Body-in-white structure for a body of a vehicle

Abstract

The invention relates to a body-in-white structure (1) for a body of a vehicle, the structure comprising a front module (5) and a rear module (6) as well as a main floor element (6) which connects the front module (5) and the rear module (7). The body-in-white structure (1) is characterised in that a roof element (8) is provided to connect the front module (5) to the rear module (7), which roof element is designed as a circumferentially closed element and forms a body-in-white module, and in that B-pillars (3) of the body-in-white structure (1) are designed as assembly parts and are assembled on the main floor element (6) and the roof element (8) after the roof element (8) and the main floor element (6) have been assembled with the front module (5) and the rear module (7). The invention further relates to a method for assembling such a body-in-white structure.

Description

[0001] Body shell structure for a vehicle body

[0002] The invention relates to a bodyshell structure for a vehicle body. The invention also relates to a method for assembling a bodyshell structure for a vehicle body.

[0003] The body shell of a vehicle essentially consists of a linear structure, whereby the body shell is assembled from individual elements, and different assembly parts can then be arranged and fixed in the body shell structure.

[0004] To enable different vehicle series, different bodyshell structures or different bodies must be implemented. This requires a multitude of different individual elements, which must be individually assembled on the production line according to the respective vehicle series. This leads to high costs and time expenditure.

[0005] For example, DE 102010 048 350 A1 discloses a floor assembly for a plurality of construction variants of a vehicle body, which is intended to reduce costs and the time required for assembly. For this purpose, a cross-variant front module and rear module are provided, with the two modules being connected to each other via a floor arrangement. Depending on the respective construction variant of the body, different floor arrangements can be used, so that the same front modules or rear modules can always be used. The disadvantage of the proposed modular variant is that it only affects one floor assembly, with further individual vehicle bodies or

[0006] Body components still require a large number of individually adapted components with high assembly costs.

[0007] The generic DE 102021 003680 A1 discloses a modular system for several construction variants of a vehicle body shell, comprising several front-end modules and rear-end modules, each with different lengths and widths, several main modules with at least different lengths, as well as several side-end modules, each with different lengths, widths, and heights, including side sills. Depending on the construction variant, corresponding modules are combined with each other, with the respective main module connecting the front-end module with the rear-end module.

[0008] The object of the present invention is to provide a bodyshell structure and a method for assembling a bodyshell structure, in which a cost-effective and simplified or improved production of the respective bodyshell structure or production thereof is possible.

[0009] According to the invention, this object is achieved by a bodyshell structure having the features of claim 1. Advantageous embodiments and further developments emerge from the dependent claims. Furthermore, a method for assembling a bodyshell structure is described.

[0010] At the core of the bodyshell structure according to the invention, a main floor element and a roof element are provided for connecting the front module to the rear module, wherein the roof element and optionally, i.e. in one embodiment variant of the bodyshell structure, also the main floor element are designed as a circumferentially closed element and each form a bodyshell module. The main floor element and the roof element are a bodyshell module and, in particular, before assembly with the front module and the rear module, are designed together without an outer skin. Thus, the main floor element and the roof element can each be designed as a circumferentially closed element or as a ring structure, or just the roof element. The main floor element and the roof element are each shaped as a bodyshell element.A special feature here is the design of the so-called landaulet and the convertible, which, by design, do not have a roof element, so that the main floor element is designed as a ring structure. In all other designs, however, the roof element and the main floor are present. In this case, the roof element is preferably designed as a ring structure.

[0011] A ring structure is understood to be a closed structure that is circumferential and structurally forms a closed ring. Such a ring structure, or a circumferentially closed structure, exhibits high stability. The circumferential, closed structure can run in one plane or be designed as a three-dimensional structure arranged in two or more intersecting planes. The ring structure offers the advantage of high stability and strength, even with relatively low material usage. This allows aspects of lightweight construction to be ideally combined with those of safety, particularly the safety of the passenger compartment.

