure 7B shows a cross section through a-a of figure 7; Figure 8 shows the two part tool split line of the cross-member viewed from the front of the component; Figure 9 shows the two part tool split line of the cross-member viewed from an end thereof; Figure 10 shows a further example structural cross-member positioned within a vehicle interior; Figure 11 shows a coupling of the cross-member of figure 10 with a vehicle frame; Figure 12 shows a detailed view of the coupling of figure 11; Figure 12A shows a cross-section through a-a of figure 12; Figure 12B shows a cross-section through b-b of figure 12; Figure 13 shows the structural cross-member of figure 10 with a steering support structure; Figure 14 shows an enlarged detail of the steering column support structure; Figure 15 shows detail of the coupling of the steering column support structure with the 5 cross-member; Figure 15a shows a cross section through a-a of figure 15: Figure 16 shows the airflow through the cross-member of figure 10; Figure 17 shows tool split line of the cross-member of Figure 10; and Figure 18 shows a mould for forming a cross-member.

Figure 1 shows a structural cross-member generally at 1. When installed in a vehicle interior, the cross-member extends between opposing parts 2a, 2b of the vehicle frame. The cross-member 1 is generally beam-like or strut-like in form, with a cross-section which is generally uniform in width and height, albeit with air ducts extending therefrom. In its longitudinal extent between the opposing parts 2a, 2b, the cross-member has a curved profile.

The cross-member 1 has internal air ducts which have outlets 3a, 3b at respective ends of the duct 1. These air ducts provide airflow to the door structures in order to provide air to 20 side windows for example.

The cross-member 1 also has outlets 4a, 4b, provided at the ends of diverging tubular portions 5a 5b, which extend from the cross-member 1 on a driver-side of the duct 1. The cross-member 1 also has an outlet 6a, 6b at each end on its upper surface to provide air to vents in the A-pillars of the vehicle. These diverging tubular portions can also provide a steering column support structure.

Two elongate protruding outlets 7a, 7b are provided on the upper surface of the cross-member. These outlets 7a, 7b, provide airflow to a vehicle windshield or windscreen for 30 demisting purposes.

The cross-member 1 here is coupled either directly or indirectly to a heating, ventilation and air-conditioning (HVAC) unit 8. This HVAC unit controls the delivery of air to the ducts in the cross-member 1.

Figure 2 shows the air-flow paths through the cross-member 1 as represented by the lines with arrows. In the example, a total of 8 separate air inlets are provided to the corresponding air-ducts in the cross-member. This allows greater control of temperature and flow-rate to individual air outlets. Depending on performance requirements, some outlets may share air ducts.

Four of the air inlets for one side of the cross-member are shown in Figure 3. The air inlets, 9, 10, 11, 12 are provided on a rear side of the cross-member towards the middle of the cross-member to facilitate connection to the HVAC 8. Figure 3 also shows the air outlets in the underside of the cross-member which can provide airflow to the passenger or driver foot well.

Figures 4, 4A and 4B show more detail of the internal air ducts. Figure 4a shows the cross-sectional profile through the air inlets to the longitudinally extending ducts which supply air to a driver's face via the upper duct 14 and to the foot well via lower duct 13.

Figure 4B shows the cross-sectional profile through the air inlet to the longitudinally extending ducts which supply air to one half of the cross-member to the windshield via upper duct 16 and to the A-pillar side glass demist duct via lower duct 15. As can be seen, each duct is formed as a distinct channel which extends from the inlet along the cross-member 1 to the outlet.

Figure 6 shows detail of the coupling of the cross-member 1 at one end with the vehicle frame 2b. At the end of the cross-member, the cross-member 1 is formed with coupling flanges 17, 18 arranged substantially orthogonal to one another. Coupling apertures 19, 20 are provided to allow the cross-member to be coupled to the vehicle frame 2b using bolts. The apertures 17, 18 are formed as slots to allow for lateral adjustment during fitting.

Figures 7, 7A and 7B show where the bolts 22, 21 and 23 are located. In the example, the bolts are M8 hexagonal bolts which locate in tapped holes.

Figure 8 and figure 9 show how the cross-member may be divided in the mould during manufacture. The dividing line is shown by the dashed line. However, once manufactured, the cross-member and ducts is formed as an integral component, i.e. it is a single piece. This greatly facilitates assembly into the vehicle saving both time and cost during assembly.

