Front pillar structure
The front pillar structure addresses the issue of flange separation in collisions by using bulkheads to absorb collision loads, ensuring the integrity of the joint between the outer and inner flange portions.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2023-01-13
- Publication Date
- 2026-05-26
AI Technical Summary
Existing vehicle front pillar structures fail to effectively suppress the separation of joint portions between the outer and inner flange portions during frontal collisions, particularly in small overlap collisions, leading to potential peeling at the spot welds.
A front pillar structure comprising a front pillar outer panel, inner panel, outer bulkhead, and inner bulkhead, where the bulkheads form closed cross-sectional shapes with the panels and are positioned to absorb collision loads through plastic deformation, reducing the load on the joint between the flange portions.
The structure effectively suppresses the separation of flange joint portions by distributing and absorbing collision loads, preventing peeling and relative displacement of the panels, enhancing structural integrity during frontal collisions.
Smart Images
Figure 0007865220000001 
Figure 0007865220000002 
Figure 0007865220000003
Abstract
Description
Technical Field
[0001] The present invention relates to a front pillar structure.
Background Art
[0002] A vehicle front structure that suppresses the rearward movement of the front pillar during a small overlap collision has been conventionally known (see, for example, Patent Document 1). In this vehicle front structure, a bulkhead disposed in the closed cross-section of the front pillar and a cowl top side panel are directly joined, and in a side view, the cowl top panel, the cowl top side panel, the bulkhead (front pillar), and the door belt line reinforce are arranged in a straight line. Thereby, during a small overlap collision, the collision load is transmitted to the rear side of the vehicle of the front pillar.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, during a frontal collision including a small overlap collision of the vehicle, in a plan view, due to the deformation of the front pillar outer panel accompanying the retreat of the cowl top side panel, there is a possibility that the joint portion between the outer flange portion on the rear side of the vehicle of the front pillar outer panel and the inner flange portion on the rear side of the vehicle of the front pillar inner panel peels off (the spot weld portion breaks). Thus, there is still room for improvement in the structure for suppressing the peeling of the joint portion between the outer flange portion and the inner flange portion on the rear side of the vehicle.
[0005] Therefore, the present invention aims to provide a front pillar structure that can suppress the separation of the joint portion between the outer flange portion on the rear side of the front pillar outer panel and the inner flange portion on the rear side of the front pillar inner panel during a frontal collision of a vehicle. [Means for solving the problem]
[0006] To achieve the above objectives, the front pillar structure of the first aspect of the present invention comprises: a front pillar outer panel having outer flange portions on the front and rear sides of the vehicle; a front pillar inner panel having inner flange portions joined to the outer flange portions on the front and rear sides of the vehicle, respectively; an outer bulkhead joined to the front pillar outer panel so as to form a closed cross-sectional shape with the front pillar outer panel and positioned between the front pillar outer panel and the front pillar inner panel; an inner bulkhead joined to the front pillar inner panel so as to form a closed cross-sectional shape with the front pillar inner panel and positioned between the front pillar outer panel and the front pillar inner panel, and on the rear side of the outer bulkhead, overlapping with the outer bulkhead in the vehicle width direction; and a cowl top side panel positioned on the front side of the front pillar outer panel.
[0007] According to the first embodiment of the invention, the outer flange portion on the vehicle front side of the front pillar outer panel is joined to the inner flange portion on the vehicle front side of the front pillar inner panel, and the outer flange portion on the vehicle rear side of the front pillar outer panel is joined to the inner flange portion on the vehicle rear side of the front pillar inner panel. Furthermore, an outer bulkhead joined to the front pillar outer panel is positioned between the front pillar outer panel and the front pillar inner panel so as to form a closed cross-sectional shape with the front pillar outer panel, and an inner bulkhead joined to the front pillar inner panel is positioned between the front pillar outer panel and the front pillar inner panel, and on the vehicle rear side of the outer bulkhead, overlapping with the outer bulkhead in the vehicle width direction, so as to form a closed cross-sectional shape with the front pillar inner panel. In addition, a cowl top side panel is positioned on the vehicle front side of the front pillar outer panel.