[0012] The bodyshell structure is designed for a vehicle body, comprising a front module and a rear module. The A-pillars and the C-pillars can be integrated into the respective module, i.e., the front module or the rear module. According to the invention, the B-pillars are mounted subsequently, after assembly of the roof element and the main floor element with the front module and the rear module. This allows the entire bodyshell to be designed modularly, with individual modules being able to be exchanged to implement different vehicle variants, such as sedans or station wagons and the like. This advantageously results in shorter and more cost-effective change times when creating variants or when implementing new models, since, in particular, the entire bodyshell system does not always have to be modified. The entire construction can be lighter because duplicate structures can be eliminated.Furthermore, mixed construction can be simplified because the modules are manufactured individually and the entire bodyshell does not have to be fed through the production line during assembly. In particular, the main floor element and the roof element, and in particular the front module and the rear module, can be pre-assembled or upgraded separately from one another in secondary lines before assembly. This can reduce the number of main assembly lines. A further advantage arises in recycling, as the individual modules can be easily separated. The modular design also offers further benefits, such as the easy interchangeability of the modules, so that new vehicle variants or shapes can be implemented quickly and easily. In particular, the existing production line in the bodyshell does not have to be changed for this, which is a crucial advantage.

[0013] Unlike before, the body shell no longer needs to be passed through a drying / baking oven after surface coating, especially using cathodic dip coating (CDP). This makes it possible to construct individual modules from different materials, even if they differ significantly in their thermal expansion.

[0014] A further advantage is the improved accessibility of the individual modules, both during pre-assembly and during assembly of the bodyshell structure. Because the B-pillars are installed after the roof element and the main floor element have been installed, along with the front and rear modules, this results in excellent lateral access to the bodyshell during assembly, simplifying the installation of components.

[0015] Preferably, the A-pillar can be integrated into the front module and the C-pillar into the rear module, each forming a ring structure. A ring structure is understood to mean, in particular, a closed structure that is circumferential and forms a closed ring structure. In particular, the A-pillar and the C-pillar are each formed as a circumferential ring structure or a circumferentially closed structure, respectively, so that they inherently exhibit high stability.

[0016] The circumferentially closed element of the roof element and / or the main floor element can also be referred to as a circumferential, closed structure or ring structure, or can be designed as a ring structure. The ring structure of the roof element and / or the main floor element can each extend in a single plane, forming two ring structures arranged parallel to one another.

[0017] The ring structure of the front module and / or the rear module can be designed as a three-dimensional structure which, in particular, does not run solely in one plane. This means that elements can also be formed within the ring structure which are oriented transversely to the circumferential closed structure or inclined to a vehicle transverse direction and a vehicle longitudinal direction. Such elements can, for example, form cross member elements to which the main floor element and the roof element can be fixed to the front module or the rear module. This makes it possible, for example, to form an angled circumferential ring structure which can be used in particular for the A-pillar and the C-pillar. The cross member elements can be part of the ring structure itself. The ring structures can touch the roof element in an upper region and be fixed to it.Advantageously, the assembly is easily accessible, which also simplifies installation. The ring structures can also form a type of roll cage, thereby contributing to the vehicle's safety.

[0018] According to a very advantageous development of the concept, the ring structure and / or the circumferentially closed element can be made of a high-strength material. For example, the respective ring structure and / or the circumferentially closed element can be made of cast steel or cast aluminum. This makes it possible to implement particularly delicate pillars that only provide very little visible coverage. Small cross-sections can positively influence the overall appearance of the vehicle. Furthermore, design freedom arises from separating the side wall into individual components, allowing for fewer restrictions due to pressing, particularly due to deep-drawability, press size, and the like.

[0019] According to the invention, the main floor element and the roof element are fixed to the front module and the rear module in an assembled state. In particular, fixing can take place in the roof area of ​​the vehicle's body shell, which area is easily accessible.

[0020] A further advantageous embodiment can provide for the main floor element to have a main floor for arranging at least one battery. Thus, the main floor element can have a battery box, which is designed in particular as a load-bearing crash structure. During assembly, after the main floor element has been mounted on the front and rear modules, the B-pillar can be attached to the battery box. Furthermore, the sill can be integrated into the main floor element. This advantageously not only results in efficient space utilization, but also in an advantage in compensating for tolerances, since the tolerances need to be taken into account not from the entire production process, but only from this subsystem.

[0021] Advantageously, implementing a main floor element with a main floor and arranging at least one battery further avoids duplicate structures. This also opens up new options for supplier-supplied components and in-house production in assembly and manufacturing.

[0022] According to a very advantageous development of the idea, it can be provided that assembly parts are pre-assembled on the respective module and / or the main floor element and / or the roof element. The assembly parts can advantageously be used when good accessibility is possible to each module or element through the individual modules or elements. For example, indirect lighting, in particular x-raying of micro-perforations, the attachment of sensors and / or displays and the like can be enabled, whereby the elements can in particular be integrated directly into the outer skin. The improved accessibility can facilitate the assembly of cable harnesses and rigid busbars in particular. Furthermore, new packaging spaces can be used.In one embodiment, for example, the vehicle seats can already be pre-assembled in the main floor element, whereby they can be easily inserted by a robot due to the good accessibility.

