Note: Descriptions are shown in the official language in which they were submitted.
CA 02854741 2014-06-19
MOUNTING BRACE ASSEMBLY FOR STEERING COLUMN MEMBER
FIELD OF THE INVENTION
This invention relates to a mounting brace assembly adapted for securing a
steering column member to a vehicle cross-support member, most preferably in a
position
braced against a vehicle cowl top. The invention further relates to a mounting
brace
arrangement which includes a pair of mounting base arms coupled to associated
mounting locations provided on a vehicle cross-support member.
BACKGROUND OF THE INVENTION
In the automobile industry, vehicle cross-support members, crossbeams, cross
car
beams, and other similar components (collectively referred hereinafter as
"vehicle cross-
support members" or "cross-support members") are utilized as part of the
vehicular body
structure. The vehicle cross-support member normally spans between or fastened
to a
pair of laterally disposed vertical pillars, or A-pillars, in the region
generally below the
windscreen and a cowl top, and between a forward engine compartment and a
rearward
passenger compartment, so as to extend in a direction transverse to the length
of an
automobile. As part of a motor vehicle body, the cross-support member provides
for
cross car stiffness and rigidity against for example side load impacts.
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Located forwardly of the driver and the front-row passenger, the cross-support
member also supports or provides mounting surfaces for various vehicle
components,
including an instrument panel, a glove and/or storage compartment, a center
console, a
dashboard and a steering column member. Although direct attachment may be
possible,
various attachment devices or assemblies could be utilized to effect
attachment of such
vehicle components to the cross-support member. The attachment devices and
assemblies are preferably designed such that the noise and vibrations
transferring from
the vehicle engine, drivetrain, transmission or any other moving parts are
reduced for
optimal passenger comfort. For vehicle components subject to or exerting a
load or
force, the attachment devices and assemblies preferably incorporate
constructions
adapted for improving load transfer, dispersion and/or distribution. Reduction
of weight
and production costs are also of important consideration in designing and
implementing
the attachment devices and assemblies.
A number of attachment or mounting assemblies for securing a steering column
member in a vehicle are known. By way of an example, United States Patent No.
8,256,830 to Hitz describes a plurality of standardized support arms, a number
of which
are configured in the form of steering column support arms each having a U-
shaped cross
section defined by a pair of legs. Each of the legs forming part of the
steering column
support arm of Hitz include an area secured in a preformed transversal slot of
a vehicle
cross-support member on the driver side. Hitz furthermore describes
reinforcement
members having the same U-shaped cross section, and which are coupled to the
steering
column support arms to form a rectangular cross section. Hitz suggests that
the
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standardized support arms may alternatively be formed as other support or
reinforcement
components secured to the cross-support member, such as a transmission tunnel
support
arm and a splash shield support arm, so as to permit reduction of production
costs
associated with fabricating multiple vehicle components.
United States Patent No. 8,146,986 to Bierkamp describes a holder configured
for
attachment to a tubular vehicle cross-support member to effect securement of
different
vehicle components. The holder of Bierkamp possesses a U shaped configuration
defined by two limbs interconnected by a bridge, and which are sized to be
received in a
parallel spaced slots transversely oriented to a longitudinal axis of the
cross-support
member. Bierkamp suggests that two or more holders may be secured to the cross-
support member to effect steering column attachment. The specific
configuration of the
holder of Bierkamp is described as advantageous in that it allows for sliding
and
rotational adjustment or positioning of the holder on the tubular cross-
support member
prior securing or welding the holder thereto.
The attachment devices described in Hitz and Bierkamp may suffer disadvantages
in that forces generated by a steering column member, such as rotational
forces, may not
be transferred or distributed efficiently to other structural elements of the
vehicle.
Furthermore, as the generated forces are mainly channeled to the vehicle cross-
support
member, deficiencies in the attachment between the cross-support member and
the
devices of Hitz and Bierkamp may possibly lead to structural and/or functional
failures.
Given the increasing complexity and components included with steering column
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members, such as airbags and various control and adjustment elements,
improvements to
the load transfer and distribution from the steering column member may be
desired.
SUMMARY OF THE INVENTION
One possible non-limiting object of the present invention is to provide a
mounting
brace assembly for securing a steering column member to a vehicle cross-
support
member, and which is for improving load transfer and distribution from the
steering
column member to other vehicle structural elements.
Another possible non-limiting object of the present invention is to provide a
mounting brace assembly for securing a steering column member to a vehicle
cross-
support member, and which allows for structural reinforcement or connection
between
different structural elements of a vehicle.
Another possible non-limiting object of the present invention is to provide a
mounting brace assembly which allows for more stabilized attachment of a
steering
column member, and which is for improving noise, vibration and harshness
("NVH")
performance.
Another possible non-limiting object of the present invention is to provide a
mounting brace assembly which allows for improved streamlined and precise
installation
on a cross-support member as part of an automated manufacturing process.
