A-pillar structure and vehicle

Abstract

This application provides an A-pillar structure and vehicle that can minimize significant abrupt changes in the stiffness of the A-pillar structure. According to an example of this application, the A-pillar structure includes: a lower A-pillar reinforcement, an upper A-pillar reinforcement, and a connecting plate. The lower A-pillar reinforcement has an overlapping top wall and a connecting bottom wall opposite to the overlapping top wall, with an overlapping area formed between the overlapping top wall and the connecting bottom wall. The upper A-pillar reinforcement has an overlapping section extending into the overlapping area, the overlapping section engaging with the overlapping top wall. The connecting plate is located in the overlapping area and includes a first portion and a second portion connected together. The first portion is fixedly connected to the overlapping section, and the second portion is located at the end of the first portion away from the overlapping section, and the second portion is fixedly connected to the overlapping top wall.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and more specifically, to an A-pillar structure and a vehicle. Background Technology

[0002] As vehicle weight increases and collision safety standards continue to rise, the challenges to vehicle collision safety are also growing. The A-pillar structure is a crucial component of the vehicle body structure, playing a vital role in a collision. In frontal collisions, especially 25% offset collisions, the A-pillar structure must bear the horizontal load from the front of the vehicle. The horizontal load is transferred from the lower A-pillar reinforcement to the upper A-pillar reinforcement.

[0003] To ensure the overall connection strength of the A-column structure, the lower and upper reinforcement members of the A-column are typically assembled using lap welding, forming an overlap area of ​​a specific length. The cross-sectional structure of this overlap area is a superposition of the upper and lower reinforcement members, and its cross-sectional area and material distribution differ significantly from either a single lower or upper reinforcement member. When a horizontal load is continuously transferred from the lower reinforcement member to the overlap area, the sudden increase in the moment of inertia causes a significant abrupt change in the stiffness of the A-column structure. This abrupt change in stiffness leads to a decrease in load transfer efficiency, easily causing stress concentration in the overlap area, which may result in abnormal deformation of the A-column structure, or even welding failure at the overlap, structural fracture, and other problems. Summary of the Invention

[0004] This application provides an A-pillar structure and vehicle that can minimize significant abrupt changes in the stiffness of the A-pillar structure.

[0005] In a first aspect, this application provides an A-pillar structure, comprising: The A-pillar reinforcement has an overlapping top wall and a connecting bottom wall opposite to the overlapping top wall, and an overlapping area is formed between the overlapping top wall and the connecting bottom wall; The A-pillar reinforcement has an overlapping section that extends into the overlapping area, and the overlapping section is fixedly connected to the top wall of the overlapping area. A connecting plate, located in the overlapping area, includes a first part and a second part connected together. The first part is fixedly connected to the overlapping section, and the second part is located at the end of the first part away from the overlapping section. The second part is fixedly connected to the top wall of the overlapping section.

[0006] In some optional embodiments, the connection between the overlapping segment and the overlapping top wall has a step difference, the overlapping segment has a first overlapping surface, the overlapping top wall has a third overlapping surface, the first part is fixedly connected to the first overlapping surface, and the second part is fixedly connected to the third overlapping surface.

[0007] In some alternative embodiments, the distance between the first overlapping surface and the third overlapping surface is the step difference.

[0008] In some alternative embodiments, the thickness of the second portion is less than the step difference.

[0009] In some alternative embodiments, the first portion is fitted to the first overlapping surface, and the first portion is fixedly connected to the first overlapping surface by spot welding.

[0010] In some alternative embodiments, the second portion is fitted to the third overlapping surface, and the second portion is fixedly connected to the third overlapping surface by spot welding.

[0011] In some alternative embodiments, the connecting plate further includes a transition portion that is smoothly connected to the first portion and the second portion, respectively.

[0012] In some alternative embodiments, the A-pillar reinforcement is a thermally expanded tube beam.

[0013] In some alternative embodiments, when the overlapping section has a first overlapping surface, the first overlapping surface is the inner wall surface of the hot-expansion tube beam.

[0014] In some alternative embodiments, the side end of the connecting plate is provided with a bend.

[0015] In some alternative embodiments, the cross-sectional area of ​​the reinforcement on the A-pillar is larger than the cross-sectional area of ​​the connecting plate.

[0016] In some alternative embodiments, the length of the first portion is equal to the length of the second portion.

[0017] In some alternative embodiments, the length of the second portion is greater than the length of the first portion.

[0018] In some alternative embodiments, the thickness of the connecting plate is less than the thickness of the overlapping top wall, and the thickness of the overlapping top wall is less than the thickness of the overlapping section.

[0019] In some embodiments, the thickness of the first portion is equal to the thickness of the second portion.

[0020] In some alternative embodiments, the thickness of the connecting plate gradually decreases in the direction from the first portion to the second portion.

[0021] Secondly, this application provides a vehicle, comprising: The A-pillar structure as described in any of the above items.