[0023] The invention further relates to a method for assembling a bodyshell structure comprising a front module, a rear module, a main floor element, and a roof element, comprising the following steps: First, the front and rear modules, each of which forms a bodyshell module, as well as the main floor and roof elements, are manufactured independently of one another and are connected to one another. B-pillars designed as assembly parts are then mounted to the main floor element and the roof element. Finally, an outer skin that is not rigidly constructed to the bodyshell structure is attached to the bodyshell structure after it has been assembled. The same features and advantages apply to the assembly method as already described with regard to the bodyshell structure.

[0024] According to a very advantageous development of the concept, the A-pillar and the C-pillar each form a ring structure, and the modules are connected to the main floor element and the roof element via the respective ring structure during assembly. As already described with regard to the bodyshell structure, this results in smaller components, allowing the use of smaller presses. The overall space requirement during assembly is reduced, and production can be structured, for example, according to modules rather than model series. This results in a lower variant complexity overall, which can reduce costs.

[0025] By installing a B-pillar after the main floor element and the roof element have been installed, high accessibility to the interior of the bodyshell can be ensured right up until the very end.

[0026] Furthermore, it is planned that the outer skin will be installed after the B-pillar has been installed. This way, for example, the joints of the individual modules can then be covered by assembled outer skin parts. In particular, the outer skin is therefore not designed to be fixed to the bodyshell. This allows the outer skin to be coated independently, for example. This enables the use of different coating processes, such as anodizing, tesilizing, and the like. A separate outer skin and the implementation of smaller individual modules or elements offer further advantages in the implementation of surface coatings, particularly cathodic dip painting (CDP). This allows, for example, a thicker CDP coating with a shorter heating and cooling time in the CDP oven. Furthermore, aluminum structures can be exposed to higher temperatures, which allows for improved final strength.Furthermore, more homogeneous adhesive curing and / or the use of energy-efficient paint systems can be achieved with a reduced system size. Furthermore, different surfaces or materials, such as stainless steel in particular, can be used. Thus, splitting the assembly of the bodyshell structure and the subsequent application of the outer skin allows for the use of new materials and / or surfaces in the outer skin, since the material does not bleed through the surface.

[0027] The subsequent assembly of the outer skin also makes it possible to use installation spaces in the shell structure which would not be accessible with a conventional construction or would only be accessible with great effort.

[0028] Ultimately, this also reduces the effort required to coat the modules; it's sufficient to apply a cathodic dip coating. This saves time and money.

[0029] Further advantageous embodiments of the bodyshell structure according to the invention and of the method also emerge from the exemplary embodiment, which is described in more detail below with reference to the figures.

[0030] Fig. 1 shows an embodiment of a shell structure in an exploded view;

[0031] Fig. 2 shows another embodiment of a shell structure in an exploded view;

[0032] Fig. 3 shows another embodiment of a shell structure in an exploded view; and

[0033] Fig. 4 an exemplary embodiment with body elements.

[0034] Figures 1 to 3 show different embodiments of a bodyshell structure 1. The bodyshell structure 1 has a front module 5, a main floor element 6, a roof element 8 and a rear module 7. A-pillars 2, which are connected to form a ring structure via an upper and a lower cross member, are integrated into the front module 5, and C-pillars 4, which are connected to form a ring structure via an upper and a lower cross member, are integrated into the rear module 7. As shown in Figure 1, independent modules 5, 7 or elements 6, 8 can be implemented and manufactured independently of one another, whereby a reduction of one main line in a production line can occur. Pre-assembly of the elements 6, 8 and / or the modules 5, 7 with assembly parts can take place using several secondary lines.

[0035] The elements 6, 8 are particularly designed as ring structures. This means that they are each designed as a circumferentially closed element that forms a type of ring shape. The ring structures particularly enable the elimination of bodyshell stations and increase flexibility in assembly. The vehicle can be assembled geometrically during assembly, whereby the door openings and roof openings can be influenced by the positions of the ring structures. The respective ring structure can protrude from the plane and be designed as a spatial ring structure, as shown by the ring structures enclosing the A-pillars 2 and C-pillars 4. In this way, transverse elements can also be implemented, in particular through the ring structures or on the ring structures, in order to connect the ring structures to the main floor element 6 and the roof element 8.