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In view of the disadvantages of previously known devices, the present
invention
provides in one simplified aspect a mounting brace assembly adapted for
securing a
steering column member to a generally transversely extending vehicle cross-
support
member, and which includes a cowl top bracket, and a mounting base arm.
In another aspect, the present invention provides a mounting brace assembly
adapted for securing a steering column member to a generally transversely
extending
vehicle cross-support member in a position braced against a vehicle cowl top,
the cross-
support member including at least one mounting location defining a flange
receiving slot,
wherein the mounting brace assembly comprises a cowl top bracket for engaging
the
vehicle cowl top, and at least one mounting base arm extending longitudinally
along a
base axis from a first axial end portion to a second axial end portion, the
mounting brace
assembly being positionable in a mounted orientation with the first axial end
portion
oriented towards a rearward vehicle end for securing the steering column
member
thereto, and the second axial end portion towards a vehicle forward end, the
mounting
base arm including a flange member formed as a generally planar anchor flange
along the
base axis, the anchor flange being sized for generally upward mated insertion
in at least
part of the flange receiving slot, and the cowl top bracket being coupled to
the mounting
base arm proximal to the vehicle forward end, and comprising a load transfer
portion
shaped for juxtaposed abutment with a load bearing portion of the vehicle cowl
top,
wherein in the mounted orientation, contact between the cowl top bracket and
the vehicle
cowl top transfers rotational bearing forces from the first axial end portion
towards the
vehicle cowl top.
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In yet another aspect, the present invention provides a mounting brace
assembly
adapted for securing a steering column member to a generally transversely
extending
vehicle cross-support member in a position braced against a vehicle cowl top,
the cross-
support member including a pair of mounting locations spaced along a length of
the
cross-support member to define an inwardly spaced mounting region
therebetween, each
said mounting location defining a flange receiving slot, wherein the mounting
brace
assembly comprises a cowl top bracket for engaging the vehicle cowl top, and a
pair of
mounting base arms, each said mounting base arm extending longitudinally along
a base
axis from a first axial end portion to a second axial end portion, the
mounting brace
assembly being positionable in a mounted orientation with the first axial end
portion
oriented towards a rearward vehicle end for securing the steering column
member
thereto, and the second axial end portion towards a vehicle forward end, each
said
mounting base arm including a pair of generally parallel flange members each
integrally
joined along the base axis to an associated lateral edge of a longitudinally
elongated base
web: a first said flange member being formed as an abutment flange distal to
the inwardly
spaced mounting region, the abutment flange comprising a contact surface
portion having
a profile selected for complementary juxtaposed abutment against an underside
of the
cross-support member; and the second other said flange member being formed as
a
generally planar anchor flange proximal to the inwardly spaced mounting
region, the
anchor flange being sized for mated insertion in at least part of respective
said flange
receiving slot of an associated one of the mounting locations when the
mounting brace
assembly is in the mounted orientation; and the cowl top bracket being coupled
to one or
both said mounting base arms proximal to the vehicle forward end, and
comprising a load
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transfer portion shaped for juxtaposed abutment with a load bearing portion of
the vehicle
cowl top, wherein in the mounted orientation, contact between the cowl top
bracket and
the vehicle cowl top transfers rotational bearing forces from the first axial
end portion
towards the vehicle cowl top.
In yet another aspect, the present invention provides a mounting brace
arrangement adapted for securing a steering column member in a position braced
against
a vehicle cowl top, the mounting brace arrangement comprising a generally
transversely
extending vehicle cross-support member, a pair of mounting base arms, and a
cowl top
bracket for engaging the vehicle cowl top, the cross-support member including
a pair of
mounting locations spaced along a length of the cross-support member to define
an
inwardly spaced mounting region therebetween, each said mounting location
defining a
flange receiving slot, each said mounting base arm being coupled to the cross-
support
member at an associated one of the mounting locations, and extending
longitudinally
along a base axis from a first axial end portion to a second axial end
portion, the
mounting brace arrangement being positionable in a mounted orientation with
the first
axial end portion oriented towards a rearward vehicle end for securing the
steering
column member thereto, and the second axial end portion towards a vehicle
forward end,
each said mounting base arm including a pair of generally parallel flange
members each
integrally joined along the base axis to an associated lateral edge of a
longitudinally
elongated base web: a first said flange member being formed as an abutment
flange, the
abutment flange comprising a contact surface portion having a profile selected
for
complementary juxtaposed abutment against an underside of the cross-support
member;
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and the second other said flange member being formed as a generally planar
anchor
flange sized for mated insertion in at least part of respective said flange
receiving slot of
the associated mounting location when the mounting brace arrangement is in the
mounted
orientation; and the cowl top bracket being formed as a laterally extending
cowl top
bracket coupled to both said mounting base arms in the inwardly spaced
mounting region
forwardly of the cross-support member, wherein the cowl top bracket comprises:
an
abutment edge portion in substantially abutting contact with an outer surface
of the cross-
support member; and a load transfer portion shaped for juxtaposed abutment
with a load
bearing portion of the vehicle cowl top, wherein in the mounted orientation,
contact
between the cowl top bracket and the vehicle cowl top transfers rotational
bearing forces
from the first axial end portion towards the vehicle cowl top.