[0008] Therefore, in the event of a frontal collision, the collision load applied to the cowl top side panel is transmitted from the cowl top side panel to the front pillar outer panel, and then from the front pillar outer panel to the outer bulkhead. The collision load transmitted to the outer bulkhead is then transmitted to the inner bulkhead, and at least a portion of it is absorbed by the plastic deformation of the outer bulkhead and the inner bulkhead. As a result, the load applied to the joint between the outer flange and inner flange on the rear side of the vehicle is reduced, and separation of that joint is suppressed.
[0009] Furthermore, the front pillar structure according to the second embodiment of the present invention is the front pillar structure according to the first embodiment, wherein the outer bulkhead forms a closed cross-sectional shape with the front pillar outer panel in a plan view, and the inner bulkhead forms a closed cross-sectional shape with the front pillar inner panel in a plan view.
[0010] According to the second embodiment of the invention, the outer bulkhead forms a closed cross-sectional shape with the front pillar outer panel in a plan view, and the inner bulkhead forms a closed cross-sectional shape with the front pillar inner panel in a plan view. In other words, the outer bulkhead and the inner bulkhead are open in the vertical direction of the vehicle. Therefore, compared to the case where the outer bulkhead and the inner bulkhead form a closed cross-sectional shape in a front view, for example, from the front-rear direction of the vehicle, they are more easily plastically deformed in the front-rear direction of the vehicle and are more easily able to absorb collision loads. As a result, the load applied to the joint between the outer flange portion and the inner flange portion on the rear side of the vehicle is efficiently reduced, and the separation of the joint portion is more effectively suppressed. [Effects of the Invention]
[0011] As described above, according to the present invention, it is possible to suppress the separation of the joint portion between the outer flange portion on the rear side of the front pillar outer panel and the inner flange portion on the rear side of the front pillar inner panel during a frontal collision of a vehicle. [Brief explanation of the drawing]
[0012] [Figure 1] This is a schematic plan view showing the front pillar structure according to this embodiment. [Figure 2] This is a schematic plan view showing the initial state of the front pillar structure according to this embodiment during a collision. [Figure 3] This is a schematic plan view showing the mid-stage state of the front pillar structure according to this embodiment. [Figure 4] This is a schematic plan view showing the front pillar structure in the later stages of a collision according to this embodiment. [Figure 5] (A) A schematic plan view illustrating the front pillar structure according to this embodiment. (B) A schematic plan view illustrating the front pillar structure according to this embodiment in the late stages of a collision. [Figure 6] (A) A schematic plan view illustrating the front pillar structure of the comparative example. (B) A schematic plan view illustrating the state of the front pillar structure of the comparative example in the later stages of a collision. [Modes for carrying out the invention]
[0013] The embodiments of the present invention will be described in detail below with reference to the drawings. For the sake of explanation, in each figure, the arrow UP will indicate the upward direction of the vehicle, the arrow FR will indicate the forward direction of the vehicle, and the arrow RH will indicate the rightward direction of the vehicle. Therefore, in the following description, unless otherwise specified, the directions of up, down, front, back, and left and right will refer to the up, down, front, back, and left and right directions of the vehicle. Also, the left and right direction is synonymous with the vehicle width direction.
[0014] As shown in Figure 1, the front pillar 12 in a vehicle 11 such as an electric vehicle to which the front pillar structure 10 according to this embodiment is applied is configured in a closed cross-sectional shape by a front pillar outer panel 20 and a front pillar inner panel 30. That is, the front pillar 12 is a hollow columnar shape and extends along the vertical direction.