[0022] The A-pillar structure and vehicle provided in this application have at least the following advantages: The added connecting plate is located within the overlap area. Its first part is fixedly connected to the overlap section of the upper stiffener of the A-column, and its second part is fixedly connected to the top wall of the overlap section of the lower stiffener of the A-column. Thus, the cross-section of the A-column structure transitions sequentially from "single cross-section of the lower stiffener of the A-column" to "lower stiffener of the A-column + second part of the connecting plate" and then to "lower stiffener of the A-column + first part of the connecting plate + overlap section of the upper stiffener of the A-column." This results in a gradual increase in the moment of inertia of the A-column structure, rather than a sudden abrupt change, thereby achieving a smooth transition in the stiffness of the A-column structure. This avoids a decrease in load transfer efficiency caused by abrupt changes in stiffness and reduces the risk of stress concentration at the abrupt change location. Furthermore, by fixing the connecting plate to both the upper and lower stiffeners of the A-column, the effective overlap length of the upper and lower stiffeners is extended, further improving the reliability of the connection and the structural stability. Attached Figure Description

[0023] Figure 1 This is a partial schematic diagram of the A-pillar structure shown in one embodiment; Figure 2 yes Figure 1 Enlarged view of part A; Figure 3 This is a schematic diagram illustrating the connection between the connecting plate, the overlapping section, and the overlapping top wall in one embodiment; Figure 4 This is a schematic diagram of the structure of a connecting plate shown in one embodiment; Figure 5 This is a schematic diagram of the support structure shown in one embodiment.

[0024] Explanation of reference numerals in the attached figures: 10. Lower A-pillar reinforcement; 11. Overlapping top wall; 111. Third overlap surface; 12. Connecting bottom wall; 13. Overlapping area; 20. Upper A-pillar reinforcement; 21. Overlapping section; 211. First overlap surface; 212. Second overlap surface; 30. Connecting plate; 31. First part; 32. Second part; 33. Transition part; 34. Bending part; 40. Support member; 41. Supporting top plate; 42. Supporting bottom plate; 43. Side plate; 44. Reinforcing rib. Detailed Implementation

[0025] The technical solutions in the embodiments (or "implementations") of this specification will be clearly and completely described herein with reference to the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.

[0026] If the embodiments of this specification contain terms relating to directional indications or positional relationships (such as up, down, left, right, front, back, inside, outside, top, bottom, center, vertical, horizontal, longitudinal, transverse, length, width, counterclockwise, clockwise, axial, radial, circumferential, etc.), such terms are only used to explain the relative positional relationships and movements between components in a specific posture (as shown in the attached figures); if the specific posture changes, the directional indications or positional relationships will also change accordingly. Furthermore, the terms "first" and "second" used in the embodiments of this specification are for descriptive convenience only and should not be construed as indicating or implying relative importance.

[0027] This application provides an A-pillar structure and a vehicle, which will be described in detail below with reference to the accompanying drawings. Unless otherwise specified, the features of the following embodiments and implementations can be combined with each other.

[0028] This application provides an A-pillar structure, referencing... Figures 1 to 4 The A-pillar structure includes a lower A-pillar reinforcement 10, an upper A-pillar reinforcement 20, and a connecting plate 30.

[0029] The A-pillar lower reinforcement 10 has an overlapping top wall 11 and a connecting bottom wall 12 opposite to the overlapping top wall 11. An overlapping area 13 (i.e., the accommodating space between the overlapping top wall 11 and the connecting bottom wall 12 of the A-pillar lower reinforcement 10) is formed between the overlapping top wall 11 and the connecting bottom wall 12. The A-pillar upper reinforcement 20 has an overlapping section 21 extending into the overlapping area 13, and the overlapping section 21 overlaps with the overlapping top wall 11. A connecting plate 30 is located within the overlapping area 13. The connecting plate 30 includes a first part 31 and a second part 32 connected together. The first part 31 is fixedly connected to the overlapping section 21 (e.g., by welding, bolting, etc.), and the second part 32 is located at the end of the first part 31 away from the overlapping section 21 (i.e., the front end) and is fixedly connected to the overlapping top wall 11 (e.g., by welding, bolting, etc.).

[0030] In related technologies, the lower A-pillar reinforcement 10 and the upper A-pillar reinforcement 20 are directly overlapped. The cross-section of the overlap area 13 is a composite structure of "the lower A-pillar reinforcement 10 and the upper A-pillar reinforcement 20 superimposed," which has a step-like difference compared to the cross-section of a single lower A-pillar reinforcement 10 (in front of the overlap area 13), resulting in a sudden increase in the moment of inertia and a sudden change in stiffness. In this solution, the added connecting plate 30 is located within the overlap area 13. Its first part 31 is fixedly connected to the overlap section 21 of the upper A-pillar reinforcement 20, and its second part 32 is fixedly connected to the top wall 11 of the overlap of the lower A-pillar reinforcement 10. Therefore, the cross-section of the A-column structure transitions sequentially from "single cross-section of the lower A-column stiffener 10" to "lower A-column stiffener 10 + second part 32 of connecting plate 30" and "lower A-column stiffener 10 + first part 31 of connecting plate 30 + overlapping section 21 of upper A-column stiffener 20," resulting in a gradual increase in the moment of inertia of the A-column structure rather than a sudden abrupt change. This achieves a smooth transition in the stiffness of the A-column structure, avoiding a decrease in load transfer efficiency caused by abrupt changes in stiffness, and reducing the risk of stress concentration at the abrupt change location. Furthermore, by fixing the connecting plate 30 to both the upper A-column stiffener 20 and the lower A-column stiffener 10, the effective overlap length of the upper A-column stiffener 20 and the lower A-column stiffener 10 is extended, further improving the reliability of the connection and the structural stability.