In one embodiment, the mounting location defines two said flange receiving
slots
in a generally parallel orientation to each other, and the mounting base arm
includes a
longitudinally elongated base web and two said anchor flanges each integrally
joined to
an associated lateral edge portion of the base web, each said anchor flanges
being sized
for generally upward mated insertion in at least part of an associated one of
the flange
receiving slots. It is to be appreciated that alternatively, the two flange
receiving slots
may be disposed at an angle relative to each other, and furthermore, depending
on the
specific application of the mounting brace assembly, the two anchor flanges
may or may
not be identical to each other.
In an alternative embodiment, the mounting base arm further comprises a
longitudinally elongated base web and an abutment flange, each of the abutment
flange
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and the anchor flange being integrally joined along the base axis to an
associated lateral
edge portion of the base web, wherein the abutment flange comprises a contact
surface
portion having a profile selected for complementary juxtaposed abutment
against an
underside of the cross-support member. The contact surface portion most
preferably
comprises a longitudinal edge of the abutment flange, and the longitudinal
edge is welded
directly to the underside of the cross-support member in the mounted
orientation.
Preferably, the flange receiving slot is cooperatively defined at least by
adjoining
bottom and forward end walls of the cross-support member, and the anchor
flange
comprises a bracket attachment surface portion coupled to the cowl top
bracket, and an
insertion surface portion located to be at least partially received in an
interior of the
cross-support member, wherein in the mounted orientation, the bracket
attachment
surface portion projects forwardly from the forward end wall. Most preferably,
the anchor
flange has a generally triangular shape, most preferably a perpendicular
triangular shape,
extending at an angle to the base axis towards the second axial end portion to
form the
bracket attachment surface portion, the anchor flange tapering towards the
first axial end
portion to form the insertion surface portion.
In one embodiment, the flange receiving slot is further cooperatively defined
by a
rearward end wall of the cross-support member, together with the bottom and
forward
end walls, and the anchor flange is sized for complementary mated insertion in
the flange
receiving slot, wherein in the mounted orientation, the anchor flange projects
forwardly
from the forward end wall and rearwardly from the rearward end wall.
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In one embodiment, the mounting base arm further comprises a stop member in
the first axial end portion, the stop member being located for resting against
a rearward
end wall of the cross-support member when the mounting brace assembly is in
the
mounted orientation to restrict or prevent forward longitudinal movement of
the
mounting base arm along the base axis. Preferably, the stop member comprises a
generally co-planar projection protruding from a longitudinal edge of one or
both said
flange members, the projection being shaped for complementary juxtaposed
contact with
the rearward end wall.
The mounting base arm preferably further includes a reinforcement bridge
member interposed between the flange members, the reinforcement bridge member
being
secured to respective mutually opposed surfaces or longitudinal seating edge
portions of
the flange members, most preferably in the first or second axial end portion.
When
secured to the opposed surface of the anchor flange and the longitudinal
seating edge of
the abutment flange in the second axial end portion, the mounting base arm
preferably
further comprises a reinforcement bolt having a bolt end portion for engaging
the base
web, and the reinforcement bridge member comprises a bridge plate defining a
surface
aperture sized to receive the reinforcement bolt, the reinforcement bolt being
received in
the aperture with the bolt end portion engaging the base web. The
reinforcement bolt is
most preferably secured or welded to both the bridge plate and the base web.
In one embodiment, an upper end wall of the cross-support member defines at
least one tab receiving slot in generally vertical alignment with the flange
receiving slot,
and the anchor flange includes at least one substantially co-planar engagement
tab sized
CA 02854741 2014-06-19
to be received in the at least one tab receiving slot when the mounting brace
assembly is
in the mounted orientation. Preferably, the cross-support member defines an
elongated
interior cavity along a length of the cross-support member, and the anchor
flange
comprises a profile sized for mated juxtaposition within the elongated
interior cavity.
Most preferably, the profile is substantially identical to a cross section of
the elongated
interior cavity.
It is to be appreciated that the cross-support member for use with the
mounting
brace assembly, or forming part of the mounting brace arrangement is not
particularly
limited. The cross-support member may include a cross section having a shape
such as
but not limited to trapezoid, circle, ellipse, square, rectangle, triangle and
pentagon, or
incorporate a clamshell type construction. The cross-support member may be
provided
with a plurality of transverse sections along the length of the cross support
member, for
example, an enlarged transverse section located on the driver side and a
reduced diameter
transverse section on the passenger side, the two transverse sections joined
by a generally
vertically oriented center column.