[0015] The front pillar outer panel 20 has an outer wall portion 22 that constitutes the outer vertical wall of the front pillar 12 in the vehicle width direction. The outer wall portion 22 extends vertically with the vehicle width direction as the plate thickness direction. The front pillar outer panel 20 has a front vertical wall portion 24 that is bent inward in the vehicle width direction from the front end of the outer wall portion 22, and a rear vertical wall portion 26 that is bent inward in the vehicle width direction from the rear end of the outer wall portion 22. The front vertical wall portion 24 and the rear vertical wall portion 26 each extend vertically with the approximately front-to-rear direction as the plate thickness direction.
[0016] In addition, the front pillar outer panel 20 has a front outer flange portion 24A that is bent and extends forward from the inner end portion in the vehicle width direction of the front vertical wall portion 24, and a rear outer flange portion 26A that is bent and extends rearward from the inner end portion in the vehicle width direction of the rear vertical wall portion 26. The front outer flange portion 24A and the rear outer flange portion 26A extend along the vertical direction with the vehicle width direction as the plate thickness direction. That is, the front pillar outer panel 20 is formed in a substantially hat-shaped configuration with an opening facing inward in the vehicle width direction in a plan sectional view.
[0017] The front pillar inner panel 30 has an inner wall portion 32 that constitutes the vertical wall on the inner side in the vehicle width direction of the front pillar 12. The inner wall portion 32 extends along the vertical direction with the vehicle width direction as the plate thickness direction. In addition, the front pillar inner panel 30 has a front vertical wall portion 34 that is bent and extends outward in the vehicle width direction from the front end portion of the inner wall portion 32, and a rear vertical wall portion 36 that is bent and extends outward in the vehicle width direction from the rear end portion of the inner wall portion 32. The front vertical wall portion 34 and the rear vertical wall portion 36 extend along the vertical direction with the substantially front-rear direction as the plate thickness direction.
[0018] In addition, the front pillar inner panel 30 has a front inner flange portion 34A that is bent and extends forward from the outer end portion in the vehicle width direction of the front vertical wall portion 34, and a rear inner flange portion 36A that is bent and extends rearward from the outer end portion in the vehicle width direction of the rear vertical wall portion 36. The front inner flange portion 34A and the rear inner flange portion 36A extend along the vertical direction with the vehicle width direction as the plate thickness direction. That is, the front pillar inner panel 30 is formed in a substantially hat-shaped configuration with an opening facing outward in the vehicle width direction in a plan sectional view.
[0019] The outer flange portion 24A on the front side of the front pillar outer panel 20 and the inner flange portion 34A on the front side of the front pillar inner panel 30 are joined by a plurality of spot welds arranged vertically, and the outer flange portion 26A on the rear side of the front pillar outer panel 20 and the inner flange portion 36A on the rear side of the front pillar inner panel 30 are joined by a plurality of spot welds arranged vertically. As a result, the front pillar 12 having a closed cross-sectional shape extending along the vertical direction is formed.
[0020] Also, as shown in FIGS. 1 and 5(A), inside the front pillar 12 (between the front pillar outer panel 20 and the front pillar inner panel 30), an outer attached bulkhead 28 that forms a closed cross-sectional shape with the front pillar outer panel 20 in a plan view and an inner attached bulkhead 38 that forms a closed cross-sectional shape with the front pillar inner panel 30 in a plan view are arranged.
[0021] The outer attached bulkhead 28 is formed in a substantially hat-shaped cross-section that opens outward in the vehicle width direction in a plan view and protrudes toward the inner wall portion 32 side of the front pillar inner panel 30. Specifically described, the portion of the outer attached bulkhead 28 on the inner side in the vehicle width direction is a flat vertical wall portion 28A, and this vertical wall portion 28A extends along the vertical direction with the vehicle width direction as the plate thickness direction. And this vertical wall portion 28A is arranged close to the inner wall portion 32 (with a slight gap).