[0031] In some embodiments, the connection between the overlapping section 21 and the overlapping top wall 11 has a step difference. The overlapping section 21 has a first overlapping surface 211, and the overlapping top wall 11 has a third overlapping surface 111. A first part 31 is fixedly connected to the first overlapping surface 211, and a second part 32 is fixedly connected to the third overlapping surface 111. It should be noted that the step difference here refers to the height misalignment distance between the overlapping section 21 of the upper A-pillar reinforcement and the overlapping top wall 11 of the lower A-pillar reinforcement 10 in the direction perpendicular to the overlapping top wall 11, which is a structural height difference similar to a "step".

[0032] In this way, the first part 31 of the connecting plate 30 is fixedly connected to the first overlapping surface 211, which can enhance the structural strength of the overlapping section 21. At the same time, the second part 32 of the connecting plate 30 can make up for the step difference and realize a smooth transition between the lower A-pillar reinforcement 10 and the upper A-pillar reinforcement 20.

[0033] In some embodiments, the distance between the first overlapping surface 211 and the third overlapping surface 111 is the step difference. Here, the distance refers to the shortest distance between the first overlapping surface 211 and the third overlapping surface 111.

[0034] Thus, the first part 31 and the second part 32 of the connecting plate 30 have a more natural shape, and the height difference between the first part 31 and the second part 32 is small, so the connecting plate 30 does not need to be bent excessively. In addition, the material usage and weight of the connecting plate 30 are also smaller, which helps to save costs and reduce weight.

[0035] Of course, in some other embodiments, the first overlapping surface 211 can be other surfaces of the overlapping section 21, and the first part 31 of the connecting plate 30 can also be fixedly connected to the first overlapping surface 211.

[0036] In some embodiments, the thickness of the second portion 32 is less than the step difference.

[0037] It is easy to understand that if the thickness of the second part 32 is greater than or equal to the step difference, a new abrupt change in stiffness may occur between the second part 32 and the overlapping top wall 11. This would prevent the collision load from being evenly distributed to the A-pillar reinforcement 20 through the connecting plate 30, and instead concentrate it at the abrupt change point at the front end of the connecting plate 30. Therefore, this solution sets the thickness of the second part 32 to be less than the step difference, which can avoid introducing a new, large abrupt change in stiffness. This allows the moment of inertia of the A-pillar structure to increase gradually, thereby achieving a smooth transition in the stiffness of the A-pillar structure.

[0038] In some embodiments, the first portion 31 is fitted to the first overlapping surface 211, and the first portion 31 is fixedly connected to the first overlapping surface 211 by spot welding. Similarly, the second portion 32 is fitted to the third overlapping surface 111, and the second portion 32 is fixedly connected to the third overlapping surface 111 by spot welding.

[0039] After the overlapping section 21 of the A-pillar upper reinforcement 20 extends into the overlapping area 13, there is an inherent height difference between it and the overlapping top wall 11 of the A-pillar lower reinforcement 10. If the connecting plate 30 adopts a flush structure, it will cause an assembly gap between it and the overlapping section 21 or the overlapping top wall 11, making it impossible to form a surface contact for force transmission, thus causing local stress concentration. Therefore, this solution adapts the height of the first part 31 of the connecting plate 30 (connected to the overlapping section 21 of the A-pillar upper reinforcement 20) to the assembly height of the A-pillar upper reinforcement 20, and the height of the second part 32 (connected to the overlapping top wall 11) to the height of the overlapping top wall 11. Through the stepped height difference design, the connecting plate 30 achieves gapless surface contact with both the A-pillar upper reinforcement 20 and the overlapping top wall 11. This fitting design avoids stress concentration caused by "point contact or line contact", ensures uniform load transmission in the height direction, and is conducive to the implementation of high-strength welding methods such as spot welding.

[0040] Furthermore, the connecting plate 30 also includes a transition portion 33, which smoothly connects to the first part 31 and the second part 32. Here, "smooth connection" means that the transition portion 33 does not connect the first part 31 and the second part 32 in a straight vertical direction (i.e., the height direction). The transition portion 33 can achieve a smooth connection with the first part 31 and the second part 32 using rounded corners, bevels, or a combination of rounded corners and bevels; this application does not impose specific limitations on this.

[0041] It is understandable that if the first part 31 and the second part 32 are directly bent to form a right-angle connection, a sharp stress inflection point will be formed at the bend. During repeated load transfer such as vehicle bumps and collisions, the connecting plate 30 is very likely to crack or fail due to fatigue at the inflection point. In this solution, the transition part 33 achieves a smooth connection between the first part 31 and the second part 32 through a structural design of arc transition, slope transition, or gradual thickness transition. This allows the stress to be evenly distributed within the transition part 33, preventing the connecting plate 30 from becoming a weak point in the entire A-pillar structure and ensuring the overall structural strength.

