Patent Publication Number: US-2019168818-A1

Title: Vehicle cross members and related methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority of U.S. Provisional Patent Application No. 62/370,497 filed Aug. 3, 2016, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field of Invention 
     The present invention relates generally to vehicle cross members, and more specifically, but not by way of limitation, to car cross beams and methods for making the same. 
     2. Description of Related Art 
     Vehicles (e.g., cars, trucks, busses, and/or the like) can include a variety of cross members, such as, for example, car cross beams, pillars (e.g., A-, B-, C-, and/or D-pillars), bumper beams, and door beams, just to name a few. Such cross members may serve various purposes, such as those relating to safety, structural integrity, noise vibration and harshness (NVH) reduction, and/or the like. 
     To illustrate, many vehicles include a car cross beam for supporting a dash, a steering column, an instrument panel, heating, ventilation, and air conditioning (HVAC) components, airbags, and/or the like. Such a car cross beam may need to be rigid to, for example, resist undesirable movement of supported components (e.g., in the event of a crash), increase the structural integrity of the vehicle body, and/or reduce NVH. 
     SUMMARY 
     Many existing car cross beams are formed, at least in part, of steel and/or other heavy metals. Some existing car cross beams may be at least partially formed from lighter-weight metals, such as magnesium, aluminum, and/or the like. Other existing car cross beams may be formed, at least in part, from light weight composite materials. Many existing car cross beams, regardless of their material(s) of manufacture, are of multi-piece construction, consisting of an assembly of stamped component(s), bracket(s), beam(s), and/or the like. 
     Such existing car cross beams may be subject to a number of shortcomings. To illustrate, car cross beams including steel and/or other heavy metals may be undesirably heavy, resulting in a decrease in vehicle performance and/or an increase in assembly time and/or cost. Existing car cross beams including lighter-weight metals, such as magnesium, aluminum, and/or the like, may be relatively expensive and may necessitate increased tool maintenance (e.g., due to increased casting temperature requirements). Existing car cross beams including light weight composite materials may necessitate complex, multi-piece construction due to, for example, difficulties associated with the molding process. Existing car cross beams of multi-piece construction may complicate assembly procedures (e.g., by requiring the joining of different materials), and/or undesirably increase weight, assembly time, and/or cost. As described in more detail below, the present vehicle cross members can be configured to address some or all of these shortcomings. 
     The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially” and “approximately” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent. 
     The phrase “and/or” means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “and/or” operates as an inclusive or. 
     As used in this disclosure, a “lamina” is a layer of material that is formed by introducing a matrix material into an arrangement of fibers, and “laminae” is the plural form of lamina. A “laminate” is a layer of material including one or more laminae, whether or not consolidated. 
     Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. 
     The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), and “include” (and any form of include, such as “includes” and “including”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes,” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps. 
     Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/have/include—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb. 
     The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments. 
     Some details associated with the embodiments are described above, and others are described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment depicted in the figures. 
         FIG. 1A  is a front perspective view of a first embodiment of the present vehicle cross members. 
         FIGS. 1B and 1C  are front perspective and rear perspective views, respectively, of the cross member of  FIG. 1A . 
         FIG. 2  is a schematic cross-sectional end view of the cross member of  FIG. 1A , taken along line  2 - 2  of  FIG. 1B . 
         FIGS. 3A-3D  are schematic cross-sectional end views of supports and/or beams that may be suitable for use in some embodiments of the present cross members. 
         FIGS. 4A and 4B  are schematic exploded views of laminates that may be suitable for use in some embodiments of the present cross members. 
         FIG. 5A  is a perspective view of a joint that may be suitable for use between adjacent sections of and/or between a plastic material and one or more laminates of some embodiments of the present cross members. 
         FIG. 5B  is a schematic cross-sectional side view of the joint of  FIG. 5A , taken along line  5 B- 5 B of  FIG. 5A . 
         FIGS. 6A and 6B  are schematic views of ribs for reinforcing the joint of  FIG. 5A . 
         FIG. 7  is a back perspective view of a second embodiment of the present vehicle cross members. 
         FIG. 8A  is a schematic cross-sectional end view of the cross member of  FIG. 7 , taken along line  8 A- 8 A of  FIG. 7 . 
         FIGS. 8B and 8C  are schematic cross-sectional end views of supports and/or beams that may be suitable for use in some embodiments of the present cross members. 
         FIG. 9  is a front perspective view of a third embodiment of the present vehicle cross members. 
         FIG. 10A  is a schematic cross-sectional end view of the cross member of  FIG. 9 , taken along line  10 A- 10 A of  FIG. 9 . 
         FIGS. 10B-10K  are schematic cross-sectional end views of supports and/or beams that may be suitable for use in some embodiments of the present cross members. 
         FIG. 11A  is a front perspective view of a fourth embodiment of the present vehicle cross members. 