In one embodiment, the mounting base arm further comprises a bracket
positioning column removably mounted to the second axial end portion, and the
cowl top
bracket is secured to the bracket positioning column distal to the second
axial end
portion, the bracket positioning column being sized for positioning the load
transfer
portion in juxtaposed abutment with the load bearing portion when the mounting
brace
assembly is in the mounted orientation. Preferably, the bracket positioning
column is
positionable in the mounted orientation to extend generally vertically from
the second
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,
,
,
axial end portion to form a seating surface, and the cowl top bracket is in
seated
engagement with the seating surface. Most preferably, each said mounting base
arm
comprises the bracket positioning column, each said bracket positioning column
being
angled towards the inwardly spaced mounting region to cooperatively define the
seating
surface, and the cowl top bracket is in seated engagement with the
cooperatively defined
seating surface. It is to be appreciated that depending on the relative
position of the
vehicle cowl top to the mounting brace assembly, the bracket positioning
column may be
angled in different directions.
Preferably, the mounting brace assembly comprises two said mounting base arms
positionable in the mounted orientation at a distance from each other along a
length of the
cross-support member, and the cowl top bracket is coupled to one or both of
the
mounting base arms.
It is to be appreciated that the cowl top bracket is not particularly limited,
provided the cowl top bracket provides for engagement between the mounting
brace
assembly and the vehicle cowl top. The cowl top bracket may incorporate
different
shapes, sizes and constructions, depending on for example environmental
constraints,
dimensions at the cowl top, attachment locations and direction of attachment.
Most
preferably, the cowl top bracket includes a single piece stamped metal
construction
having a U, W or L cross section.
In one embodiment, the cowl top bracket is formed as a laterally extending
cowl
top bracket coupled to both said mounting base arms, the cowl top bracket
further
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,
,
comprising an abutment edge portion located for substantially abutting contact
with an
outer surface of the cross-support member. In an alternative embodiment, the
mounting
brace assembly comprises two said cowl top brackets each coupled to an
associated one
of the mounting base arms.
Most preferably, the flange receiving slot is cooperatively defined at least
by
adjoining bottom and forward end walls of the cross-support member, and the
anchor
flange has a generally triangular shape extending at an angle to the base axis
towards the
second axial end portion to form a bracket attachment surface portion, the
anchor flange
tapering towards the first axial end portion to form an insertion portion
located to be at
least partially received in an interior of the cross-support member in the
mounted
orientation, and wherein the cowl top bracket comprises a generally planar
bracket plate
having a pair of laterally disposed attachment flanges each coupled to
associated said
bracket attachment surface portion, the bracket plate having an inclination
angle
substantially identical to said angle to the base axis.
It is to be appreciated that engagement between the steering column member and
the mounting brace assembly is not particularly limited. In one embodiment,
the
mounting base arm preferably further comprises a mounting plate interposed
between the
flange members in the first axial end portion, the mounting plate defining a
threated bore
or threaded nut for complementary threaded engagement with a threaded
attachment bolt
in the securement of the steering column member thereto. Where the mounting
brace
assembly includes a pair of the mounting base arms, two-point mounting of the
steering
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column member in the inwardly spaced mounting region may be effected in the
mounted
orientation.
For more effective load transfer from the steering column member, each of the
mounting base arms may be configured in an alternative embodiment to effect
two-point
mounting of the steering column member. For instance, the mounting base arm
may
preferably further comprise a second threaded attachment bolt or stud, and an
anchor
plate interposed between the flange members in the second axial end portion,
the anchor
plate defining a first surface aperture sized to receive the second threaded
attachment bolt
or stud, wherein the base web defines a second surface aperture in general
alignment with
the first surface aperture, and the second threaded attachment bolt or stud is
inserted
through the first and second surface apertures to form a threaded engagement
end portion
extending from the second surface aperture, the threaded engagement end
portion being
sized for complementary threaded engagement with a threaded nut or a threaded
bore
formed in the steering column member in the securement of the steering column
member
to the mounting base arm. Where the mounting brace assembly includes a pair of
the
mounting base arms, four-point mounting of the steering column member in the
inwardly
spaced mounting region may be effected in the mounted orientation. In such
embodiment, contact between the cowl top bracket and the vehicle cowl top
preferably
transfers rotational bearing forces from the first and second axial end
portions towards
the vehicle cowl top.
It is to be appreciated that to avoid mechanical redundancies and reduce
weight,
the reinforcement bridge member (or bridge plate) and the reinforcement bolt
in the
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,
,
second axial end portion as described above may operate or be formed as the
anchor plate
and the second threaded attachment bolt/stud, respectively. To form the second
threaded
attachment bolt/stud, the reinforcement bolt is modified to include the
threaded
engagement end portion to insert through and extend past the second surface
aperture.
Preferably, the abutment flange is disposed distal to the inwardly spaced
mounting region, and the anchor flange proximal to the inwardly spaced
mounting
region.
Most preferably, the mounting base arm and the cowl top bracket are welded
together, and furthermore to the cross-support member and the cowl top in the
mounted
orientation to form a single integral unit. The welding method for forming the
integral
unit is not particular limited, as long as the method operates to couple the
individual
components. Such welding methods may include but not limited to electric
resistance
welding, shielded metal arc welding, gas metal arc welding, submerged arc
welding, flux-
cored arc welding, electroslag welding, laser beam welding, electron beam
welding,
electromagnetic pulse welding, friction stir welding, cold metal transfer
welding and any
other welding processes known in the relevant arts.