[0042] In some embodiments, the length of the first portion 31 is equal to the length of the second portion 32. This equal-length design makes the stress on the connecting plate 30 in the overlap area 13 approximately symmetrically distributed, and the transmission length of the horizontal load along the path of "A-pillar lower reinforcement 10 overlap top wall 11 - second portion 32 - first portion 31 - A-pillar upper reinforcement 20 overlap section 21" is basically consistent, thereby making the stress distribution in the connecting plate 30 more uniform and avoiding local overload.

[0043] Alternatively, in some embodiments, the length of the second portion 32 is greater than the length of the first portion 31. For example, in a 25% offset collision, the horizontal impact load first acts on the A-pillar reinforcement 10. The longer second portion 32 can increase the contact area between the connecting plate 30 and the overlapping top wall 11 of the A-pillar reinforcement 10, thereby increasing the load-bearing density per unit area. This helps to enhance the local structural strength of the A-pillar reinforcement 10, which is beneficial to improving the A-pillar reinforcement 10's ability to resist horizontal impact loads and reducing the deformation of the A-pillar reinforcement 10 in the initial stage of the collision.

[0044] In some embodiments, the thickness of the first portion 31 is equal to the thickness of the second portion 32. That is, the connecting plate 30 adopts a uniform thickness design, and can be integrally formed by stamping or bending a plate of a single thickness without the need for additional variable thickness rolling, welding and other processes, which helps to reduce production costs.

[0045] Furthermore, the thickness of the connecting plate 30 is less than the thickness of the overlapping top wall 11, and the thickness of the overlapping top wall 11 is less than the thickness of the overlapping section 21. This thickness design is based on the functional requirements of each component: the connecting plate 30 only serves as an auxiliary force transmission and stiffness transition, and does not require excessive strength. The thinner thickness can significantly reduce material usage while ensuring functionality, achieving lightweighting; the overlapping top wall 11 of the A-pillar lower reinforcement 10 needs to bear the load transmitted by the connecting plate 30 and conduct it to the connecting bottom wall 12, and therefore needs to have a certain strength; the A-pillar upper reinforcement 20 not only needs to bear the horizontal collision load, but also needs to bear the vertical load under vehicle roof pressure conditions, and has the highest strength requirements. Therefore, the thickness of the overlapping section 21 of the A-pillar upper reinforcement 20 is designed to be the thickest to ensure the core load-bearing requirements.

[0046] In some other embodiments, the thickness of the connecting plate 30 gradually decreases in the direction from the first portion 31 to the second portion 32. In other words, the thickness of the connecting plate 30 gradually decreases in the opposite direction of load transfer (i.e., from the first portion 31 to the second portion 32). This design is compatible with the increasing cross-sectional trend of the A-column overlap area 13, from "single cross-section of the lower A-column reinforcement 10" to "lower A-column reinforcement 10 and connecting plate 30" and then to "lower A-column reinforcement 10, connecting plate 30 and upper A-column reinforcement 20". During the horizontal load transfer process, as the thickness of the connecting plate 30 changes, the cross-section of the entire A-column structure gradually changes, making the moment of inertia of the entire overlap area 13 gradually smoother, thereby further avoiding stress concentration caused by abrupt changes in cross-section.

[0047] In some embodiments, the connecting plate 30 has a bend 34 at its side end. The bend 34 can effectively improve the lateral bending stiffness and stability of the connecting plate 30 itself, thereby enhancing the local stiffness and overall load-bearing capacity of the entire A-column structure in the overlap area 13.

[0048] Specifically, at least one of the first part 31, the second part 32, and the transition part 33 is provided with the bending part 34. That is, the bending part 34 can be provided in any one, any two, or any three of the first part 31, the second part 32, and the transition part 33.

[0049] In some embodiments, the cross-sectional area of ​​the overlapping section 21 of the A-pillar reinforcement 20 is larger than the cross-sectional area of ​​the connecting plate 30. The connecting plate 30, as a stiffness transition member of the A-pillar structure, is mainly used to allow the moment of inertia of the overall cross-section of the A-pillar structure to increase gradually; therefore, the cross-sectional area of ​​the connecting plate 30 is not suitable to be designed to be too large. The overlapping section 21 of the A-pillar reinforcement 20 is mainly used not only to bear horizontal loads such as those during frontal collisions, but also to bear vertical loads under top-pressure conditions, requiring high axial stiffness and compressive / bending resistance; therefore, the cross-sectional area of ​​the overlapping section 21 of the A-pillar reinforcement 20 is larger than the cross-sectional area of ​​the connecting plate 30.

[0050] It should be noted that if both the reinforcement 20 on the A-pillar and the connecting plate 30 are variable cross-section designs, the phrase "the cross-sectional area of ​​the overlapping section 21 of the reinforcement 20 on the A-pillar is greater than the cross-sectional area of ​​the connecting plate 30" means that the cross-sectional area at the smallest point of the overlapping section 21 is greater than the cross-sectional area at the largest point of the connecting plate 30.