         FIG. 11B  is a cross-sectional end view of the cross member of  FIG. 11A , taken along line  11 B- 11 B of  FIG. 11A . 
         FIGS. 12A and 12B  are schematic cross-sectional views a mold that may be suitable for forming a composite body of some embodiments of the present cross members. 
         FIGS. 13A-13C  are schematic cross-sectional views of a mold that may be suitable for forming a composite body of some embodiments of the present cross members. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1A-1C  depict a first embodiment  10   a  of the present vehicle cross members. Cross member  10   a  comprises a car cross beam in that the cross member can be coupled to a vehicle (e.g., car, truck, bus, other vehicle, and/or the like) to provide support for certain vehicle component(s), such as, for example, a dash, steering column, instrument panel, heating, ventilation, and air conditioning (HVAC) component, airbag, and/or the like. For example, cross member  10   a  can include one or more mounts, each configured to support one or more of various vehicle components; to illustrate, mount  14   a  can support a steering column and/or instrument cluster, mount  14   b  can support an airbag housing or carrier, and/or mount  14   c  can support a heating, ventilation, and air conditioning (HVAC) component. Other vehicle cross members can comprise any suitable cross member, such as, for example, a front bulkhead, rear bulkhead, A-pillar, B-pillar, C-pillar, D-pillar, bumper beam, door beam, or the like. 
     Cross member  10   a  can include an elongated beam  22  that extends between a first end  26  and a second end  30  and is configured to be secured to a vehicle, such that, for example, the beam extends transversely across at least a portion of a passenger compartment of the vehicle, serves as a horizontal load bearing portion of the cross member, and/or the like. For example, at least one of first end  26  and second end  30  of beam  22  can define one or more openings  34  (e.g., holes, slots, recesses, and/or the like) for securing the beam to a vehicle, via, for example, receiving one or more fasteners that can be disposed into the vehicle. In at least this way, some cross members (e.g.,  10   a ) can be mounted to a vehicle at one or more locations (e.g., at first end  26  and/or second end  30  of beam  22 ), without requiring separate mounting component(s) (other than fasteners), such as, for example, flange(s), mount(s), plate(s), and/or the like, which can reduce manufacturing costs, assembly time, and/or the like. Cross member  10   a  can be configured to facilitate installation of the cross member to a vehicle; for example, beam  22  can include one or more assembly features, such as, for example, one or more openings  36 , protrusions, recesses, hooks, and/or the like, from which the cross member can be lifted and/or maneuvered during assembly of the cross member to the vehicle. 
     Referring additionally to  FIG. 2 , beam  22  can include a sidewall  44  that extends between, but not necessarily to each of, first end  26  and second end  30  to define one or more channels, each extending along a longitudinal axis  24  of the beam. For example, sidewall  44  can define a first channel  48   a  and/or a second channel  48   b . Such channels (e.g.,  48   a ,  48   b , and/or the like) can provide reinforcement for support(s) and/or mount(s). For example, each channel (e.g.,  48   a ,  48   b , and/or the like) can include a bottom (e.g., deepest) portion  52  and opposing side portions,  56   a  and  56   b , that extend from the bottom portion. Bottom portion  52  and/or side portions,  56   a  and  56   b , of a channel (e.g.,  48   a ,  48   b , and/or the like) can provide a base from which a support and/or mount can extend and/or the side portions of the channel can be disposed on opposite sides of (e.g., the top and bottom of) the support and/or mount. By extending from a channel (e.g.,  48   a ,  48   b , and/or the like), a support and/or mount can extend a reduced distance from beam  22 , which can stiffen the support and/or mount and/or, in molded embodiments, facilitate molding of the support and/or mount. 
     Such channels (e.g.,  48   a ,  48   b , and/or the like) can be open. For example, each channel (e.g.,  48   a ,  48   b , and/or the like) can have a cross-section, taken perpendicularly to a long dimension of the channel, that is open, that is U- or C-shaped, and/or the like. In molded embodiments, open channels (e.g.,  48   a ,  48   b , and/or the like) can facilitate molding of a beam (e.g.,  22 ) by, for example, reducing undercut geometry of the beam, a number of moving mold portions (e.g., sliders) needed to mold the beam, and/or the like. 
     Channel  48   a  can be open on a first side  68  of beam  22 , and channel  48   b  can be open on a second side  72  of the beam that is opposite the first side. In this way, open channels  48   a  and  48   b  can provide reinforcement for and/or facilitate molding of support(s) and/or mount(s) that extend from beam  22  in differing directions. For example, a portion of open channel  48   a , such as bottom portion  52 , can provide a base from which a first support  128  (described in more detail below) can extend in a first direction (e.g.,  74 ), and a portion of open channel  48   b , such as bottom portion  52 , can provide a base from which mount  14   a  extends in a second direction (e.g.,  78 ) that is opposite the first direction. Channel  48   b  can be disposed below channel  48   a , such that, for example, at least a portion of beam  22  comprises an S-shaped cross-section. In this way, channel  48   a  can provide reinforcement for a first mount and/or support (e.g., first support  128 , which can be a connection between beam  22  and a firewall of the vehicle), and channel  48   b  can provide reinforcement for a second mount and/or support (e.g., mount  14   a , which can be for a steering column) that is disposed below the first mount and/or support. 