In an alternative embodiment, the mounting base arm, the cowl top, the cross-
support member and/or the cowl top may be coupled using other known joining
methods
including but not limited to bonding, crimping, clinching, riveting and
screwing.
The materials for preparing the individual components of the mounting brace
assembly or arrangement are not particularly limited. Possible materials
include steel,
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aluminum, iron, magnesium, carbon fiber, high strength polymers or plastics
and any
combinations or alloys thereof.
Additional and alternative features of the present invention will be apparent
to a
person skilled in the art from the following detailed description of the
preferred
embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to the following detailed description taken together
with the accompanying drawings in which:
Figure 1 is a perspective view of a mounting brace assembly in accordance with
a
preferred embodiment of the present invention, and which is shown as welded to
a
vehicle cross-support member;
Figure 2 is another perspective view of the mounting brace assembly shown in
Figure 1;
Figure 3 is a perspective view of a mounting base channel beam of the mounting
brace assembly shown in Figure 1;
Figure 4 is an elevation view of the mounting base channel beam shown in
Figure
3;
Figure 5 is a perspective view of a cowl top coupling plate of the mounting
brace
assembly shown in Figure 1;
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=
Figure 6 is a cross-sectional side view of the mounting brace assembly shown
in
Figure 1, and which is taken at a mid-point between the two mounting base
channel
beams;
Figure 7 is a perspective view of a mounting brace assembly in accordance with
an alternative preferred embodiment of the present invention, and which is
shown as
coupled to a vehicle cross-support member;
Figure 8 is a side view of a mounting base channel beam of the mounting brace
assembly shown in Figure 7;
Figure 9 is a perspective view of a cowl top bracket of the mounting brace
assembly shown in Figure 7;
Figure 10 is a perspective view of a mounting brace assembly in accordance
with
an alternative embodiment of the present invention, and which is shown as
coupled to a
vehicle cross-support member;
Figure 11 is a perspective view of a mounting brace assembly in accordance
with
an alternative preferred embodiment of the present invention, and which is
shown as
coupled to a vehicle cross-support member;
Figure 12 is another perspective view of the mounting brace assembly shown in
Figure 11; and
Figure 13 is a side view of a mounting base channel beam of the mounting brace
assembly shown in Figure 11.
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,
,
,
r
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made to Figure 1 which shows a perspective view of a mounting
brace assembly 10 in accordance with a preferred embodiment of the present
invention,
and which is coupled to a vehicle cross-support member 200. As will be
described in
greater detail below, the mounting brace assembly 10 includes a pair of
mounting base
channel beams 20, 80, and a cowl top coupling plate 100. For greater clarity,
Figures 2
shows an additional perspective view of the channel beams 20, 80 and the cowl
top
coupling plate 100 welded to the cross-support member 200.
Reference is now made to Figure 3 which illustrates a perspective view of the
mounting base channel beam 20. The mounting base channel beam 20 forms a
generally
U-shaped channel 22 which extends longitudinally from a first axial end 23 to
a second
axial end 24. As seen in Figure 4, the channel 22 includes a longitudinally
extended base
web 26 integrally joining at one lateral edge an anchor flange 28, and at the
other lateral
edge an engagement flange 30 oriented substantially parallel to the anchor
flange 28.
The anchor flange 28 includes a generally triangular profile section 32 in the
second axial
end 24, tapering from an apex 33 towards the first axial end 23. A first
mounting arm
profile section 34 of a reduced height from the base web 26 is included in the
first axial
end 23 to extend towards the second axial end 24. Disposed between the
triangular and
first mounting arm profile sections 32, 34 is a first stopping post profile
section 36
formed as an upwardly extending protrusion. The profile sections 32, 34, 36
together
form the anchor flange 28 as an integral coplanar unit. Similar to the anchor
flange 28
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the engagement flange 30 includes in the first axial end 23 a second mounting
arm profile
section 38, and stopping post profile section 40 adjacent to the second
mounting arm
profile section 38. The engagement flange 30 furthermore includes in the
second axial
end 24 a plate seat profile section 42, and located between the second
stopping post
profile section 40 and the seat profile section 42 is a cross-support member
coupling
profile section 44. The base web 26 defines in the first and second axial ends
23, 24
attachment bolt receiving apertures 46, 48, respectively.
The first and second mounting arm profile sections 34, 38 include identical
dimensions, and, together with the adjoining portion of the base web 26 in the
first axial
end 23, form a cantilevered steering column mounting arm 50 for rearward
securement of
a steering column member thereto as will be further described below.
Similarly, the first
and second stopping post profile sections 36, 40 of identical dimensions and
longitudinal
position on the channel 22 cooperatively form a stopping post 52 for
restricting
longitudinal movement of the channel beam 20 and improved load transfer as
also will be
further described below.