Figure 10 shows a further example structural cross-member 101. The cross-member 101 comprises two structural members 126 and 127, which are offset with respect to the transverse direction extending between opposing sides of the interior of the vehicle. The structural members 126, 127 have a generally oval cross section and each extend approximately a third the total length of the cross-member 101.

These two structural members 126, 127, connect with a central section 130 of the cross-member. The central section 130 connects with side frame members 128, 129, which extend laterally from a front side with respect to the transverse or longitudinal extent of the cross-member. These side frame members 128, 129 are coupled at their distal ends to a base frame member 131, which provides a coupling point with the upper surface of a transmission tunnel or floor of the vehicle. A closed frame is formed by the side frame members 128, 129, the base frame member 131 and the central section 130 of the cross-member.

Two laterally extending coupling members or arms 133, 132, extend from front of the cross-member from the central section 130 towards the vehicle windshield. These coupling members have coupling points in the form of apertures to couple to a vehicle fore frame part in the region of the underside of the vehicle windscreen. The base frame member 131, side frame members 128, 129 and coupling members 133, 132 form a generally wishbone-shaped structure.

The cross-member 101 is formed as an integral part. This helps to ensure the structural integrity of the part.

The cross-member 101 provides structural reinforcement between the opposing sides 102a, 102b of the vehicle. The lower frame members 128,129 as well as the coupling members 133, 132, provide additional structural reinforcement in the fore aft direction of the vehicle.

In the example shown, the cross-member 101 has air outlets 106a, 106b at either end. It is envisaged that additional air outlets and internal air ducts can be provided within the integral cross-member component.

The cross-member 101 has a generally curved profile in the fore aft direction along the forwardly extending coupling members 133, 132 and over the side frame members 128, 129.

The cross-member 101 can provide support to dashboard components as well as a steering column.

The lower frame members 128, 129 may be visible after complete assembly of the vehicle. The layout of fibres within these parts may be chosen to provide attractive a-surfaces.

Figure 11 shows detail of the coupling of the cross-member at one side with a vehicle 10 body frame 102a. In the example, the cross-member 101 is connected and coupled to the body frame 102a using bolts 134, 135.

Further detail of the coupling is shown in figures 12, 12A and 12B. As shown in these figures, the bolts 134, 134 are inserted through flange sections 118, 119 in the end of the cross-member 101 and then through corresponding holes in flanges 136, 137 in the vehicle frame 102a. In the example, the flanges 118, 119 are of a thickness 12 mm. Typically, M8 hexagonal bolts are used to couple the cross-member with the vehicle frame. Bolts may also be used to couple the lower frame section 131 to the vehicle floor or transmission tunnel.

Figure 13 shows the cross-member 101 and a steering column support structure 138 coupled to the underside of one side of the cross-member.

The steering column support structure 138 comprises, in the example, two spaced 25 brackets 139, 140, which are bolted to integrally formed flange sections 141, 142 of the cross-member 101.

Figures 15 and 15A show more detail of the coupling of the steering column support brackets 139, 140 with the flange sections 141, 142 of the cross-member.

Figure 16 shows the air flow within the cross-member 101. Internally, there are provided blanked sections represented by the dashed lines to direct airflow either to outlets 106a, 106b to provide air to passengers or to outlets 143a, 143b to provide airflow to the vehicle windscreen.

Figure 17 shows a possible mould split line in the cross-member 101 for manufacture thereof. The split line is represented by the dashed lines.

The manufacture of the cross-member 1, 101 comprises laying fibre reinforced resin material, typically in sheet form 145a, 145b with thickness 2.5mm into mould halves 144a, 144b for the respective halves 24, 25, 124, 125 of the cross-member. In the example, the fibre reinforced resin material may be carbon fibre reinforced resin, typically in the form of prepreg sheets.

In order to form the internal air ducts within the cross-member, inflatable bladders 146 are placed within the mould halves 144a, 144b.

The mould 144a, 144b is heated and subject to a vacuum while the bladders are inflated in order to form the ducts within the component. After the resin has set, the bladders 146 may be deflated and removed.

The bladders can be hand cut and welded using templates and manual techniques or die cut, mould formed and sealed for repeatability. Bladders can be fitted over a removable perforated wand that can supply air pressure and be evacuated for removal. Memory foam can be used in the core of a bladder to aid support of the core prior to pressurization. The internal pressure in the bladder can typically range between 2 and 10 bar.

A structural cross-member as in the examples described, when arranged in a vehicle and spanning between opposing sides of the interior vehicle frame, can provide structural rigidity and torsional rigidity to the vehicle frame. The use of a fibre reinforced material can also significantly reduce the weight of the components compared with conventional arrangements.