     Such channels (e.g.,  48   a ,  48   b , and/or the like) can be dimensioned and/or located along beam  22  pursuant to strength, stiffness, component mounting, and/or the like requirements. For example, channel  48   b  can be located along beam  22  such that the channel provides a mounting location (e.g.,  14   a ) for a steering column and/or resists bending, torsion, and/or shear loads applied to the beam by the steering column. In order to reduce the weight, size, and/or cost of cross member  10   a , channel  48   b  may not extend the full length of beam  22 . Channel  48   b  can have a length  94  that is smaller than (e.g., less than or equal to half of) a length  86  of beam  22  and/or a length  90  of channel  48   a , where the lengths are measured along longitudinal axis  24  of the beam. Channel  48   b  can be located along beam  22  closer to one end (e.g.,  30 ) of the beam than to the other end (e.g.,  26 ) of the beam. More particularly, beam  22  can include longitudinally adjacent first and second sections,  98  and  102 , respectively, and channel  48   b  can extend across at least a majority of the second section, but not necessarily across at least a majority of the first section. 
     For further example, channel  48   a  can extend across at least a majority of beam  22  to strengthen and/or stiffen at least a majority of the beam; to illustrate, length  90  of the channel can be substantially equal to length  86  of the beam, the channel can extend across at least a majority of first section  98  and second section  102 , and/or the like. A portion of channel  48   a  that is proximate to one end of the beam (e.g.,  30 ), such as a portion of the channel disposed on second section  102 , can have a larger height  110  and/or width  112  than a portion of the channel that is proximate to the other end of the beam (e.g.,  26 ), such as a portion of the channel disposed on first section  98 . In at least this way, channel  48   a  can provide for increased strength and/or stiffness of beam  22  where reinforcement of the beam may be desirable, such as, for example, where loads are applied to the beam by a steering column, where the beam is connected to a vehicle (e.g., via first support  128  and/or second support  140 ), and/or the like. 
     Beam  22  can define ribs  120  extending from sidewall  44  and into one or more channels (e.g.,  48   a ,  48   b , and/or the like) defined by the sidewall. At least some of ribs  120  within channel  48   a  can be substantially aligned (e.g., substantially coplanar) with at least some of ribs  120  within channel  48   b , which can facilitate transfer of loads between the ribs; to illustrate, rib  120   a  can be aligned with rib  120   b . To promote structural efficiency, at least some of ribs  120  can extend from sidewall  44  in a direction that is substantially perpendicular to the sidewall. Portions of beam  22  where reinforcement of the beam may be desirable (e.g., where loads are applied to the beam by a steering column, where the beam is connected to a vehicle, and/or the like) can have more ribs than other portions of the beam. For example, second section  102  can have more ribs  120  than first section  98 . Such ribs (e.g.,  120 ) can increase the strength and/or stiffness of a cross member (e.g.,  10   a ) in exchange for a relatively small increase in the weight of the cross member. 
     Cross member  10   a  can comprise a first support  128  extending from second side  72  of beam  22  and configured to secure the beam to a vehicle (e.g., to a firewall of the vehicle). For example, first support  128  can define one or more openings  132  (e.g., holes, slots, recesses, and/or the like) for securing beam  22  to a vehicle, via, for example, receiving one or more fasteners that can be disposed into the vehicle. First support  128  can be located along beam  22  where reinforcement of the beam may be desirable (e.g., where loads are applied to the beam by a steering column). For example, first support  128  can be located closer to one end (e.g.,  30 ) of beam  22  than the other end (e.g.,  26 ) of the beam. For further example, first support  128  can extend from second section  102  of beam  22 . 
     Cross member  10   a  can comprise a second support  140  extending downwardly from beam  22  and configured to secure the beam to a vehicle (e.g., to a floor and/or tunnel of the vehicle). For example, second support  140  can define one or more openings  144  (e.g., holes, slots, recesses, and/or the like) for securing beam  22  to a vehicle, via, for example, receiving one or more fasteners that can be disposed into the vehicle. As with first support  128 , second support  140  can be located along beam  22  to strengthen and/or stiffen portion(s) of the beam, such as, for example, a portion of the beam where loads are applied by a steering column, a portion of the beam that is connected to a vehicle, and/or the like. For example, second support  140  can extend from channel  48   b  (e.g., from side portion  56   b ), facilitating transfer of loads between the channel and the second support. For further example, second support  140  can extend from channel  48   b  at an end of the channel. In at least this way, a (e.g., relatively short, when compared to length  86 ) portion of the beam to which loads are applied by a steering column and/or that is connected to a firewall of a vehicle, such as second section  102 , can be supported on one end by the vehicle (e.g., via opening(s)  34 ) and on the other end by second support  140 , enhancing the strength and/or stiffness of the portion of the beam. 
       FIG. 3A  is a schematic cross-sectional end view of second support  140 , taken along line  3 A- 3 A of  FIG. 1A . As shown, second support  140  can define one or more channels, each extending along a longitudinal axis  142  of the second support. For example, second support  140  can define a first channel  148   a  and/or a second channel  148   b . As described above for beam  22 , second support  140  can define ribs  120  that extend into one or more channels (e.g.,  148   a ,  148   b , and/or the like) of the second support. Second support  140 , via such channels (e.g.,  148   a ,  148   b , and/or the like), can resist bending, torsion, and/or the like loads, while having a relatively low weight (e.g., when compared to a channel-less structure). 