[0051] In some embodiments, the A-pillar reinforcement 20 may adopt a hot-air expansion tube beam structure. In this case, the wall thickness of some areas of the hot-air expansion tube beam may be different from that of other areas along the length and / or circumference (i.e., variable wall thickness design). For example, in areas of high stress (such as the connection position between the hot-air expansion tube beam and the lower A-pillar reinforcement 10, the load-bearing area in the middle of the hot-air expansion tube beam, etc.), a larger wall thickness may be provided to enhance the local structural strength; while in areas of low stress (such as the extension area far from the connection end), the wall thickness may be appropriately reduced to reduce the overall weight while ensuring strength, thereby achieving a lightweight design.

[0052] The aforementioned variable thickness structure can be achieved through TRB (Tailored Rolled Blanks) or TWB (Tailored Welded Blanks) processes. Specifically, in the forming process, a plate with a variable wall thickness is first obtained by rolling or laser welding, and then the plate with a variable wall thickness is wound and welded to obtain a tube with a variable wall thickness. Finally, after multiple processes such as hot air expansion forming, the aforementioned hot air expansion tube beam with a variable wall thickness is obtained.

[0053] In other embodiments, if the reinforcement 20 on the A-pillar is a hot-expansion tube beam, the wall thickness of the hot-expansion tube beam can be set to be equal along its length and / or circumferential direction (i.e., equal wall thickness design). This design simplifies the structural design and molding process of the hot-expansion tube beam, reduces manufacturing costs, and is suitable for applications with lower weight requirements and strict cost control.

[0054] In some embodiments, when the reinforcement 20 on the A-pillar is a hot-expansion tube beam, the first lap surface 211 described above is the inner wall surface of the hot-expansion tube beam.

[0055] Specifically, since the hot-expansion tube beam is a hollow tubular structure, the first part 31 of the connecting plate 30 can extend into the cavity of the overlapping section 21 and overlap with the top wall of the cavity of the overlapping section 21 (fixed by welding); when the A-pillar reinforcement 20 is a plate-like structure, the first part 31 of the connecting plate 30 can be fitted onto the side of the A-pillar reinforcement 20 facing away from the overlapping top wall 11, and overlapped by welding or bolts. Of course, in other embodiments, the first part 31 can also be fixedly connected to other inner wall surfaces of the overlapping section 21 (such as the inner bottom wall or inner side wall). Further, the outline of the second part 32 of the connecting plate 30 is set to match the outline of the corresponding connection position of the overlapping top wall 11. In other words, the outer contour and curvature of the second part 32 of the connecting plate 30 (the area fixedly connected to the overlapping top wall 11 of the A-pillar reinforcement 10) are consistent with the outline shape of the area to be connected by the overlapping top wall 11 of the A-pillar reinforcement 10. For example, if the connection position of the overlapping top wall 11 is an arc-shaped surface, then the surface of the second part 32 needs to be designed as an arc-shaped surface with the same curvature; if the overlapping top wall 11 is a plane, then the second part 32 is designed as a plane. This adaptive design allows the second part 32 to fully fit with the overlapping top wall 11, further improving force transmission efficiency and avoiding local stress concentration.

[0056] In some embodiments, reference Figure 5 and combined Figures 1 to 4 The A-pillar structure also includes a support member 40, which is located between the overlapping section 21 and the connecting bottom wall 12, and is used to fix the overlapping section 21 and the connecting bottom wall 12. The fixing connection method includes, but is not limited to, welding, riveting, and screwing.

[0057] It's easy to understand that in traditional designs, the upper A-pillar reinforcement 20 only overlaps with the lower A-pillar reinforcement 10, lacking vertical support. Under large vertical loads, the upper A-pillar reinforcement 20 is prone to bending or localized collapse. In this design, however, a support 40 is installed between the overlap section 21 and the bottom wall of the overlap of the upper A-pillar reinforcement 20. The support 40 provides more stable vertical support. When the upper A-pillar reinforcement 20 is subjected to a vertical load, the load is distributed to the lower reinforcement through the support 40, reducing stress concentration at the upper A-pillar reinforcement 20 and preventing bending or localized collapse due to excessive vertical loads, thus better protecting passengers. In other words, the support is equivalent to adding a pillar within the overlap area 13, forming a stable support frame together with the top and bottom walls of the overlap. When the reinforcement 20 on the A-pillar bears a vertical load, the support 40 can provide a reverse support force, improve the overall compressive and bending resistance, suppress the bending tendency of the overlapping section 21, maintain the survival space of the passenger compartment, and thus provide better protection for passengers.

[0058] In summary, thanks to the reinforcement effect of support member 40, the A-pillar structure of this design has significantly improved its downward load-bearing capacity under top pressure conditions, meeting more stringent collision safety standards. Furthermore, this design only requires adding one support member 40 to the existing A-pillar structure, without major modifications to the existing structure, resulting in lower costs and suitability for mass production.