As seen in Figure 1, for added structural rigidity, a reinforcement bridge 54
is
welded to mutually opposed surfaces of the anchor and engagement flanges 28,
30 along
the mounting arm 50 and the stopping pot 52 in the first axial end 23. As seen
in Figure
2, the channel beam 20 further includes an anchor bridge plate 56 welded to a
longitudinal edge of the seat profile section 42 of the engagement flange 30,
and an
opposed surface of the anchor flange 28 in the second axial end 24. The anchor
bridge
plate 56 defines a surface aperture aligned with the attachment bolt receiving
aperture 48
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,
,
=
,
of the base web 26, and an attachment bolt 58 is fixedly received through the
surface
aperture and the attachment bolt receiving aperture 48. The attachment bolt 58
includes a
dowel pin portion 59 extending from the attachment bolt receiving aperture 48
for
securing the steering column member during operation as will be further
described
below. As seen in Figure 1, the mounting arm 50 also includes a mounting plate
60
defining a threaded bore in alignment with the attachment bolt receiving
aperture 46 of
the base web 26.
Although not strictly limited, the channel beam 20 preferably extends
longitudinally between about 20 cm and about 80 cm, and between about 2 cm and
about
20 cm in width. The anchor flange 28 preferably extends between about 5 cm and
about
40 cm from the base web 26 to the apex 33, and the triangular profile section
32 has an
inclination angle between about 5 and about 70 relative to the channel 22.
The first and
second mounting arm profile section 34, 38 extends between about 1 cm and 5 cm
from
the base web 26, and the first and second stopping post profile sections 36,
40 between
about 3 cm and 10 cm. The profile sections 42, 44 extend about 2 cm to 8 cm
from the
base web 26. The channel beam 20 is most preferably formed as a single piece
stamped
metal with a thickness between about 0.1 cm and about 1.0 cm.
The mounting base channel beam 80 is identical to the mounting base channel
beam 20 as described above, except the channel beam 80 forms a mirrored image
of the
channel beam 20.
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Reference is made to Figure 5 which shows a perspective view of the cowl top
coupling plate 100. The cowl top coupling plate 100 incorporates a generally
planar
single piece construction most preferably formed with one or more stamped
reinforcing
ridges or ribs 102 for increased planar structural rigidity. Formed along the
two opposed
lateral edges of the cowl top coupling plate 100 are lateral attachment
flanges 104, 106.
The coupling plate 100 includes a load transfer portion 107 adjacent to a
first transverse
edge 112, and which defines a pair of holes 108, 110 positioned for engaging a
vehicle
cowl top as will be further described below. A second transverse edge 114
opposite to
the first transverse edge 112 is shaped for attachment to the cross-support
member 200 as
also will be further detailed below.
Although not particularly limited, the cowl top coupling plate 100 preferably
measures between about 10 cm and about 50 cm in width, between about 15 cm and
about 60 cm in length, and between about 0.1 cm and 1.0 cm in thickness.
For installation, as seen in Figures 1 and 6, the channel beams 20, 80 are
welded
to the cross-support member 200 along a length of the cross-support member 200
to
define an interior mounting region 240 therebetween. In particular, the
channel beam 20
is first positioned on the cross-support member 200 by partially inserting the
triangular
profile section 32 into an associated flange receiving slot (not explicitly
shown)
preformed on adjoining bottom and forward walls 222, 224 of the cross-support
member
200, until the coupling profile section 44 is in contact with the bottom wall
222. As seen
in Figure 1, the channel beam 20 is oriented such that with the cross-support
member 200
affixed transversely to a length of a vehicle, the anchor flange 28 is
adjacent to the
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CA 02854741 2014-06-19
,
,
,
interior mounting region 240, and the steering column mounting arm 50 is
positioned
towards a rearward end of the vehicle, and the second axial end 24 towards a
forward end
of the vehicle below the vehicle cowl top (not shown). Furthermore, as seen in
Figure 6,
when properly placed the stopping post 52 is in abutting contact with a rear
wall 226 of
cross-support member 200, preventing longitudinal forward movement of the
channel
beam 20. Most preferably, the triangular profile section 32 is sized to abut
against
longitudinal ends of the flange receiving slot when the stopping post 52 is in
contact with
the rear wall 226, so as to restrict both forward and rearward longitudinal
movement of
the channel beam 20. After proper placement, the channel beam 20 is welded in
place to
the cross-support member 200.
The other channel beam 80 is positioned and welded to the cross-support member
200 in a manner identical to that of the channel beam 20 as described above,
with a
respective anchor flange 82 being disposed adjacent to the interior mounting
region 240,
the respective first and second axial ends 84, 86 directed towards the
rearward and
forward ends of the vehicle, respectively.
With the channel beams 20, 80 welded to the cross-support member 200, the cowl
top coupling plate 100 is positioned and welded to the triangular profile
sections of the
channel beams 20, 80 at the lateral attachment flanges 104, 106, such that an
upper or
lower surface of the load transfer portion 107 is in contact with the vehicle
cowl top (not
shown). The cowl top coupling plate 100 is joined to the cowl top preferably
using
threaded studs and/or bolts, or fastening rivets, received through the holes
108, 110. For
more rigid attachment to the cross-support member 200, the second transverse
edge 114
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CA 02854741 2014-06-19
,
,
is welded to an adjacent angled top wall 228 of the cross-support member 200.
