FIELD OF INVENTION

[0001] The present invention relates to a side intrusion beam, and more particularly to the side intrusion beam having variable thickness being used in a door of a vehicle.

BACKGROUND

[0002] Due to raising global energy crisis, and environmental problems, automobile manufacturers are focusing on light weight technologies to improve the fuel efficiency of vehicles and to comply with the emission norms. One such implementation is making the doors of the vehicle lighter to reduce the overall weight of the vehicle. The doors are being made lighter by reducing the thickness of the body and by decreasing the size of the door frame structure. However, reducing weight may be detriment to the impact resistance of the door.

[0003] To overcome this, vehicles are being equipped with energy absorbing structures such as side impact beams provided within the doors to ensure the safety of passengers or reduce damage of a vehicle body in a vehicle collision. Few examples of side impact beams are provided in patents US10343501, US5887938, US5580120, US9487066 etc., theses side impact beams have different profiles such as circular, hat shaped etc., so designed as to protect the occupant in case of a crash. Conventional side impact beams are made up of thin steel sheets of AHSS grade and are easy to manufacture. However, it was found that even though side impact beams having simple shapes such circular, elliptical etc., are easy to manufacture, they may not qualify for high energy absorbing capacity during the vehicle collision (such as side crash) of the vehicle. Accordingly, a side impact beam which meets or exceeds energy absorption targets during a crash without increasing in size and without adding weight, or with a reduction in weight, is desirable. OBJECTIVE OF INVENTION

[0004] It is an object of the invention to provide a side intrusion beam design providing hollow tubular beam body of variable thickness which meets or exceeds energy absorption targets during a crash.

[0005] It is an object of the invention to provide a side intrusion beam design having improved the energy absorption of the crash member with AHSS material.

[0006] Another objective of the present invention to provide a side intrusion beam design having a circular section with variable thickness in the middle of the bar for an improved performance in dynamic (~50kmph) 3-point bend test.

[0007] It is an object of the invention to provide a side intrusion beam design, which can effectively absorb the collision energy, thereby reducing the damages received by a vehicle body or an impact received by passengers of the vehicle.

SUMMARY OF INVENTION

[0008] This summary is provided to introduce concepts related to a side intrusion beam design having variable thickness. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0009] In one aspect of the present invention, a side intrusion beam of vehicle for absorbing an impact is provided. The side intrusion beam is a monolithic hollow tubular member comprising at least two end portions and a central portion disposed between the two end portions. The central portion has greater wall thickness than the two end portions. The central portion and the at least two end portions are defined by uniform inner diameter (D).

[0010] In an embodiment, the at least two end portions include a first end portion and a second end portion disposed opposite to the first end portion. The central portion is disposed between the first end portion and the second end portion.

[0011] In an embodiment, the first end portion defines a first outer diameter (Di), the second end portion defines a second outer diameter (D2), and the central portion defines a central outer diameter (De). [0012] In an embodiment, the first outer diameter (Di) and the second outer diameter (D2) are equivalent.

[0013] In an embodiment, the central outer diameter (De) is greater than the first outer diameter (Di) and the second outer diameter (D2).

[0014] In an embodiment, a thickness (t) of the central portion is greater than a thickness (ti, t2) of at least two end portions.

[0015] In an embodiment, the thickness (t) of the central portion is at least 15% greater than the thickness (ti, t2) of at least two end portions. The thickness (ti) of the first end portion is equivalent to thickness (t2) of second end portion.

[0016] In an embodiment, the side intrusion beam is adapted to be mounted within a door of a vehicle.

[0017] In an embodiment, the side intrusion beam is mounted in between the outer and inner door panel.

[0018] In an embodiment, the side intrusion beam is either clamped or simply supported in the inner door panel of the door.

[0019] In an embodiment, the first end portion and the second end portion of the side intrusion beam are clamped to the inner door panel of the door via clamps (Ci, C2).

[0020] In an embodiment, the side intrusion beam is made of metal. In an embodiment, the side intrusion beam is made of steel.

[0021] In an embodiment, the central portion has uniform thickness (ti) along the length of the central portion.

[0022] In an embodiment, length (Li) of the central portion is at least 10% of total length (L) of the side intrusion beam.

[0023] In an embodiment, the first end portion and the second end portion of the side intrusion beam are supported in the inner door panel of the door via simple support provided at the end portion.

[0024] Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 illustrates a vehicle door having a side intrusion beam, according to an embodiment of the present invention;

[0026] Figures 2a, 2b, 3a, and 3b illustrate views of the side intrusion beam, according to an embodiment of the present invention;

[0027] Figures 4a, and 4b illustrate views of a circular side impact beam known in the art;

[0028] Figures 5a, and 5b illustrate views of an elliptical side impact beam known in the art; and

[0029] Figure 6 illustrates a graph showing energy absorption comparison of the side intrusion beam of the present invention, the prior art elliptical side impact beam, and the prior art circular side impact beam.

[0030] The drawings referred to in this description are not to be understood as being drawn to scale except if specifically noted, and such drawings are only exemplary in nature.

DETAILED DESCRIPTION

[0031] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0032] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.

[0033] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.