[0059] In some embodiments, the support member 40 includes a top support plate 41, a bottom support plate 42, and at least one side plate 43. The top support plate 41 is fixedly connected to the overlapping section 21, the bottom support plate 42 is fixedly connected to the connecting bottom wall 12, and the side plate 43 is connected between the top support plate 41 and the bottom support plate 42.

[0060] Thus, the overlapping section 21 of the top support plate 41 and the upper reinforcement 20 of the A-pillar is fixed in surface contact, and the overlapping bottom wall of the bottom support plate 42 and the lower reinforcement 10 of the A-pillar is also fixed in surface contact. Under top pressure conditions, the vertical load borne by the upper reinforcement 20 of the A-pillar is transferred sequentially through the path of the top support plate 41, the side plate 43, and the bottom support plate 42, avoiding local stress concentration caused by point contact or line contact. Furthermore, the side plate 43 forms a vertical support rib, which can effectively resist the bending deformation of the support member 40 itself, so that the support member 40 will not collapse during the vertical load transfer process, thus continuously providing stable support and load transfer.

[0061] The number of side plates 43 can be set as needed. For example, depending on the top pressure load requirements of different vehicle models, one, two or more (more than two) side plates 43 can be selected. Multiple side plates 43 can form multiple vertical supports, which can greatly improve the overall rigidity of the support component 40. Alternatively, for vehicle models with smaller loads, only one side plate 43 can be set, which can reduce the amount of material used while meeting performance requirements.

[0062] In some embodiments, the overlapping section 21 includes a second overlapping surface 212 near the supporting base plate 42, and the supporting top plate 41 is fitted to the second overlapping surface 212 and fixedly connected.

[0063] In this way, the supporting top plate 41 is directly attached to the second lap surface 212, eliminating the stress concentration phenomenon generated at the contact point when there is a point contact or line contact connection. This can also provide a larger connection area, allowing for more connection points or longer welds, whether it is welding, riveting or screwing.

[0064] Similarly, the supporting base plate 42 is fitted and fixedly connected to the connecting bottom wall 12. The principle and technical effect are the same as described above, and therefore will not be repeated here.

[0065] Furthermore, the supporting top plate 41 and the second lap surface 212 are fixedly connected by spot welding. Spot welding is a connection method in which the base materials are fused together, resulting in high connection strength. It does not require any additional connecting parts such as welding wire, welding rod, rivets, or bolts. Compared with riveting, it can reduce the weight of the connection part; compared with bolting, the weight reduction effect is more obvious, which is in line with the development trend of automotive lightweighting, improving structural strength without increasing the weight of the vehicle body.

[0066] Similarly, the supporting base plate 42 and the connecting bottom wall 12 are fixedly connected by spot welding.

[0067] In some embodiments, the supporting top plate 41, the supporting bottom plate 42, and at least one side plate 43 form a partially enclosed structure. That is, the support member 40 is not a solid block structure, but a semi-enclosed structure with multiple enclosures.

[0068] Thus, compared to a solid structure or a fully enclosed structure (such as a fully enclosed shell) for the support component 40, this solution can reduce material usage while ensuring support strength, aligning with the overall vehicle lightweighting design trend. Of course, in other embodiments, the support component 40 can be a solid structure, such as a solid block or solid column. Alternatively, the support component 40 can be a closed structure, such as a fully enclosed shell without openings. However, it is not limited to these. In other words, this application does not impose a unique limitation on the specific structural form of the support component 40. The structural type of the support component 40 can be flexibly selected based on the overall vehicle weight, top pressure safety standards, lightweighting goals, and production process conditions of different vehicle models, achieving a balance between performance requirements, cost control, and process adaptability. For example, for small passenger vehicles, a partially enclosed structure of the support component 40 is preferred, balancing lightweighting and load-bearing capacity; for heavy commercial vehicles, a solid block structure or a fully enclosed structure of the support component 40 can be selected to meet the requirements of high load bearing capacity.

[0069] In some embodiments, there are multiple side plates 43, and the multiple side plates 43 are connected in sequence.

[0070] In this way, multiple side plates 43 are connected in sequence, forming a frame-like three-dimensional support cavity together with the supporting top plate 41 and supporting bottom plate 42. This increases the overall stiffness of the support member 40, thereby better fulfilling its supporting and load-transfer functions. In other words, after multiple side plates 43 are connected in sequence, they together with the supporting top plate 41 and supporting bottom plate 42 form a continuous semi-enclosed cavity. Compared to multiple spaced side plates 43, the multiple side plates 43 connected in this scheme are equivalent to constructing multiple continuous vertical support ribs between the supporting top plate 41 and the bottom plate, resulting in higher stiffness of the support member 40. Specifically, the load is transferred to each side plate 43 through the supporting top plate 41, which can distribute the concentrated load to different side plates 43, preventing buckling deformation of a single side plate 43 due to overload. This strengthens the overall bending stiffness of the support member 40 and further prevents local bending or collapse of the overlapping section 21 of the reinforcement member 20 on the A-pillar.

