Extruded B-pillar reinforcement weight reduction
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Solution Overview
Problem
The existing B-pillar structure in vehicles is limited in weight reduction due to the single thickness doubler required for meeting roof strength and side impact collision requirements, which adds unnecessary weight.
Innovation Solution
A vehicle pillar design incorporating an outer panel, an inner panel, and a reinforcement with closed cells and flanges, where the reinforcement extends from the inner panel to the striker attachment area on the outer panel, allowing for weight reduction while maintaining structural integrity through the use of extruded aluminum components and strategic fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single thickness doubler is used in the B-pillar, then the roof strength and side impact collision requirements are met, but the vehicle weight increases
Solution Approach 1:
The doubler is divided into multiple thickness sections along its length. The first section has a first thickness, the second section has a second thickness greater than the first, and the third section has a third thickness greater than the second. This segmentation allows the doubler to provide enhanced strength at critical locations (upper portion for roof strength, lower portion for side impact) while reducing material usage and weight in less critical areas.
Solution Approach 2:
Different sections of the doubler have different thicknesses tailored to local structural requirements. The upper portion (first section) has thinner material optimized for roof strength, while the lower portion (third section) has thicker material optimized for side impact resistance. This local quality variation ensures optimal strength-to-weight ratio throughout the B-pillar structure.
2Strength
If the doubler thickness is increased to meet strength requirements, then the load bearing capacity improves, but the weight reduction potential is limited
Solution Approach 1:
The doubler is segmented into three distinct thickness sections, allowing load bearing capacity to be optimized at each location rather than uniformly throughout. The progressive thickness increase from first to third section matches the varying load requirements along the B-pillar height.
Solution Approach 2:
Each section of the doubler is locally optimized for its specific functional requirements. The third section at the lower portion has maximum thickness for side impact load bearing, while the first section at the upper portion has reduced thickness where full load bearing capacity is less critical, achieving optimal weight-strength balance.
Data Source
AI summary
A pillar for a vehicle is disclosed that includes an outer panel, an inner panel, and an extruded reinforcement attached between the inner and outer panels. The reinforcement extends from an upper end of the inner panel to a striker attachment area on the outer panel. A lower end of the reinforcement is trimmed to be spaced from the inner panel. The inner panel may be full height of the pillar or may extend from the rocker to the striker area where the inner panel overlaps the reinforcement. The reinforcement above the striker area may function as the inner panel above the striker area. A method is disclosed for making a B-pillar for a vehicle.