[0022] The front portion of the outer attached bulkhead 28 is a front wall portion 28B that is bent and extended outward at a substantially right angle from the front end portion of the vertical wall portion 28A in the vehicle width direction, and this front wall portion 28B extends along the vertical direction with the front-rear direction as the plate thickness direction. The rear portion of the outer attached bulkhead 28 is a rear wall portion 28C that is bent and extended outward at a substantially right angle from the rear end portion of the vertical wall portion 28A in the vehicle width direction, and this rear wall portion 28C extends along the vertical direction with the front-rear direction as the plate thickness direction.
[0023] Furthermore, the front flange portion 28D extends from the outer end of the front wall portion 28B in the vehicle width direction, bent at approximately a right angle toward the front, and the rear flange portion 28E extends from the outer end of the rear wall portion 28C in the vehicle width direction, bent at approximately a right angle toward the rear. The front flange portion 28D and the rear flange portion 28E extend vertically, with the vehicle width direction being the plate thickness direction.
[0024] The front flange portion 28D and the rear flange portion 28E are joined to the outer wall portion 22 of the front pillar outer panel 20 by spot welding. As a result, the outer bulkhead 28 and the outer wall portion 22 of the front pillar outer panel 20 form a closed cross-sectional shape that is open in the vertical direction.
[0025] The inner bulkhead 38 is formed in a roughly hat-shaped cross-section that opens inward in the vehicle width direction when viewed from above, and protrudes toward the outer wall portion 22 of the front pillar outer panel 20. Specifically, the outer portion of the inner bulkhead 38 in the vehicle width direction is a flat vertical wall portion 38A, and this vertical wall portion 38A extends vertically with the vehicle width direction as the plate thickness direction. This vertical wall portion 38A is positioned with a predetermined gap between it and the outer wall portion 22.
[0026] The front of the inner bulkhead 38 is a front wall portion 38B that extends from the front end of the vertical wall portion 38A, bent at approximately a right angle inward in the vehicle width direction, and this front wall portion 38B extends vertically with the plate thickness direction being the front-rear direction. The rear of the inner bulkhead 38 is a rear wall portion 38C that extends from the rear end of the vertical wall portion 38A, bent at approximately a right angle inward in the vehicle width direction, and this rear wall portion 38C extends vertically with the plate thickness direction being the front-rear direction.
[0027] Furthermore, the front flange portion 38D extends from the inner end of the front wall portion 38B in the vehicle width direction, bent at approximately a right angle toward the front, and the rear flange portion 38E extends from the inner end of the rear wall portion 38C in the vehicle width direction, bent at approximately a right angle toward the rear. The front flange portion 38D and the rear flange portion 38E extend vertically, with the vehicle width direction being the plate thickness direction.
[0028] The front flange portion 38D and the rear flange portion 38E are joined to the inner wall portion 32 of the front pillar inner panel 30 by spot welding. As a result, the inner bulkhead 38 and the inner wall portion 32 of the front pillar inner panel 30 form a closed cross-sectional shape that is open in the vertical direction.
[0029] Furthermore, the inner bulkhead 38 is positioned behind the outer bulkhead 28, overlapping it in the vehicle width direction. In other words, the outer bulkhead 28 is positioned in front of the inner bulkhead 38, overlapping at least a portion of the inner bulkhead 38 when viewed from the front.
[0030] The outer bulkhead 28 and the inner bulkhead 38 are positioned with a predetermined gap in the front-rear direction. This gap is set to prevent the generation of abnormal noise due to contact between the outer bulkhead 28 and the inner bulkhead 38 during normal vehicle operation, and to facilitate assembly between the outer bulkhead 28 and the outer wall portion 22, and between the inner bulkhead 38 and the inner wall portion 32.
[0031] Furthermore, a cowl top side panel 14 is positioned on the front side of the front pillar outer panel 20. In other words, the rear end portion 14A of the cowl top side panel 14 is connected to the front outer flange portion 24A, the front vertical wall portion 24, and the front portion of the outer wall portion 22 of the front pillar outer panel 20. The outer bulkhead 28 and the inner bulkhead 38 are positioned, for example, on the rear side of the cowl top side panel 14 and in front of the beltline reinforcement (not shown).