[0034] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

[0035] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0036] Referring to Figure 1, a door (100) of a vehicle comprising an exemplary side intrusion beam (120), according to embodiment of the present invention is illustrated. The door (100) is adapted to be hingably mounted to a vehicle body of the vehicle. The door (100) includes an outer door panel (not shown), an inner door panel (102), and a frame structure (103). The door (100) is covered on its outer side by the outer door panel and on its inner side by the inner door panel (102). The side intrusion beam (120) is adapted to be mounted within the door (100) of a vehicle. More particularly, the side intrusion beam (120) is mounted in a door space (109) defined between the outer and inner door panel (102). The side intrusion beam (120) of the present invention reinforces the door (100) of the vehicle with minimal encumbrance and little added weight. The side intrusion beam (120) increases vehicle occupant safety by absorbing the energy of an impact in case of collision of the vehicle.

[0037] In order to structurally reinforce the door (100) against side door impacts, the side intrusion beam (120) in one example is mounted substantially in the longitudinal direction of the vehicle within the door space (109). In another example, the side intrusion beam (120) is inclined with respect to the longitudinal direction to cover different impact heights in the door (100) of the vehicle. Alternatively, the side intrusion beam (120) may be aligned within the door space (109) according to the design of the vehicle, without limiting the scope of the invention. In one example, the side intrusion beam (120) is either clamped or simply supported to the inner door panel (102) of the door (100). In another example, the side intrusion beam (120) is either clamped or simply supported to the frame structure (103) of the door (100). In yet another example, the side intrusion beam (120) is either clamped or simply supported to the outer door panel of the door (100). In the illustrated example, the side intrusion beam (120) is made of metal. More particularly, the side intrusion beam (120) is made of metal such as steel (AHSS material).

[0038] Referring to Figures 1, 2b, 3a, 3b, and 3c, the side intrusion beam (120) is a monolithic hollow tubular member comprising at least two end portions (110, 112) and a central portion (114) disposed between the two end portions (110, 112). The central portion (114) and the at least two end portions (110, 112) are defined by uniform inner diameter (D). The at least two end portions (110, 112) include a first end portion (110) and a second end portion (112) disposed opposite to the first end portion (110). The central portion (114) is disposed between the first end portion (110) and the second end portion (112). In the illustrated example, the side intrusion beam (120) is clamped to the inner door panel (102) of the door (100). More particularly, the first end portion (110) and the second end portion (112) of the side intrusion beam (120) are clamped to the inner door panel (102) of the door (100) via clamps (Ci, C2) (as shown in Figures 2a, and 2b). In another example, the first end portion (110) and the second end portion (112) of the side intrusion beam (120) are supported in the inner door panel (102) of the door (100) via simple support (not shown) provided at the end portion (110, 112).

[0039] In the illustrated example, length (Li) of the central portion (114) is at least 10% of total length (L) of the side intrusion beam (120) (shown in Figure 3c). The first end portion (110) defines a first outer diameter (Di), the second end portion (112) defines a second outer diameter (D2), and the central portion (114) defines a central outer diameter (De). In the illustrated example, the first outer diameter (Di) and the second outer diameter (D2) are equivalent. Alternatively, the first outer diameter (Di) and the second outer diameter (D2) may have different dimensions, without limiting the scope of the invention. In the illustrated example, the central outer diameter (De) is greater than the first outer diameter (Di) and the second outer diameter (D2).

[0040] In the illustrated example, the central portion (114) has greater wall thickness than the two end portions (110, 112). The first end portion (110) defines a first thickness (ti), the second end portion (112) defines a second thickness (t2), and the central portion (114) defines a central thickness (t). The central thickness (t) of the central portion ( 114) is greater than the thickness (ti, t2) of at least two end portions (110, 112). In the illustrated example, the first thickness (ti) and the second thickness (t2) are equivalent. In the illustrated example, the thickness (t) of the central portion (114) is at least 15% greater than the thickness (ti) of the first end portion (110) and the thickness (t2) of the second end portion ( 110) . In the illustrated example, the central portion (114) has uniform thickness (t) along the length of the central portion (114).

[0041] Referring to Figures 4a and 4b, different views of the conventional circular side impact beam is illustrated. Referring to Figures 5a, 5b, and 5c, different views of the conventional elliptical side impact beam is illustrated. Referring to Figure 6, the graph illustrates comparison between the side intrusion beam of the present invention, the prior art elliptical side impact beam, and the prior art circular side impact beam. The graph shows energy absorption in “kJ” and displacement in “mm” of each beam. The test was performed on each beam in 3 -point bend impact set-up. As can be seen in Figure 6, the side intrusion beam (120) of the present invention absorbs same energy at lesser displacement compared to the prior art circular side impact beam and the prior art elliptical side impact beam.

[0042] The present invention relates to the side intrusion beam (120) which reinforces the door (100) of the vehicle without adding weight and without compromising on the ease of manufacturability, as compared to the conventional side impact beams. The disclosure provides a novel design of the side intrusion beam (120) having variable thickness which improves energy absorption and limits max displacement. The side intrusion beam (120) increases vehicle occupant protection against a side impact at the door (100) of the vehicle and limits intrusion of the door (100) into the compartment of the vehicle in the event of a lateral impact. Further, the side intrusion beam (120) is less bulky and provides a reduction of manufacturing costs while maintaining vehicle safety standards.

[0043] Furthermore, the terminology used herein is for describing embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.

[0044] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others. [0045] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.