     Such channels (e.g.,  148   a ,  148   b , and/or the like) can be open. For example, each channel (e.g.,  148   a ,  148   b , and/or the like) can have a cross-section, taken perpendicularly to a long dimension of the channel, that is U- or C-shaped, and/or the like. In molded embodiments, open channels (e.g.,  148   a ,  148   b , and/or the like) can facilitate molding of a support (e.g.,  140 ) by, for example, reducing undercut geometry of the support, a number of moving mold portions (e.g., sliders) needed to mold the support, and/or the like. 
     Channel  148   a  can be open on a first side  152  of second support  140 , and channel  148   b  can be open on a second side  156  of the second support that is opposite the first side. Each channel (e.g.,  148   a ,  148   b , and/or the like) can include a bottom (e.g., deepest) portion  158  and opposing side portions,  160   a  and  160   b , that extend from the bottom portion. In a support (e.g.,  140 ), a bottom portion (e.g.,  158 ) of a first channel (e.g.,  148   a ) can abut a bottom portion (e.g.,  158 ) of a second channel (e.g.,  148   b ) and/or side portion(s) (e.g.,  160   a  and/or  160   b ) of the first channel can be substantially co-planar with side portion(s) (e.g.,  160   a  and/or  160   b ) of the second channel, such that, for example, at least a portion of the support comprises an I-shaped cross-section. 
     As shown in  FIGS. 3B-3D , other cross members can include a support (e.g.,  140 ) having any suitable structure, such as, for example, one in which channels (e.g.,  148   a ,  148   b , and/or the like) abut one another at respective side portion(s) (e.g.,  160   a  and/or  160   b ) of the channels (e.g.,  FIG. 3B , in which side portions  160   a  and  160   b  of channel  148   b  abut side portion  160   b  of channel  148   a  and side portion  160   a  of channel  148   c , respectively), one in which channel(s) (e.g.,  148   a ,  148   b , and/or the like) have depth(s) that vary along respective bottom portion(s) (e.g.,  158 ) of the channel(s) (e.g.,  FIG. 3C , in which opposing channels  148   a  and  148   b  cooperate to define a Z-shaped cross-section of the support), one comprising a single channel (e.g.,  FIG. 3D ), and/or the like. The cross-sections depicted in  FIG. 3A-3D  may each be a suitable cross-section for a beam (e.g.,  22 ), such as, for example, a cross-section for a first section (e.g.,  98 ) of the beam. 
     First support  128  and/or second support  140  can be unitary or integrally formed with beam  22 . In at least this way, some cross members (e.g.,  10   a ) can be mounted to a vehicle at one or more locations (e.g., at first support  128  and/or second support  140 ), without requiring separate mounting component(s) (other than fasteners), such as, for example, flange(s), mount(s), plate(s), and/or the like, which can reduce manufacturing costs, assembly time, and/or the like. In other cross members, a first support (e.g.,  128 ) and/or a second support (e.g.,  140 ) can comprise separate component(s) that can be coupled to (e.g., via welding, bonding, fasteners, and/or the like) a beam (e.g.,  22 ). 
     Cross member  10   a  can comprise a composite body  164  that defines beam  22 , first support  128 , second support  140 , and/or the like. Body  164  can be characterized as a “composite” in that the body comprises a plastic material  170  and one or more laminates  174 , where the plastic material and the laminate(s) are combined to form a unitary structure. As one non-limiting example, body  164  can be formed by overmolding plastic material  170  onto one or more laminates  174 . 
     Plastic material  170  can comprise a thermoplastic material, such as polyethyleneimine, polyetherimide, or a derivative thereof, polyethylene terephthalate, polycarbonate, polybutylene terephthalate, poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate), glycol-modified polycyclohexyl terephthalate, poly(phenylene oxide), polypropylene, polyethylene, polyvinyl chloride, polystyrene, polymethyl methacrylate, thermoplastic elastomer, terephthalic acid elastomer, poly(cyclohexanedimethylene terephthalate), polyethylene naphthalate, polyamide (e.g., PA6, PA66, and/or the like), polysulfone sulfonate, polyether ether ketone, polyether ketone ketone, acrylonitrile butyldiene styrene, polyphenylene sulfide, polycarbonate/polybutylene succinate, a co-polymer thereof, or a combination thereof, or a thermoset material, such as unsaturated polyester resin, polyurethane, bakelite, duroplast, urea-formaldehyde, diallyl-phthalate, epoxy resin, epoxy vinylester, polyimide, cyanate ester of polycyanurate, dicyclopentadiene, benzoxazine, a co-polymer thereof, or a combination thereof. Plastic material  170  can include dispersed elements, such as, for example, discontinuous or short fibers (e.g., carbon fibers, glass fibers, basalt fibers, aramid fibers, polyethylene fibers, polyester fibers, polyamide fibers, steel fibers, textile fibers, or a combination thereof), which can account for 10 to 70% of the plastic material by weight. 
     One or more laminates (e.g.,  174 ) can each include any suitable number of laminae (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more laminae), each having fibers (e.g.,  186 ) dispersed within a matrix material (e.g.,  190 ). For example, a lamina can comprise from 30 to 70% fibers (e.g.,  186 ) by volume and/or from 10 to 85% fibers by weight. A matrix material (e.g.,  190 ) of a lamina can include any suitable matrix material, such as, for example, one or more of the thermoplastic materials described above and/or one or more of the thermoset materials described above. A matrix material (e.g.,  190 ) of a lamina and a plastic material (e.g.,  170 ) can include a same material, which can facilitate a bond between the plastic material and the lamina. 