By integrating all of the air ducts within a single unit, the part count is significantly reduced in comparison with conventional arrangements. Furthermore, fewer secondary operations 30 are required during assembly which has resultant improvement in dimensional accuracy and repeatability. Space savings can also be made.

The present invention may be carried out in various ways and various modifications are envisaged to the embodiments described without extending outside the scope of the 35 invention as defined in the accompanying claims.

Claims

CLAIMS1. A structural cross-member for spanning between opposing sides of a vehicle interior, said cross-member comprising integrated air duds for the supply of air to the interior of a vehicle.
2. A structural cross-member as claimed in claim 1, wherein the cross-member is formed as a monolithic or integral component.
3. A structural cross-member as claimed in claim 1, wherein the cross-member is formed of carbon-fibre reinforced plastic.
4. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member comprises a plurality of internally formed air ducts.
5. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member is formed with a coupling for coupling the air ducts directly or indirectly to a heating, ventilation and air-conditioning, HVAC, unit.
6. A structural cross-member as claimed in any one of the preceding claims, wherein air ducts are provided within the cross-member with outlets being provided arranged at opposing ends of the cross-member for providing air flow to vehicle door ventilation units.
7. A structural cross-member as claimed in any one of the preceding claims, wherein air ducts are provided within the cross-member with outlets being provided arranged along the upper surface of the cross-member for providing air flow to a vehicle windscreen.
8. A structural cross-member as claimed in any one of the preceding claims, wherein air ducts are provided within the cross-member with outlets being provided arranged along the lower surface of the cross-member for providing air flow to a vehicle footwell.
9. A structural cross-member as claimed in any one of the preceding claims, wherein air ducts are provided within the cross-member with outlets being provided arranged along the upper surface of the cross-member for providing air flow to ventilation units in the A-pillars of a vehicle.
10. A structural cross-member as claimed in any one of the preceding claims, wherein the air ducts are provided within the cross-member include with outlets provided along the front face of the cross-member for providing air flow to a face of a vehicle occupant.
11. A structural cross-member as claimed in any one of the preceding claims, wherein at least four distinct individual air ducts are provided within the cross-member.
12. A structural cross-member as claimed in any one of the preceding claims, wherein at least eight distinct individual air ducts are provided within the cross-member.
13. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member including a steering column mounting.
14. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member includes coupling points for coupling the cross-member to a vehicle frame component.
15. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member has a generally curved profile over its longitudinal extent.
16. A structural cross-member as claimed in any one of the preceding claims, wherein the cross-member includes one or more laterally extending connection members for coupling to a vehicle transmission tunnel and/or a vehicle frame in the region of a vehicle windshield.
17. A structural cross-member as claimed in claim 16, wherein the one of the laterally extending connection members is formed as a closed frame.
18. A structural cross-member as claimed in claim 16 or 17, wherein the laterally extending connection members have a generally curved profile in the fore and aft direction.
19. A vehicle interior, comprising a structural cross-member as claimed in any one of the preceding claims, the cross-member being coupled to opposing sides of the vehicle interior.
20. A vehicle interior as claimed in claim 19, including a one or more fascia panels and dash board panels arranged over or connected to said structural cross-member, the cross-member being at least partially exposed to provide an interior A-surface.
21. A vehicle interior as claimed in claim 19 or 20, wherein the structural cross-member is coupled to the transmission tunnel of the vehicle or to the floor of the vehicle at a location substantially equidistant between the longitudinal ends of the structural cross-member.
22. A vehicle interior as claimed in any one of claims 19 to 21, wherein the structural member is coupled to the vehicle frame in the region below the vehicle windshield.
23. A vehicle comprising a cross-member as claimed in any one of claims 1 to 18 or a vehicle interior as claimed in any one of claims 19 to 22.
24. A method of manufacturing a structural cross-member as claimed in any one of the preceding claims, comprising the steps of: a. laying fibre-reinforced resin sheets or prepregs into a mould or mould parts; b. arranging one or more bladders within the mould to define said air ducts; c. applying a vacuum to said mould while expanding said bladders; d. heating the mould to cure said composite part.
25. A structural cross-member substantially as described herein with reference to the accompanying drawings.
26. A vehicle interior substantially as described herein with reference to the accompanying drawings.
27. A vehicle substantially as described herein with reference to the accompanying drawings.
28. A method of manufacturing a structural cross-member substantially as described herein with reference to the accompanying drawings.