[0071] The number of side panels 43 can be set as needed. For example, the number of side panels 43 can be increased for large vehicles, while the number of side panels 43 can be reduced for small cars.

[0072] In the embodiment shown in the figure, there are three side plates 43, which are connected sequentially. The angle between any two adjacent side plates 43 is approximately 90°. Each side plate 43 is connected to the top support plate 41 and the bottom support plate 42. That is, the top support plate 41, the bottom support plate 42, and the three side plates 43 together form a channel-shaped structure with an opening. This opening faces the main body of the A-pillar reinforcement 10, but is not limited to this. In other words, the channel-shaped support member 40 is similar to an open box girder, with strong bending strength and torsional deformation resistance. After a vertical load is applied to the top support plate 41, it can be transferred to the bottom support plate 42 through the three side plates 43, which can disperse the concentrated stress. The overall load-bearing capacity and structural reliability of the support member 40 are high.

[0073] In some embodiments, the included angle between the side plate 43 and the supporting top plate 41 is in the range of 60° to 120°. For example, the included angle between the side plate 43 and the supporting top plate 41 can be 60°, 70°, 80°, 90°, 100°, 110°, or 120°, but is not limited thereto.

[0074] When the included angle is within the range of 60° to 120°, the side plate 43 can provide vertical support mainly in the vertical component, which can maximize the stiffness and bearing capacity of the support member 40 in the vertical direction. In particular, when the included angle is 90°, the side plate 43 is perpendicular to the support top plate 41. At this time, the support of the side plate 43 to the top plate is pure vertical support, which can maximize the resistance to the vertical load under the top pressure condition. When the included angle is less than 60° or greater than 120°, the vertical supporting force of the side plate 43 may be insufficient, and the support member 40 is prone to bending and losing its bearing capacity. Therefore, in this solution, the included angle between the side plate 43 and the support top plate 41 is limited within the range of 60° to 120°, which can ensure the vertical supporting force of the support member 40.

[0075] Of course, the included angle between the side plate 43 and the support bottom plate 42 can also be within the range of 60° to 120°. Exemplarily, the included angle between the side plate 43 and the support bottom plate 42 can be 60°, 70°, 80°, 90°, 100°, 110°, 120°, but not limited thereto.

[0076] Specifically, the support member 40 is integrally in a "Z" shape. The number of the side plates 43 is one. One end of the side plate 43 is connected to the end of the support top plate 41, and the other end of the side plate 43 is connected to the end of the support bottom plate 42. That is, a single side plate 43 is used to connect the support top plate 41 and the support bottom plate 42. The overall structure of the support member 40 is relatively simple. On the premise of meeting the basic vertical support requirements, the material consumption is less, which is beneficial to cost saving and lightweight.

[0077] Alternatively, the support member 40 is integrally in a "C" shape. The number of the side plates 43 and the support bottom plates 42 are both two. The two side plates 43 are respectively the first side plate 43 and the second side plate 43, and the two support bottom plates 42 are respectively the first bottom plate and the second bottom plate. The first side plate 43 is respectively connected to the support top plate 41 and the first bottom plate, and the second side plate 43 is respectively connected to the support top plate 41 and the second bottom plate. In this way, after the vertical load passes through the support top plate 41, it can be simultaneously dispersed and transmitted to the two bottom plates through two paths of the first side plate 43 and the second side plate 43, avoiding stress concentration. Moreover, this structure has strong bending and anti-twisting deformation resistance when承受垂直压力时承受 vertical pressure and is not prone to bending.

[0078] In some embodiments, at least one side plate 43 is provided with a reinforcing rib 44, and the reinforcing rib 44 extends along the direction from the support top plate 41 to the support bottom plate 42.

[0079] It is easy to understand that under top pressure conditions, the stress form of the side plate 43 is: a compressive-bending load in the direction from the supporting top plate 41 to the supporting bottom plate 42. The stiffener 44 is equivalent to adding a supporting rib in this direction, which can significantly improve the bending resistance of the side plate 43, thereby enabling the support member 40 to maintain the structural integrity under top pressure conditions and effectively transfer the load of the upper stiffener 20 of the A-column to the lower stiffener 10 of the A-column.

[0080] The number of reinforcing ribs 44 can be set as needed, and this application does not impose specific limitations on this. In particular, when there are multiple side plates 43, each side plate 43 can be provided with a reinforcing rib 44. Alternatively, the side plate 43 with the largest area among the multiple side plates 43 can have a reinforcing rib 44. When the area of ​​the side plate 43 is small, it is more difficult to form the reinforcing rib 44 on the side plate 43; the larger the area of ​​the side plate 43, the easier it is to form the reinforcing rib 44.

[0081] In some embodiments, the support member 40 is disposed at the end of the overlapping section 21 and is fixedly connected to the end of the overlapping section 21. That is, the support member 40 is supported at the end of the overlapping section 21 that extends into the lower A-pillar reinforcement 10. The end of the overlapping section 21 refers to the free end of the upper A-pillar reinforcement 20 that extends into the overlapping area 13 of the lower A-pillar reinforcement 10. In particular, the fact that the support member 40 is disposed at the end of the overlapping section 21 means that a reasonable gap is allowed between the support member 40 and the end of the overlapping section 21 due to factors such as manufacturing tolerances, welding deformation, and cumulative assembly errors.