     Fibers (e.g.,  186 ) of a lamina can include any suitable fibers, such as, for example, any of the fibers described above. Fibers (e.g.,  186 ) of a lamina can be arranged and/or structured in any suitable fashion. For example, fibers (e.g.,  186 ) of a lamina can be continuous and/or discontinuous. For further example, fibers (e.g.,  186 ) of a lamina can include yarns, which, in turn, can comprise braided and/or commingled strands, and such a yarn can include strands of a first material (e.g., a polymeric material) and strands of a second material (e.g., a non-polymeric material) that is different than the first material. For yet further example, fibers (e.g.,  186 ) of a lamina can be oriented relative to one another such that substantially all of the fibers are substantially parallel to one another (e.g., as in a lamina formed from a unidirectional fiber tape), such that the fibers define a woven structure (e.g., as in a lamina having a plane, twill, satin, basket, leno, mock leno, or the like weave, whether two- or three-dimensional), or the like. 
     As will be described in more detail below, laminate(s) (e.g.,  174 ) can be disposed along a structure (e.g., beam  22 , first support  128 , second support  140 , and/or the like) to increase the strength and/or stiffness of the structure. To illustrate, for a given laminate (e.g.,  174 ) disposed along a structure (e.g., beam  22 , first support  128 , second support  140 , and/or the like), fibers (e.g.,  186 ) that are substantially aligned with a long dimension and/or longitudinal axis of the structure can resist bending of the structure, and fibers that are angularly disposed relative to the long dimension and/or longitudinal axis of the structure can resist torsion of the structure. 
       FIG. 4A  depicts a schematic exploded view of a laminate  174   a  that may be suitable for use in some cross members (e.g.,  10   a ). Laminate  174   a  can include a lamina  194   d  in which substantially all of fibers  186  are substantially parallel to one another (e.g., the lamina can be formed from a unidirectional fiber tape). Fibers  186  of lamina  194   d  can be aligned in a first direction  198   a , and laminate  174   a  can include a lamina  194   e  having fibers  186  aligned in a second direction  198   b  that is angularly disposed relative to the first direction. For example, a smallest angle  202  between first direction  198   a  and second direction  198   b  can be approximately 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees. More particularly, laminate  174   a  can include six (6) laminae,  194   a - 194   f , each having fibers  186  that are angularly disposed at approximately 45, −45, 0, 0, −45, and 45 degrees, respectively, relative to a long dimension and/or longitudinal axis of the lamina, the laminate, and/or a structure (e.g., beam  22 , first support  128 , second support  140 , and/or the like) along which the laminate is disposed. Placing 0 degree lamina(e) (e.g.,  194   c ,  194   d , and/or the like) of a laminate (e.g.,  174   a ) between other, non-0 degree laminae (e.g.,  194   a ,  194   b ,  194   e ,  194   f , and/or the like) of the laminate can mitigate undesirable fiber (e.g.,  186 ) movement (e.g., fiber splitting) within the 0 degree lamina(e), which can occur, for example, during overmolding. Other laminate(s) (e.g.,  174 ) can each include lamina(e) having fibers that are angularly disposed at any suitable angle relative to a long dimension and/or longitudinal axis of the lamina, the laminate, and/or a structure (e.g., beam  22 , first support  128 , second support  140 , and/or the like) along which the laminate is disposed, such as, for example, approximately −90, −85, −80, −75, −70, −65, −60, −55, −50, −45, −40, −35, −30, −25, −20, −15, −10, −5, 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, and/or 90 degrees. Laminae of a laminate (e.g.,  174 ) can be stacked in a symmetric (e.g.,  FIG. 4A ) or asymmetric configuration. 
       FIG. 4B  depicts a schematic exploded view of a laminate  174   b  that may be suitable for use in some cross members (e.g.,  10   a ). Laminate  174   b  can include a lamina  194   g  having fibers  186  that define a woven structure. For example, lamina  194   g  can include a first set of fibers  186  that are substantially aligned with one another and a second set of fibers  186  that are substantially aligned with one another, where the second set of fibers is woven with and angularly disposed relative to the first set of fibers. More particularly, lamina  194   g  of laminate  174   b  can be a 0/90 lamina in which the second set of fibers is angularly disposed relative to the first set of fibers at an angle of approximately 90 degrees. Laminate  174   b  can include six (6) laminae,  194   g - 194   l , each of which can be a 0/90 lamina; however, other laminates (e.g.,  174 ) can include 0/90, +30/−60, −30/+60, +45/−45, and/or the like woven lamina(e) (e.g., as well as non-woven lamina(e)). 
     One or more laminates  174  of cross member  10   a  can be dimensioned and/or located on and/or within the cross member pursuant to strength, stiffness, component mounting, and/or the like requirements. For example, one or more of laminate(s)  174  can be disposed along beam  22  to, for example, increase the strength and/or stiffness of the beam where loads are applied to the beam (e.g., by a steering column), where the beam is mounted to a vehicle (e.g., via first support  128 , second support  140 , and/or the like), and/or the like. One or more of laminate(s)  174  disposed along beam  22  can have fibers (e.g.,  186 ) that are substantially aligned with longitudinal axis  24  of the beam and/or fibers (e.g.,  186 ) that are angularly disposed relative to the longitudinal axis of the beam (e.g., at an angle of approximately 15, 30, 45, 60, 75, and/or 90 degrees). 
