Center pillar assembly with gusset for 3-door vehicle
Solution Overview
Problem
The center pillar assembly of 3-door vehicles faces challenges in reducing manufacturing costs while maintaining strength, particularly due to the need for additional reinforcement members and the limitations of using ultra-high strength steel with restricted formability, leading to increased costs and weakened strength in collision performance.
Innovation Solution
The center pillar assembly incorporates a gusset with a cross-section ' shape to connect the outer reinforcement member's upper and lower portions to the quarter glass flange, allowing for cold press-molding using ultra-high strength steel over 980 MPa, eliminating the need for additional reinforcement and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper portion of the outer reinforcement member is formed in a cross section of ''-shape to be welded to a quarter glass flange, then it can be connected to the quarter glass, but the strength of the 'Neck' part becomes weak and requires additional reinforcement members
Solution Approach 1:
The outer reinforcement member is divided into an upper portion and a lower portion with different cross-sectional shapes. The upper portion has a ''-shape for welding to the quarter glass flange, while the lower portion has a ''-shape for collision resistance. This segmentation allows each part to be optimized for its specific function without compromising the other.
2Weight of moving object
If ultra-high strength steel is used as material of the outer reinforcement member to accomplish light weight, then weight is reduced, but the section must be hardly changed and formability is restricted
Solution Approach 1:
The patent changes the geometric parameters of the cross-section, making both the upper and lower portions have the same ''-shape. This parameter change simplifies the manufacturing process for ultra-high strength steel while maintaining the required strength and collision performance, eliminating the need for complex section transitions.
3Strength
If the sections of upper portion and lower portion are changed steeply from ''-shape to ''-shape, then collision performance is improved, but it is difficult to press-mold ultra-high strength steel and manufacturing cost increases
Solution Approach 1:
The patent applies local quality by giving the upper portion a ''-shape specifically for connection to the quarter glass flange, while the lower portion has a ''-shape for collision resistance. Both portions maintain the same cross-sectional shape, eliminating steep transitions and making press-molding of ultra-high strength steel feasible while preserving local optimization for each function.
4Strength
If additional reinforcement member is welded to reinforce the 'Neck' part, then strength is improved, but manufacturing cost is increased
Solution Approach 1:
The patent merges the upper portion and lower portion into a single integrated outer reinforcement member with a continuous ''-shaped cross-section. This eliminates the need for additional reinforcement members by designing the basic structure to provide sufficient strength throughout, including the Neck part, thereby reducing manufacturing cost and structural complexity.
Data Source
AI summary
A center pillar assembly of a 3-door vehicle may include a side outer panel, one end portion of which is formed with a quarter glass flange, an outer reinforcement member for a center pillar for reinforcing the side outer panel, in which its upper portion and its lower portion are formed in a cross section of ‘’-shape, a gusset for connecting the upper portion of the outer reinforcement member with the quarter glass flange, wherein one lateral side portion of the outer reinforcement member is connected to the gusset, and a side inner panel being arranged in an inner part of the side outer panel, one lateral side portion thereof being connected to the one lateral side portion of the outer reinforcement member and the gusset.