[0082] The end of the lap section 21 extending into the lower A-pillar reinforcement 10 is the end of the load transfer and also the area with the largest bending moment, making it prone to bending or collapse. Placing the support member 40 at this end directly supports this weak area, counteracting the bending moment at the end and preventing it from bending downwards, thus providing better support. Specifically, the middle of the lap section 21 of the upper A-pillar reinforcement 20 typically contains weld points, weld seams, or other assembly structures. The end of the lap section 21 extending into the lower A-pillar reinforcement 10 is the end space of the lap area 13, which is relatively open. Placing the support member 40 at this location provides just the right amount of support.

[0083] In some embodiments, the A-pillar reinforcement 20 is a hot-expansion tube beam. The hot-expansion tube beam itself has high structural strength and torsional stiffness, which helps to improve the overall structural strength and torsional stiffness of the A-pillar reinforcement 20, thereby improving the vehicle's safety performance.

[0084] Furthermore, the second overlapping surface 212 is the outer wall of the hot air expansion tube beam near the connecting bottom wall 12, so as to better support the hot air expansion tube.

[0085] Based on the same inventive concept, this application also provides a vehicle that includes the A-pillar structure of any of the above embodiments or implementations. The vehicle can be a sedan, truck, van, SUV, or any other type of civilian or commercial vehicle. In one specific embodiment, the vehicle is a high-voltage traction battery-powered electric vehicle (e.g., a pure battery electric vehicle, a hybrid electric vehicle, a plug-in hybrid electric vehicle, etc.); in another specific embodiment, the vehicle is an autonomous driving vehicle (i.e., an intelligent driving vehicle), which can automatically control its driving, steering, braking, and other maneuvering functions through an onboard control system without direct input from a human driver. Because this vehicle uses the above-described A-pillar structure, it possesses the same technical effects as the aforementioned A-pillar structure, namely, smooth transition of A-pillar stiffness, high load transfer efficiency, and strong connection reliability, effectively improving the vehicle's collision safety performance and structural stability.

[0086] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. An A-pillar structure, characterized in that, include: The A-pillar reinforcement has an overlapping top wall and a connecting bottom wall opposite to the overlapping top wall, and an overlapping area is formed between the overlapping top wall and the connecting bottom wall; The A-pillar reinforcement has an overlapping section that extends into the overlapping area, and the overlapping section overlaps and engages with the top wall of the overlapping area. A connecting plate, located in the overlapping area, includes a first part and a second part connected together. The first part is fixedly connected to the overlapping section, and the second part is located at the end of the first part away from the overlapping section. The second part is fixedly connected to the top wall of the overlapping section.

2. The A-pillar structure according to claim 1, characterized in that, The connection between the overlapping section and the overlapping top wall has a step difference. The overlapping section has a first overlapping surface, and the overlapping top wall has a third overlapping surface. The first part is fixedly connected to the first overlapping surface, and the second part is fixedly connected to the third overlapping surface.

3. The A-pillar structure according to claim 2, characterized in that, The distance between the first overlapping surface and the third overlapping surface is the step difference.

4. The A-pillar structure according to claim 2, characterized in that, The thickness of the second part is less than the step difference.

5. The A-pillar structure according to claim 2, characterized in that, The first part is fitted to the first overlapping surface, and the first part is fixedly connected to the first overlapping surface by spot welding; And / or, the second part is fitted to the third overlapping surface, and the second part is fixedly connected to the third overlapping surface by spot welding.

6. The A-pillar structure according to claim 2, characterized in that, The connecting plate also includes a transition section, which is smoothly connected to the first section and the second section respectively.

7. The A-pillar structure according to any one of claims 1 to 6, characterized in that, The reinforcement on the A-pillar is a thermally expanded tube beam.

8. The A-pillar structure according to claim 7, characterized in that, When the overlapping section has a first overlapping surface, the first overlapping surface is the inner wall surface of the hot air expansion tube beam.

9. The A-pillar structure according to claim 1, characterized in that, The connecting plate has a bent section on its side.

10. The A-pillar structure according to claim 1, characterized in that, The cross-sectional area of ​​the reinforcement member on the A-pillar is greater than the cross-sectional area of ​​the connecting plate.

11. The A-pillar structure according to claim 1, characterized in that, The length of the first part is equal to the length of the second part; Alternatively, the length of the second part is greater than the length of the first part.

12. The A-pillar structure according to claim 1, characterized in that, The thickness of the connecting plate is less than the thickness of the overlapping top wall, and the thickness of the overlapping top wall is less than the thickness of the overlapping section.

13. The A-pillar structure according to claim 1, characterized in that, The thickness of the first part is equal to the thickness of the second part; And / or, in the direction from the first portion to the second portion, the thickness of the connecting plate gradually decreases.

14. A vehicle, characterized in that, include: The A-pillar structure as described in any one of claims 1 to 13.

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