     More particularly, as shown in  FIG. 2 , one or more of laminate(s)  174  can be disposed along beam  22  such that the laminate(s) border at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter  218   a  of channel  48   a . Similarly, one or more of laminate(s)  174  can be disposed along beam  22  such that the laminate(s) border at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter  218   b  of channel  48   b . In other words, one or more of laminate(s)  174  can underlie, overlie, define, and/or be disposed within sidewall  44  at bottom portion  52  and/or opposing side portions  56   a  and/or  56   b  of channels  48   a  and/or  48   b . At least a single one of laminate(s)  174  can border at least a portion of (e.g., at least a majority of) inner cross-sectional perimeter  218   a  of channel  48   a  and at least a portion of (e.g., at least a majority of) inner cross-sectional perimeter  218   b  of channel  48   b . In these ways and others, one or more of laminate(s)  174  can provide reinforcement for support(s) and/or mount(s) (e.g., first support  128 , second support  140 , mount  14   a , and/or the like), via, for example, strengthening and/or stiffening portion(s) of beam  22  where the support(s) and/or mount(s) are located, being disposed on opposite sides of (e.g., the top and the bottom of) the support(s) and/or mount(s), and/or the like. 
     One or more laminates  174  that are disposed along beam  22  may not extend the entire length  86  of beam  22 . For example, one or more laminates  174  that are disposed along beam  22  can span a total distance  216  along the beam, measured along longitudinal axis  24  of the beam, that is smaller than (e.g., less than or equal to half of) length  86  of the beam. For further example, one or more laminates  174  that are disposed along beam  22  can be disposed closer to one end (e.g.,  30 ) of the beam than to the other end (e.g.,  26 ) of the beam (e.g., the laminate(s) can extend across at least a majority of second section  102 , but not necessarily across at least a majority of first section  98 ). In general, plastic material (e.g.,  170 ) may be less expensive than laminate(s)  174 ; thus, such cross members (e.g.,  10   a ) can provide for reduced manufacturing costs without undesirably compromising the strength and/or stiffness of the cross members, as illustrated in the examples below. In some cross members, laminate(s) (e.g.,  174 ) can be disposed along a beam (e.g.,  22 ) such that one or more openings (e.g.,  34 ) of the beam for securing the beam to a vehicle extend through the laminate(s), thereby increasing the strength and/or stiffness of the beam at a mounting location of the beam to a vehicle. 
     Referring additionally to  FIGS. 5A and 5B , shown is a joint  228  that may be suitable for use between adjacent sections (e.g., first section  98  and second section  102 ) of a cross member (e.g.,  10   a ) and/or between a plastic material (e.g.,  170 ) and one or more laminates (e.g.,  174 ). Joint  228  can be characterized as a lap joint; for example, at the joint, a first section (e.g.,  98 ) can be joined to a second section (e.g.,  102 ) such that a portion  232  of the first section overlies and/or underlies a portion  236  of the second section. At least one of portion  232  and portion  236  can include a recess  240  within which the other portion is disposed, which can increase the surface area of the interface between the portions, provide for a smooth transition between the portions, and/or the like. One of portions  232  and  236  can be substantially comprised of (by weight and/or volume) or consist of plastic material  170 , and the other of the portions can be substantially comprised of (by weight and/or volume) or consist of laminate(s)  174 . As shown in  FIGS. 6A and 6B , joint  228  can be reinforced with ribs  120  that extend across a seam  244  between portions  232  and  236 , each of which can extend in a direction that is substantially perpendicular to the seam ( FIG. 6A ) or in a direction that is angularly disposed relative to the seam ( FIG. 6B ). In these ways and others, joint  228  can facilitate connection of and/or load transfer between adjacent sections (e.g., first section  98  and second section  102 ) of a cross member (e.g.,  10   a ) and/or a plastic material (e.g.,  170 ) and one or more laminates (e.g.,  174 ). 
     Referring now to  FIG. 7 , shown is a second embodiment  10   b  of the present vehicle cross members. Cross member  10   b  can be substantially similar to cross member  10   a , with the primary exceptions described below. In cross member  10   b , one or more laminates  174  that are disposed along beam  22  can span a total distance  216  along the beam, measured along longitudinal axis  24  of the beam, that is greater than or equal to half of length  86  of the beam. For example, distance  216  can be substantially equal to length  86 , one or more laminates  174  that are disposed along beam  22  can extend across at least a majority of first section  98  and second section  102 , and/or the like. 
     Similarly to as described above for cross member  10   a , in cross member  10   b , one or more of laminate(s)  174  can be disposed along beam  22  (e.g., first section  98  thereof) such that the laminate(s) border at least a portion of (e.g., at least a majority of) inner cross-sectional perimeter  218   a  of channel  48   a  ( FIGS. 8A-8C ). In other words, one or more of laminate(s)  174  can underlie, overlie, define, and/or be disposed within sidewall  44  at bottom portion  52  ( FIGS. 8A and 8C ) and/or opposing side portions  56   a  and/or  56   b  ( FIGS. 8B and 8C ) of channel  48   a . In these ways and others, one or more laminates  174  of cross member  10   b  can facilitate the cross member in resisting high-impact (e.g., crash-related) loads. 
     Referring now to  FIG. 9 , shown is a third embodiment  10   c  of the present vehicle cross members. Cross member  10   c  can be substantially similar to cross member  10   a , with the primary exceptions described below. In cross member  10   c , one or more of laminate(s)  174  can be disposed along second support  140  to, for example, increase the strength and/or stiffness of the second support, facilitate load transfer between beam  22  and the second support, and/or the like. One or more of laminate(s)  174  disposed along second support  140  can have fibers (e.g.,  186 ) that are substantially aligned with longitudinal axis  142  of the second support and/or fibers (e.g.,  186 ) that are angularly disposed relative to the longitudinal axis of the second support (e.g., at an angle of approximately 15, 30, 45, 60, 75, and/or 90 degrees). More particularly, as shown in  FIGS. 10A-10K , one or more of laminate(s) (e.g.,  174 ) can be disposed along a second support (e.g.,  140 ) such that the laminate(s) border at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter (e.g.,  252   a ,  252   b , and/or the like) of each of one or more of channel(s) (e.g.,  148   a ,  148   b ,  148   c , and/or the like) of the second support. The cross-sections depicted in  FIGS. 10A-10K  may each be a suitable cross-section for a beam (e.g.,  22 ), such as, for example, a cross-section for a first section (e.g.,  98 ) of the beam. 