As best
seen in Figure 6, when welded to the channel beams 20, 80 and the cross-
support
member, the plane of the coupling plate 100 has an inclination angle
substantially
identical to or less than the angle defined by an upper edge of the triangular
profile
section 32 from the base web 26.
For operation, a steering column member (not shown) is secured to the mounting
brace assembly using four-point mounting configuration. To effect attachment,
the
steering column member is provided with a pair of reinforcement lateral sides,
and an
associated one of the reinforcement lateral sides is mounted to the mounting
arm 50 of
the channel beam 20 using a threaded attachment bolt inserted through the
attachment
bolt receiving aperture 46, and threadably engaged to the threaded bore of the
mounting
plate 60. The dowel pin portion 59 of the attachment bolt 58 extending
generally
downwardly in the second axial end 24 is inserted into a dowel pin receiving
bore
provided on the associated reinforcement lateral side of the steering column
member to
be secured thereon using an engagement nut. The opposite reinforcement lateral
side of
the steering column member is mounted to the channel beam 80 in a manner
identical to
that described above for the channel beam 20, such that the steering column
member is
positioned in the interior mounting region 240 between the channel beams 20,
80.
The applicant has appreciated that the mounting brace assembly 10 may permit
improved transfer, dispersion and distribution of the load and forces, such as
rotational,
translational and torsional forces, generated from the attached steering
column member
towards the cross-support member 200 and the vehicle cowl top. Load transfer
may for
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CA 02854741 2014-06-19
example further involve transferring of a portion of the steering column
member loads
received by the mounting arm 50 to the stopping post 52 and into the rearward
wall 226
of the cross-support member 200.
It is to be appreciated that the channel beams 20, 80 are not particularly
limited
for installation in the preferred orientation seen in Figures 1 and 2. The
channel beams
20, 80 may in the alternative be positioned such that one or both of the
respective anchor
flanges are disposed distal to the interior mounting region 240, depending on,
for
example, the attachment point to the vehicle cowl top, and the intended load
distribution
path from the channel beams 20, 80.
It is to be further appreciated that depending on the specific application,
and the
dimensions and requirements of the vehicle, various modifications and
adjustments may
be made to the mounting brace assembly of the present invention. By way of an
alternative embodiment, Figure 7 shows a mounting brace assembly 310
configured for
installation in a vehicle with a generally vertically oriented attachment
point on the
vehicle cowl top.
The mounting brace assembly 310 includes a pair of mounting base channel
beams 320, 380, and is seen in figure 7 as coupled to the vehicle cross-
support member
200. As seen in Figure 8, the channel beam 320 is substantially identical to
the channel
beam 20 described above, with the exception that the channel beam 320 includes
an
anchor flange 328 which includes profile sections modified from those of the
channel
beam 20. In particular, the anchor flange 328 includes two profile sections,
or namely a
24
CA 02854741 2014-06-19
mounting arm profile section 334 in a first axial end 323, and which is
integrally joined
to an adjacent sloped profile section 332 extending to a second axial end 324.
Unlike the
channel beam 20, the anchor flange 328 does not include any stopping post
profile
section. Rather, a stopping post profile section 340 included with an
engagement flange
330 of the channel beam 320 alone forms a stopping post positioned for
contacting the
rear wall 226 when the anchor flange 328 is positioned and welded to the cross-
support
member 200.
To accommodate the sloped profile section 332, the flange receiving slot
preformed on the cross-support member 200 further extends to the rear wall
226.
Although the anchor flange 328 is shown in Figure 8 as having the two adjacent
profile
sections 332, 334, the anchor flange 328 may alternatively include only the
sloped profile
section 332 extending to the first axial end 323 for additional or modified
load transfer
path from the first axial end 323.
The mounting brace assembly 310 is also different from the mounting brace
assembly 10 in that two separate cowl top brackets 400, 420 are welded to the
mounting
base channel beams 320, 380, respectively. As seen in Figure 9, the cowl top
bracket 400
has a generally rectangular attachment plate 402 with a pair of laterally
opposed return
flanges 404, 406 and a transversely oriented cowl top coupling flange 408. The
cowl top
coupling flange 408 defines a fastener receiving aperture 410 for receiving a
fastening
rivet, stud or bolt in the securement of the mounting brace assembly 310 to
the vehicle
cowl top.
CA 02854741 2014-06-19
,
,
,
,
For installation, the channel beams 320, 380 are welded to the cross-support
member 200 in a manner identical to that described above for the mounting
brace
assembly 10. The cowl top bracket 400 is coupled to the channel beam 320 by
positioning and welding the attachment plate 402 to the sloped profile section
332 at an
upper end surface facing away from the interior mounting region 240, such that
the cowl
top coupling flange 408 is in juxtaposed contact with the vertically oriented
attachment
point (not shown) on the vehicle cowl top. For increased rigidity, a
reinforcing lip 412
provided on the return flange 406 is welded to the top wall 228 of the cross-
support
member 200. For illustration purposes, the cowl top bracket 420 is shown in
Figure 7 as a
simplified variation of the cowl top bracket 400, and which may be more suited
when
requirements for local cross car rigidity are less severe, and reducing
material and
production time is preferred.