[0032] Furthermore, a front pillar inner gusset 16 is attached to the inner side in the vehicle width direction of the inner wall portion 32 of the front pillar inner panel 30. A dash cross member (not shown) is attached to the front portion 16A of the front pillar inner gusset 16, and the end of the instrument panel reinforcement 18 is attached to the rear portion 16B of the front pillar inner gusset 16 via a bracket 17. The instrument panel reinforcement 18 is a pipe-shaped member installed in the vehicle width direction.
[0033] The operation of the front pillar structure 10 according to this embodiment, which has the configuration described above, will now be explained.
[0034] First, let's explain what happens when a vehicle equipped with the comparative example front pillar structure shown in Figure 6 is involved in a frontal collision. As shown in Figure 6(A), in this comparative example front pillar structure, the outer bulkhead 28 and the inner bulkhead 38 are not provided inside the front pillar 12.
[0035] When a vehicle equipped with the comparative example's front pillar structure is involved in a frontal collision, a collision load is applied to the cowl top side panel 14 from the front. As shown in Figure 6(B), the cowl top side panel 14 is displaced at its front end in the vehicle width direction and at its rear end outward and rearward in the vehicle width direction, while the collision load is applied to the front pillar 12.
[0036] As described above, the front pillar 12 does not have an outer bulkhead 28 or an inner bulkhead 38. Therefore, when the collision load applied to the cowl top side panel 14 is transmitted from the cowl top side panel 14 to the front pillar outer panel 20, the front vertical wall portion 24 of the front pillar outer panel 20 undergoes plastic deformation toward the rearward side outward in the vehicle width direction, and the outer wall portion 22 of the front pillar outer panel 20 is displaced toward the rearward side outward in the vehicle width direction.
[0037] As a result, a load is applied to the rear outer flange portion 26A of the front pillar outer panel 20 in a direction away from the rear inner flange portion 36A of the front pillar inner panel 30, causing the outer flange portion 26A to separate from the inner flange portion 36A. In other words, the spot weld between the outer flange portion 26A and the inner flange portion 36A breaks, and the front pillar outer panel 20 is displaced relative to the front pillar inner panel 30 in a direction away from it.
[0038] In contrast, in the front pillar structure 10 according to this embodiment, as shown in Figures 1 and 5(A), an outer bulkhead 28 and an inner bulkhead 38 are provided inside the front pillar 12. Therefore, fracture of the spot weld between the outer flange portion 26A and the inner flange portion 36A is suppressed or prevented, and relative displacement of the front pillar outer panel 20 in the direction away from the front pillar inner panel 30 is suppressed. This will be explained below.
[0039] When a vehicle 11 equipped with the front pillar structure 10 according to this embodiment is involved in a frontal collision, a collision load is applied to the cowl top side panel 14 from the front. As shown in Figure 2, the front end of the cowl top side panel 14 is displaced inward in the vehicle width direction, and the rear end 14A of the cowl top side panel 14 is displaced outward and rearward in the vehicle width direction, while the collision load is transmitted from the cowl top side panel 14 to the front pillar outer panel 20.
[0040] When a collision load is transmitted from the cowl top side panel 14 to the front pillar outer panel 20, the front vertical wall portion 24 of the front pillar outer panel 20 undergoes plastic deformation toward the rearward side in the vehicle width direction, and the outer wall portion 22 of the front pillar outer panel 20 is displaced toward the rearward side in the vehicle width direction. As shown in Figure 3, at least the inner portion in the vehicle width direction of the outer bulkhead 28 joined to the outer wall portion 22 is displaced toward the rear, and then the wall portion 28C comes into contact with (interferes with) the front wall portion 38B of the inner bulkhead 38.
