Front pillar assemblies with front pillar lower reinforcement members having lower wrap reinforcement structures

A vehicle including a lower reinforcement assembly for a front pillar assembly includes a rocker outer reinforcement member that extends in a vehicle lengthwise direction and includes a vertically oriented face. An upper portion extends inwardly from the face in a vehicle widthwise direction and a lower portion extends inwardly from the face in the vehicle widthwise direction thereby defining a vehicle lengthwise extending cavity. A front pillar lower reinforcement member is connected to the rocker outer reinforcement member. The front pillar lower reinforcement member includes an upwardly extending pillar portion and a lengthwise extending rocker portion having a vertically oriented face that extends downwardly terminating at the face of the outer reinforcement member at a lower edge that extends in the vehicle lengthwise direction. The front pillar lower reinforcement member includes a lower wrap reinforcement structure that extends downwardly beyond the lower edge and inwardly in the vehicle widthwise direction over a corner of the rocker outer reinforcement member. The corner connects the face of the rocker outer reinforcement member and the lower portion of the rocker outer reinforcement member.

TECHNICAL FIELD

The present specification generally relates to front pillar assemblies in vehicles and, more particularly, to a front pillar assembly with a front pillar lower reinforcement member having a lower wrap reinforcement structure.

BACKGROUND

Vehicles typically use various frame structures, such as reinforcements, to provide vehicle stiffness. For example, front pillar assemblies can provide structural support for a roof of the vehicle as well as transfer a force from a frontal impact to other vehicle structures. Reinforcement structures may be used to reduce deformation of the vehicle. Which structures reduce deformation of the vehicle during an impact can depend on the type and direction of impact. For example, for a frontal impact, different vehicle structures may be implicated depending on the location and direction of the frontal impact. Two types of frontal offset impacts include a moderate overlap frontal crash and a small overlap frontal crash. While moderate overlap frontal crashes affect a relatively moderate number of vehicle reinforcement structures and collision mechanisms, small overlap frontal crashes affect outer edges of the vehicle.

SUMMARY

In one embodiment, a vehicle including a lower reinforcement assembly for a front pillar assembly includes a rocker outer reinforcement member that extends in a vehicle lengthwise direction and includes a vertically oriented face. An upper portion extends inwardly from the face in a vehicle widthwise direction and a lower portion extends inwardly from the face in the vehicle widthwise direction thereby defining a vehicle lengthwise extending cavity. A front pillar lower reinforcement member is connected to the rocker outer reinforcement member. The front pillar lower reinforcement member includes an upwardly extending pillar portion and a lengthwise extending rocker portion having a vertically oriented face that extends downwardly terminating at the face of the outer reinforcement member at a lower edge that extends in the vehicle lengthwise direction. The front pillar lower reinforcement member includes a lower wrap reinforcement structure that extends downwardly beyond the lower edge and inwardly in the vehicle widthwise direction over a corner of the rocker outer reinforcement member. The corner connects the face of the rocker outer reinforcement member and the lower portion of the rocker outer reinforcement member.

In another embodiment, a front pillar lower reinforcement member includes a pillar portion and a rocker portion having a face that terminates at a lower edge extending along a length of the rocker portion. A lower wrap reinforcement structure has a downwardly extending portion that is arranged and configured to extend outwardly beyond the lower edge along a face of a rocker outer reinforcement member and an inwardly extending portion that is arranged and configured to extend over a corner that connects the face of the rocker outer reinforcement member and an inwardly extending lower portion of the rocker outer reinforcement member.

In another embodiment, a lower reinforcement assembly for a front pillar assembly of a vehicle includes a rocker outer reinforcement member that extends in a vehicle lengthwise direction and includes a vertically oriented face. An upper portion extends inwardly from the face in a vehicle widthwise direction and a lower portion extends inwardly from the face in the vehicle widthwise direction thereby defining a vehicle lengthwise extending cavity. A front pillar lower reinforcement member includes an upwardly extending pillar portion and a lengthwise extending rocker portion having a face that terminates at a lower edge extending along a length of the rocker portion. A lower wrap reinforcement structure has a downwardly extending portion that extends downwardly beyond the lower edge along a face of the rocker outer reinforcement member and an inwardly extending portion that extends along the lower portion of the rocker outer reinforcement member at an angle to the downwardly extending portion.