     One or more of laminate(s)  174  can be disposed along second support  140  such that one or more openings  144  of the second support for securing the second support to a vehicle extend through the laminate(s), thereby increasing the strength and/or stiffness of the second support at a mounting location of the second support to a vehicle. In some cross members, at least a single one of laminate(s) (e.g.,  174 ) can be disposed along a beam (e.g.,  22 ) and along a second support (e.g.,  140 ). 
     Referring now to  FIGS. 11A and 11B , shown is a fourth embodiment  10   d  of the present cross members. Cross member  10   d  can be substantially similar to cross member  10   a , with the primary exceptions described below. Cross member  10   d  can include one or more ribs  120   c  that extend from sidewall  44  and away from one or more channels (e.g.,  48   a ,  48   b , and/or the like). For example, cross member  10   d  can include rib(s)  120   c  that extend from side portion(s)  56   a  and/or  56   b  of channel  48   a  and away from the channel ( FIG. 11B ). Rib(s)  120  can extend from side portion(s)  56   a  and/or  56   b  at an end of the side portion(s) that is opposite bottom portion  52 . In some cross members (e.g.,  10   d ), one or more of laminate(s) (e.g.,  174 ) can underlie, overlie, define, and/or be disposed within rib(s) (e.g.,  120   c ). Ribs(s)  120   c  can stiffen beam  22  and can resist buckling of the beam when the beam is subjected to side loads. Such rib(s) (e.g.,  120   c ) can be present in other embodiments (e.g.,  10   a ,  10   b ,  10   c , and/or the like) of the present cross members. 
     Referring now to  FIGS. 12A and 12B and 13A-13C , shown are molds,  256   a  and  256   b , respectively, that may each be suitable for forming a composite body (e.g.,  164 ) of some embodiments of the present vehicle cross-members (e.g.,  10   a ,  10   b ,  10   c ,  10   d , and/or the like). As shown in  FIGS. 12A and 12B , mold  256   a  can include two or more mold portions,  260   a  and  260   b , configured to position a laminate  174   c  within a mold cavity  264  of the mold. Once laminate  174   c  is positioned within mold cavity  264 , plastic material (e.g.,  170 ) can be injected into the mold cavity to form a composite body (e.g.,  164 ). Such injection can be performed via any suitable number of injection gate(s), which can be opened simultaneously and/or sequentially. 
     Additional mold portion(s) or slider(s) can be used to facilitate forming a composite body (e.g.,  164 ), depending on, for example, the number and/or relative orientation(s) of laminate(s) (e.g.,  174 ) of the composite body. For example, as shown in  FIGS. 13A-13C , mold  256   b  can include two or more mold portions,  260   c  and  260   d , configured to position a laminate  174   d  within a mold cavity  264  of the mold. Mold  256   b  can include an additional mold portion or slider  260   e  configured to position a laminate  174   e  within mold cavity  264 . Laminate  174   d  can extend in a first direction (e.g., to ultimately define at least a portion of a second support  140 ), and laminate  174   e  can extend in a second direction that is angularly disposed relative to the first direction (e.g., to ultimately define at least a portion of a beam  22 ). Once laminates  174   d  and  174   e  are positioned within mold cavity  264 , plastic material (e.g.,  170 ) can be injected into the mold cavity to form a composite body (e.g.,  164 ). 
     Some embodiments of the present methods for forming a vehicle cross member (e.g.,  10   a ,  10   b ,  10   c ,  10   d , and/or the like) comprise forming, in a mold, a composite body (e.g.,  164 ) including a plastic material (e.g.,  170 ) and one or more laminates (e.g.,  174 ), each having fibers (e.g.,  186 ) dispersed within a matrix material (e.g.,  190 ). In some methods, forming, in the mold, the body comprises forming the one or more laminates in the mold. For example, in some methods, forming the one or more laminates in the mold comprises placing one or more layers of material, each comprising an arrangement of fibers, into the mold and overmolding the plastic material onto the one or more layers of material (e.g., thereby introducing the plastic material into the arrangement(s) of fibers to form the one or more laminates). Some methods comprise placing the one or more (e.g., at least partially pre-formed) laminates into the mold and overmolding the plastic material onto the one or more laminates. In some methods, the one or more laminates are at least partially consolidated (e.g., heated and/or compressed) before the one or more laminates are placed into the mold. 
     Examples 
     Structural analysis software was used to compare structural characteristics of cross member  10   a  with those of a comparable metal cross beam. In this instance, cross member  10   a  includes a laminate (e.g.,  174 ) having glass fibers (e.g.,  186 ) dispersed within a polypropylene matrix material (e.g.,  190 ). The laminate comprises approximately 45% fibers by volume. The laminate has a layup of 10 laminae, each having fibers that are angularly disposed at 45, −45, 0, 0, 0, 0, 0, 0, −45, and 45 degrees, respectively, relative to longitudinal axis  24  of beam  22 . In this instance, cross member  10   a  includes a plastic material (e.g.,  170 ) comprising long glass fiber-filled polypropylene, having 40% fibers by weight. 
     To illustrate, modal frequencies and deflections under various loads for cross member  10   a  and the comparable metal car cross beam are shown in the tables below. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Modal Frequencies of one Embodiment of the Present Vehicle Cross 
               