[0041] In other words, the collision load transmitted from the front pillar outer panel 20 to the outer bulkhead 28 is transmitted to the inner bulkhead 38, and at least a portion of it is absorbed by the plastic deformation of the outer bulkhead 28 and the inner bulkhead 38. As a result, the relative displacement of the outer wall portion 22 toward the rearward side in the vehicle width direction is suppressed, and the load applied to the rear outer flange portion 26A of the front pillar outer panel 20 in a direction away from the rear inner flange portion 36A of the front pillar inner panel 30 is reduced.
[0042] In other words, as shown in Figures 4 and 5(B), the load applied to the spot weld between the outer flange portion 26A and the inner flange portion 36A is reduced, and the fracture (peeling) of the spot weld is suppressed or prevented. Therefore, the separation of the outer flange portion 26A from the inner flange portion 36A is suppressed or prevented, and the relative displacement of the front pillar outer panel 20 away from the front pillar inner panel 30 is suppressed.
[0043] Furthermore, the outer bulkhead 28 forms a closed cross-sectional shape with the outer wall portion 22 (front pillar outer panel 20) in a plan view, and the inner bulkhead 38 forms a closed cross-sectional shape with the inner wall portion 32 (front pillar inner panel 30) in a plan view. In other words, the outer bulkhead 28 and the inner bulkhead 38 are open in the vertical direction.
[0044] Therefore, the outer bulkhead 28 and the inner bulkhead 38 are more susceptible to plastic deformation in the front-to-back direction and can absorb collision loads more easily than when they form a closed cross-sectional shape in a front view, for example, from the front-to-back direction. As a result, the load applied to the spot weld between the rear outer flange portion 26A and the inner flange portion 36A is efficiently reduced, and the fracture (peeling) of the spot weld is more effectively suppressed or prevented.
[0045] The front pillar structure 10 according to this embodiment has been described above based on the drawings. However, the front pillar structure 10 according to this embodiment is not limited to the illustrated version, and can be modified as appropriate without departing from the spirit of the present invention. For example, the outer bulkhead 28 and the inner bulkhead 38 may be arranged to form a closed cross-sectional shape in a front view, as long as they have a structure that is easily plastically deformed in the front-rear direction. [Explanation of symbols]
[0046] 10 Front pillar structure 14 Cowl Top Side Panel 20 Front Pillar Outer Panel 24A Outer flange section 26A Outer flange section 28 Outer bulkhead 30 Front Pillar Inner Panel 34A Inner flange section 36A Inner flange section 38 Inner bulkhead
Claims
[Claim 1] A front pillar outer panel formed in a substantially hat shape, having an outer wall portion that constitutes the outer vertical wall of the front pillar in the vehicle width direction with the vehicle width direction as the plate thickness direction, a front outer flange portion with the vehicle width direction as the plate thickness direction, and a rear outer flange portion with the vehicle width direction as the plate thickness direction. In a plan view, the front pillar inner panel is formed in a substantially hat shape, having an inner wall portion that constitutes the vertical wall on the inner side of the front pillar in the vehicle width direction with the vehicle width direction as the plate thickness direction, a front inner flange portion with the vehicle width direction as the plate thickness direction, and a rear inner flange portion with the vehicle width direction as the plate thickness direction, wherein the front inner flange portion is joined to the front outer flange portion, and the rear inner flange portion is joined to the rear outer flange portion. In a plan view, the outer bulkhead is joined to the outer wall portion such that it forms a closed cross-sectional shape with the outer wall portion, and is positioned between the outer wall portion and the inner wall portion. In a plan view, the inner wall portion is joined to the inner wall portion so as to form a closed cross-sectional shape with the outer wall portion, and the inner bulkhead is positioned between the outer wall portion and the inner wall portion, and on the rear side of the outer bulkhead, overlapping the outer bulkhead in the vehicle width direction, The cowl top side panel is positioned on the front side of the front pillar outer panel, Equipped with, A front pillar structure configured such that, in a plan view, the gap between the outer bulkhead and the inner wall portion along the vehicle width direction is smaller than the gap between the inner bulkhead and the outer wall portion along the vehicle width direction.