# US 7,407,221 B2 · Support structures using tubes having variable wall thicknesses > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,407,221 B2 - Document ID: US7407221B2 - Status: Granted - Kind: B2 - Application number: 10/997,808 - Filed: 2004-11-24 - Published: 2005-06-23 - Granted: 2008-08-05 - Earliest claimed: 2003-11-24 - Assignees: L & W Engineering - Inventors: James Kring; Gene Goins; Dean Richardson - Web page: https://patentgrep.com/patent/US7407221B2 ## CPC - B62D 25/145: {having a crossbeam incorporated therein} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) ## Abstract A support structure for components within a vehicle is provided. The support structure includes a beam comprising a hollow metal tube coupled to vehicle's body. The tube is constructed of a single piece of tubing having first and second portions. The first portion has a first diameter and a first thickness, the second portion has a second diameter and a second thickness. The second diameter is larger than the first diameter and the second thickness is greater than the first thickness. ## Claims ### Claim 1 A cross vehicle structure member for a vehicle extending across the vehicle between the vehicle pillars comprising: a beam comprising a hollow metal tube extending across the vehicle between the vehicle pillars, the tube is constructed of a single monolithic piece of tubing having a first portion, coupled to a first side of the vehicle and having a first outer diameter, a first inner diameter and a first thickness; a second portion, coupled to a second side of the vehicle and having a second outer diameter, second inner diameter and a second thickness, said first inner diameter and outer diameter being smaller than the second inner diameter and outer diameter; a secondary cross beam member extending generally parallel the primary cross beam member and having generally the same length as the primary cross beam member; at least one structure supporting bracket secured between the primary cross beam and the secondary cross beam; and at least one second bracket configured to support a steering column coupled to the second portion. ### Claim 2 (depends on 1) The cross vehicle structure according to claim 1 wherein said beam further comprises a plurality of structure supporting brackets. ### Claim 3 (depends on 1) The cross vehicle structure according to claim 1 wherein the beam comprises a plurality of third brackets configured to support a knee bolster. ### Claim 4 (depends on 1) The cross vehicle structure according to claim 1 wherein the first and second thickness are between 0.7 mm and about 3.5 mm. ### Claim 5 (depends on 1) The cross vehicle structure according to claim 1 further comprising a plurality of sheet metal support brackets. ### Claim 6 (depends on 1) The cross vehicle structure according to claim 1 wherein said beam is formed of a metal selected from the group consisting of HSLA 50, mild steel, aluminum, or aluminum alloys. ### Claim 7 A cross vehicle structural member comprising: a primary cross beam member including a beam comprising a hollow monolithic metal tube extending substantially between two interior surfaces of the vehicle, the tube being constructed of a single piece of tubing having first and second portions, the first portion, coupled to a first side of a vehicle and having a first inner diameter and a first thickness, the second portion, coupled to a second side of the vehicle and having a second inner diameter and a second thickness, the second inner diameter is greater than the first inner diameter and the second thickness is greater than the first thickness; a secondary cross beam member extending generally parallel the primary cross beam member and having generally the same length as the primary cross beam member; a plurality of brackets secured between the primary cross beam and the secondary cross beam including a first bracket secured at a first end of said primary cross beam member and a first end of said secondary cross beam member and a second bracket secured at a second end of said primary cross beam member and a second end of said secondary cross beam member; and a bracket configured to support a steering column coupled to the second portion. ### Claim 8 (depends on 7) The cross vehicle structure according to claim 7, the to plurality of brackets being formed of sheet metal and having a cross sectional shape selected from the group consisting of T-shape, L-shape, I-shape, and U-shape. ### Claim 9 A support structure for supporting an instrument panel within a vehicle comprising: a primary cross beam member including a hollow metal tube coupled to the vehicle body, the tube being constructed of a single monolithic piece of tubing having a first portion, coupled to a first side of the vehicle and having first inner and outer diameters and a first thickness and a second portion, coupled to a second side of the vehicle and having a cylindrical outer surface and second outer and inner diameters and a second thickness, said first thickness being smaller than the second thickness; a secondary cross beam member extending generally parallel the primary cross beam member and having generally the same length as the primary cross beam member; at least one bracket secured between the primary cross beam member and the secondary cross beam member; a plurality of instrument panel supporting brackets welded to the hollow metal tube; and a steering column support bracket welded to the cylindrical outer surface. ### Claim 10 (depends on 9) The support structure for supporting an instrument panel according to claim 9 wherein the second inner diameter is larger than the first inner diameter. ### Claim 11 (depends on 10) The support structure for supporting an instrument panel according to claim 10 wherein the hollow metal tube is formed of a metal selected from the group consisting of HSLA 50, mild steel, grade 1010 steel, aluminum, and aluminum alloys. ### Claim 12 A support structure for supporting a component within a vehicle comprising: a primary cross beam member including a single piece of tubing having first and second portions for supporting the vehicle component, the first portion has a first outer diameter and a first thickness, the second portion has a second inner diameter and a second thickness, the second inner diameter is larger than the first outer diameter and the second thickness is greater than the first thickness; a secondary cross beam member extending generally parallel the primary cross beam member and having generally the same length as the primary cross beam member; a plurality of brackets disposed between the primary cross beam member and the secondary cross beam member and welded to the tubing, at least a subset of said brackets configured to be coupled to the vehicle component. ### Claim 13 (depends on 7) The cross vehicle structural member according to claim 7 including at least a third bracket and a fourth bracket each positioned inwardly of the first bracket and the second bracket, a third member secured between the third bracket and the fourth bracket. ### Claim 14 (depends on 13) The cross vehicle structural member according to claim 13 wherein the third member is a dashboard deck plate. ### Claim 15 (depends on 13) The cross vehicle structural member according to claim 13, wherein a fourth member is secured at a first end using one of the third bracket and the fourth bracket and at a second end using one of the first bracket and the second bracket. ### Claim 16 (depends on 15) The cross vehicle structural member according to claim 15, wherein a frame member is disposed between the second end of the fourth member and one of the first bracket and the second bracket. ### Claim 17 (depends on 16) The cross vehicle structural member according to claim 16, wherein a supplemental bracket is secured between the primary cross beam and the fourth member. ### Claim 18 (depends on 7) The cross vehicle structural member according to claim 7, further comprising: a third bracket positioned between the first bracket and the second bracket; a fourth bracket positioned between the first bracket and the second bracket; a third member comprising a dashboard deck plate secured at a first end to the third bracket and at a second end to the fourth bracket; and a fourth member secured at a first end using one of the third bracket and the fourth bracket and at a second end using one of the first bracket and the second bracket.