The cowl top brackets 400 and 420, in addition to the anchor bridge plate 56
and
attachment bolt 58, allow for the production of single integral pre-assembly
units by
welding to the predetermined locations on the channel beams 320 and 380,
respectively,
and which may be prepared prior to installation on the cross-support member
200.
It is to be appreciated that the cowl top brackets 400, 420 may be attached to
either surfaces of the respective anchor flanges of the channel beams 320,
380, depending
on the specific location and geometry of the attachment point on the vehicle
cowl top.
Reference is now made to Figure 10 which illustrates as an alternative
embodiment a mounting brace assembly 510 modified for application in a vehicle
having
26
CA 02854741 2014-06-19
,
,
. ,
a single attachment point on the cowl top. The mounting brace assembly 510
includes
mounting base channel beams 520, 580 and a cowl top bracket 600. The channel
beam
520 and the cowl top bracket 600 welded thereto are identical to the above-
described
channel beam 320 and the cowl top bracket 400, respectively, including a cowl
top
coupling flange 608 having a threaded nut 610 on a surface thereof. The
threaded nut
610 is provided for complementary threaded engagement with a threaded cowl top
attachment bolt (not shown) in the securement of the cowl top bracket 400 to
the vehicle
cowl top (not shown). Alternatively, only a hole may be present on the cowl
top coupling
flange 608, allowing for securement of the cowl top bracket 600 to the vehicle
cowl top
as described above for the cowl top bracket 400.
Furthermore, the mounting base channel beam 580 is identical to the channel
beam 20 described above, except that the channel beam 580 includes two
generally
parallel engagement flanges 582, 584, both identical to the engagement flange
30 of the
channel beam 20 described above. Given the absence of any anchor flange, the
cross-
support member 200 preferably does not include a flange receiving slot at the
location
where the channel beam 580 is coupled. Furthermore, as both of the engagement
flanges
582, 584 include plate seat profile sections 586, 588, respectively,
positionable forwardly
of the cross-support member 200, the channel beam 580 includes a reinforcement
plate
556 welded to respective longitudinal seating edges of the seat profile
section 586, 588.
Reference is now made to Figure 11 which illustrates as an alternative
embodiment a mounting brace assembly 710 which incorporates modified
constructions
for added rigidity of the cross-support member 200. The mounting brace
assembly 710
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CA 02854741 2016-06-27
includes a pair of mounting base channel beams 720, 780, and a cowl top
coupling
bracket 800. As seen in Figure 13, the channel beam 720 includes an anchor
flange 728
having in a first axial end 723 a mounting arm profile section 734, a leg
support profile
section 764 in a second axial end 724, and a locating flange profile section
766 disposed
between the profile sections 734, 764. The locating flange profile section 766
is provided
with a couple of coplanar insertion tabs 768, 770 sized for mated insertion in
associated
tab receiving slots preformed on the top wall 228 and a second top wall 230,
respectively,
when the mounting brace assembly 710 is welded to the cross-support member
200. As
seen in Figure 11, the channel beam 720 furthermore includes an engagement
flange 730
disposed parallel to the anchor flange 728, and which is identical to the
engagement
flange 30 described above, so as to include a plate seat profile section 742
in the second
axial end 24. The leg support profile section 764 of the anchor flange 728
includes an
end portion 772 angled away from the opposed engagement flange 730.
The mounting brace assembly 710 further includes a pair of cowl top bracket
legs
790, 792 coupled to respective second axial ends of the channel beams 720,
780. As best
seen Figure 12, the cowl top bracket leg 790 includes on one end a seating
plate 794
welded to a longitudinal seating edge of the plate seat profile section 742,
and which is
further secured to a longitudinally extending base web 726 using a bolt. The
cowl top
bracket leg 790 is welded to or supported against the leg support profile
section 764.
Likewise, the cowl top bracket leg 792 is coupled to the respective second
axial end of
the channel beam 780 in a manner identical to that of the cowl top bracket leg
790 as
described above, such that when welded to the cross-support member 200, the
cowl top
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CA 02854741 2014-06-19
bracket legs 790, 792 extend at an angle towards the interior mounting region
240 to
cooperatively define a cowl top bracket seating surface. A bottom surface of
the cowl top
coupling bracket 800 is welded to the cowl top bracket legs 790, 792 in seated
engagement with the seating surface.
While the invention has been described with reference to preferred
embodiments,
the invention is not or intended by the applicant to be so limited. A person
skilled in the
art would readily recognize and incorporate various modifications, additional
elements
and/or different combinations of the described components consistent with the
scope of
the invention as described herein.
29
