Vehicle C Pillar Rigidity via Curved Welded Joint
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Solution Overview
Problem
The existing construction of vehicle C pillars made from diecast aluminum alloy, which are divided into upper and lower members and joined by welding, lacks sufficient transverse and torsional rigidity, and alignment issues arise due to manufacturing variations, leading to increased labor hours and potential bending at flat portions.
Innovation Solution
A vehicle pillar construction featuring an upper member with a U-shaped cross section and a lower member with a mounting plate, where the connecting plate and mounting plate are welded together, and the side walls are coined to provide integral fixation, enhancing rigidity and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the C pillar is divided into upper and lower members and joined by welding along the parting line, then the manufacturing complexity is reduced and assembly is facilitated, but the transverse rigidity and torsional rigidity of the pillar are insufficient
Solution Approach 1:
The invention applies curvature by forming the joining portions of the upper and lower members into arc shapes instead of straight lines. The arc-shaped joining portions allow the members to be joined along a curved path, which significantly improves the transverse rigidity and torsional rigidity of the pillar while maintaining the divided-member construction for manufacturing benefits
Solution Approach 2:
The invention transitions from a one-dimensional linear joining path to a two-dimensional arc-shaped joining path. By joining the upper and lower members along an arc shape rather than a straight line, the structural rigidity is enhanced while still maintaining the manufacturability benefits of divided members
2Ease of manufacture
If the C pillar is divided into upper and lower members, then the manufacturing flexibility is improved, but the alignment of joining portions becomes difficult and manufacturing variations cannot be absorbed
Solution Approach 1:
The invention changes the geometric parameters of the joining portions by forming them with arc shapes and appropriate dimensions. This allows for tolerance absorption and easier alignment during assembly, as the arc-shaped joining portions can accommodate manufacturing variations while maintaining proper alignment between upper and lower members
3Ease of manufacture
If the end portions of the C pillar and roof bow are formed flat for fixation, then the assembly is simplified, but bending easily appears and plate thickness needs to be increased leading to increased labor hours
Solution Approach 1:
The invention replaces flat end portions with arc-shaped joining portions. This curved geometry provides inherent resistance to bending forces while maintaining assembly simplicity, eliminating the need to increase plate thickness and reducing labor hours
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration increases the rigidity of the C pillar, facilitates easier alignment of the upper and lower members, and reduces manufacturing variations, resulting in a stronger and more rigid structure capable of handling forces from any direction while maintaining a compact size for efficient diecasting.
Implementation Method 1
the connecting plate and the mounting plate are welded to each other
Implementation Method 2
the first side walls and the second side walls or the first and second side walls and wall members attached to the first and second side walls, are coined to each other
Data Source
AI summary
An upper member of a pillar has a substantially U-shaped cross section, and includes first side walls extending substantially in a transverse direction of the vehicle at least at a lower portion, and a connecting plate at a lower end while keeping the U-shaped cross section. A lower member includes a mounting plate opposed to the connecting plate at a lower portion being lower than an upper end, and second side walls extending substantially in the transverse direction at both end portions of the mounting plate in a longitudinal direction of the vehicle. The connecting plate and the mounting plate are welded to each other in a state that they are in abutment with each other, and the first side walls and the second side walls are joined to each other, and the upper member and the lower member are integrally fixed to each other.