[0036] During assembly, the modules and / or elements 5, 6, 7, 8 can be fixed to one another. In particular, the front module 5 and the rear module 7 are first connected to the main floor element 6. Subsequently, the roof element 8 can be connected to the front module 5 and the rear module 7. Following this, the B-pillars 3 can be mounted to the roof element 8 and the main floor element 6. Before mounting the B-pillars 3, additional assembly parts can be installed inside the bodyshell structure. Due to the absence of B-pillars, this can be done ergonomically and without great expenditure of time. This allows assembly work to be carried out with high accessibility to the interior of the bodyshell.

[0037] In particular, at least one cross member can be integrated into the main floor element 6. For example, the main floor element 6 can be designed as a circumferential ring, see Fig. 1, with internal cross struts, see dashed lines in Fig. 2, or as a battery tray, see Fig. 3. In Fig. 3, the cross members are therefore designed separately from the battery tray, whereby the battery tray is only schematically shown as a flat element (lower arrow with reference number 6). This element can have a recess for receiving the batteries and a circumferential frame, whereby the frame can in particular form a ring element or a circumferentially closed element. Furthermore, the roof element 8 can be shortened, as shown in Fig. 2. This allows different roof designs to be implemented, such as different roof variants with a glass roof and / or a sliding roof.

[0038] Another embodiment of the bodyshell structure 1 can be seen in Fig. 4. In contrast to Fig. 1, a body 9 is shown here. This can be arranged subsequently after assembly of the modules 5, 7 and the elements 6, 8, and in particular, cover the fixing points of the modules 5, 7 with the elements 6, 8.

[0039] The bodyshell structure according to the invention and the method accordingly make it possible to implement a lower level of variant complexity, with the variant creation being implemented in particular only through the assembly of different prefabricated elements 6, 8 and modules 5, 7. For example, by using different rear modules 7, a station wagon or a sedan can be implemented, while the same designs are used for the module 5 and the elements 6, 8. The main floor element 6 can in particular be equipped with a battery, whereby accessibility when inserting the battery can be improved. The ring structures of the elements 6, 8 make it possible to implement a filigree design that enables a luxurious appearance of the vehicle and a wide variety of designs. In particular, the roof openings can be enlarged, whereby vehicles with different variants of glass roofs or sunroofs can also be implemented.In particular, by varying the length of the main floor element 6 and / or the roof element 8, different vehicle lengths can be implemented, whereby the same module can be used for the front module 5.

Claims

New patent claims 1. A bodyshell structure (1) for a vehicle body, comprising a front module (5) and a rear module (7) as well as a main floor element (6) connecting the front module (5) and the rear module (7), characterized in that a roof element (8) is provided to connect the front module (5) to the rear module (7), which roof element is designed as a circumferentially closed element and forms a bodyshell module, and in that B-pillars (3) of the bodyshell structure (1) are designed as assembly parts and are mounted to the main floor element (6) and the roof element (8) after the roof element (8) and the main floor element (6) have been assembled with the front module (5) and the rear module (7).

2. Body shell structure (1) according to claim 1, characterized in that sills are integrated on the main floor element (6).

3. Body shell structure (1) according to claim 1, characterized in that the A-pillar (2) is integrated in the front module (5) and the C-pillar (4) is integrated in the rear module (7) and each forms a ring structure.

4. Shell structure (1) according to claim 2 or 3, characterized in that the ring structure and / or the circumferentially closed element is formed from a high-strength material.

5. Shell structure (1) according to one of claims 1 to 4, characterized in that the main floor element (6) has a main floor for arranging at least one battery.

6. Shell structure (1) according to one of claims 1 to 5, characterized in that Assembly parts on the respective module (5, 6, 7, 8) are pre-assembled and tested.

7. Shell structure (1) according to one of the preceding claims, characterized in that an outer skin (9) which is not rigid with the shell structure is attached to the shell structure (1).

8. A method for assembling a bodyshell structure (1) comprising a front module (5), a rear module (7), a main floor element (6) and a roof element (8) according to one of claims 1 to 7, comprising the following steps: - first, the front and rear modules (5, 7), each of which forms a shell module, as well as the main floor and roof elements (6, 8), which are manufactured independently of one another, are connected to one another, - then B-pillars (3) designed as assembly parts are mounted on the main floor element (6) and the roof element (8), and - finally, a non-shell-proof outer skin (9) is attached to the shell structure (1) after it has been assembled.

9. Method according to claim 8, characterized in that the A-pillars (2) and the C-pillars (4) each form their own ring structure with upper and lower cross members and the modules (5, 7) are connected to the main floor element (6) and / or the roof element (8) via the respective ring structure during assembly.

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