               
                 Members and a Comparable Metal Car Cross Beam 
               
            
           
           
               
               
               
            
               
                   
                   
                 Comparable Metal Car Cross 
               
               
                 Mode 
                 Cross Member 10a (Hz) 
                 Beam (Hz) 
               
               
                   
               
            
           
           
               
               
               
            
               
                 1 
                 41.5 
                 41.3 
               
               
                 2 
                 42.1 
                 42.3 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Deflections under Various Loads for one Embodiment of the Present 
               
               
                 Vehicle Cross Members and a Comparable Metal Car Cross Beam 
               
            
           
           
               
               
               
               
            
               
                   
                   
                 Cross 
                 Comparable Metal 
               
               
                   
                   
                 Member 10a 
                 Car Cross Beam 
               
               
                 Load Description 
                 Load (N) 
                 (mm) 
                 (mm) 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 Steering Wheel 
                 1000 
                 2.55 
                 2.548 
               
               
                 (Vertical) 
               
               
                 Steering Wheel 
                 1000 
                 2.82 
                 2.843 
               
               
                 (Horizontal) 
               
               
                 Gravity 
                 Weight of 
                 1.21 
                 1.54 
               
               
                   
                 Cross Member 
               
               
                 Passenger Airbag 
                 1000 
                 2.416 
                 2.416 
               
               
                 Glove Box 
                  50 
                 1.092 
                 1.093 
               
               
                   
               
            
           
         
       
     
     Despite being approximately 30% lighter than the comparable metal car cross beam, as shown, structural performance of cross member  10   a  is substantially similar to the comparable metal car cross beam. In addition, the comparable metal car cross beam requires the assembly of a significant number of separate components (e.g., approximately 20) when compared to cross member  10   a , which can be largely or wholly formed in a mold as a unitary body  164  (e.g., including mount(s)  14   a ,  14   b ,  14   c , and/or the like, support(s)  128 ,  140 , and/or the like, and/or the like); thus, cross member  10   a  may provide for reduced assembly time and/or cost. 
     Some embodiments of the present vehicle cross members comprise: an elongated beam having a first end, a second end, and a sidewall extending between the first and second ends to define a first channel extending along a longitudinal axis of the beam and across at least longitudinally adjacent first and second sections of the beam, the first channel being open on a first side of the beam, and a second channel extending along the longitudinal axis and across at least the second section, the second channel being disposed below the first channel and open on a second side of the beam that is opposite the first side. 
     Some cross members comprise a car cross beam. In some cross members, at least one of the first end and the second end of the beam defines one or more openings into the beam for securing the beam to a vehicle. Some cross members comprise one or more mounts, each configured to couple a component to the beam, wherein the component is selected from the group consisting of: a steering column, an airbag housing or carrier, and an instrument cluster. 
     In some cross members, the first channel extends a first length along the longitudinal axis of the beam, the second channel extends a second length along the longitudinal axis, and the second length is less than or equal to half of the first length. Some cross members comprise one or more ribs extending into the first and second channels. 
     Some cross members comprise a composite body including a plastic material and one or more laminates, each having fibers dispersed within a matrix material, wherein the body defines the beam. In some cross members, the plastic material comprises a thermoplastic material, a thermoset material, or a combination thereof. In some cross members, for at least one of the one or more laminates, the fibers comprise carbon fibers, glass fibers, basalt fibers, textile fibers, or a combination thereof. In some cross members, for at least one of the one or more laminates, the matrix material comprises a thermoplastic material, a thermoset material, or a combination thereof. In some cross members, for at least one of the one or more laminates, the matrix material comprises the plastic material. 
     In some cross members, at least one of the one or more laminates is disposed along the beam such that the at least one laminate borders at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter of each of the first and second channels. In some cross members, the laminate(s) disposed along the beam span a total distance along the beam measured along the longitudinal axis of the beam that is less than or equal to half of a length of the beam measured along the longitudinal axis. In some cross members, the laminate(s) disposed along the beam span a total distance along the beam measured along the longitudinal axis of the beam that is greater than half of a length of the beam measured along the longitudinal axis. 
     Some cross members comprise a first support (e.g., defined by the body) extending from the second side of the beam, the first support configured to secure the beam to a vehicle. In some cross members, the first support extends from the second section of the beam. 
     Some cross members comprise a second support (e.g., defined by the body) extending downwardly from the beam, the second support configured to secure the beam to a vehicle. In some cross members, the second support extends from the second section of the beam. In some cross members, the second support defines one or more openings for securing the second support to a vehicle. In some cross members, at least one of the one or more openings extends through at least one of the one or more laminates. 
     In some cross members, the second support defines a third channel extending along a longitudinal axis of the second support. In some cross members, the second support defines a fourth channel extending along the longitudinal axis of the second support, the third channel is open on a first side of the second support, and the fourth channel is open on a second side of the second support that is opposite the first side. In some cross members, at least one of the one or more laminates is disposed along the second support such that the at least one laminate borders at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter of the third channel. In some cross members, at least one of the one or more laminates is disposed along the second support such that the at least one laminate borders at least a portion of (e.g., at least a majority of) an inner cross-sectional perimeter of the fourth channel. 
     Some of the present methods for forming a vehicle cross member comprise forming, in a mold, the composite body of any of the present vehicle cross members. In some methods, forming, in the mold, the body comprises forming the one or more laminates in the mold. In some methods, forming the one or more laminates in the mold comprises placing one or more layers of material, each comprising an arrangement fibers, into the mold and overmolding the plastic material onto the one or more layers of material. Some methods comprise placing the one or more laminates into the mold and overmolding the plastic material onto the one or more laminates. 
     The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. 
     The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.