DETAILED DESCRIPTION

Embodiments described herein generally relate to front pillar assemblies with a front pillar lower reinforcement members having lower wrap reinforcement structures. The front pillar lower reinforcement members include a pillar portion and a rocker portion. The pillar portion extends generally in an up and down direction and rocker portion extends generally in a vehicle lengthwise direction along a rocker assembly forming a somewhat L-shape. The front pillar lower reinforcement member includes a lower wrap reinforcement structure that extends downwardly along the rocker assembly and inwardly along the rocker assembly in a vehicle widthwise direction thereby wrapping at least a portion of the rocker assembly. The lower wrap reinforcement structure may be of limited extent along an entire length of the rocker reinforcement portion of the front pillar lower reinforcement member. While the driver's side structures may be discussed below, the passenger's side structures may include similar or the same body structures. Accordingly, the driver's side structure is discussed herein.

Referring toFIG. 1, a vehicle body10has a door opening12with a front edge of the door opening12being defined by a front pillar14(sometimes referred to as an A-pillar), a rearward edge of the door opening12being defined by a center pillar16(sometimes referred to as a B-pillar) and a lower edge of the door opening12being defined by a rocker assembly18. An upper edge of the door opening12may be defined by a roof side rail19. As used herein, the forward traveling direction of a vehicle may be referred to as “front,” the rearward travelling direction may be referred to as “rear,” the vertical upward direction may be referred to as “upper,” the vertical downward direction may be referred to as “lower” and directions along the width of the vehicle may be referred to “outward” and “inward.” A rear pillar20(sometimes referred to as a C-pillar) may also be provided to define another door opening22between the rear pillar20and the center pillar16. The vehicle body10may include more or less pillars than the illustrated front pillar14, center pillar16and rear pillar20, such as a D-pillar.

Generally, the front pillar14may include an outer panel assembly24and an inner panel assembly26. Similarly, the rocker assembly18may include an outer panel assembly28and an inner panel assembly30(see, for example,FIG. 4). The outer panel assembly24and inner panel assembly26of the front pillar14may be welded or otherwise joined together to form a somewhat enclosed structure. The outer panel assembly28and the inner panel assembly30may also be welded or otherwise joined to form a somewhat enclosed structure, as can be seen byFIG. 4. The vehicle body10includes a side body outer panel31that forms the general outer shape of the vertically extending front pillar14and lengthwise extending rocker assembly18. The vehicle body10may have an upper front pillar region32, a lower front pillar region34and a rocker assembly region36that is connected to the lower front pillar region34forming a somewhat L-shape. Because the lower front pillar region34and rocker assembly region36of the vehicle body10are primarily described below, components of other regions may be omitted for clarity.

Referring toFIG. 2, an exploded view of the lower front pillar region34and rocker assembly region36of the vehicle body10is illustrated. The rocker assembly region36includes a rocker inner reinforcement member40and a rocker outer reinforcement member42. The rocker inner reinforcement member40extends generally in the vehicle lengthwise direction and is sized to be received within the rocker outer reinforcement member42, which also extends generally in the vehicle lengthwise direction. The rocker inner reinforcement member40includes a generally vertically oriented face44, an upper portion46extending inwardly from the top of the face44in the vehicle widthwise direction and a lower portion48extending inwardly from the bottom of the face44in the vehicle widthwise direction, forming somewhat of a U-shape cross-section and a vehicle lengthwise extending cavity49. Similarly, the rocker outer reinforcement member42includes a generally vertically oriented face50, an upper portion52extending inwardly from the top of the face50in the vehicle widthwise direction and a lower portion54extending inwardly from the bottom of the face50in the vehicle widthwise direction, forming somewhat of a U-shape cross-section and a vehicle lengthwise extending cavity55. The rocker inner reinforcement member40may be connected to the rocker outer reinforcement member42in any suitable fashion, such as spot welding to join any one or more of their faces44and50, upper portions46and52and lower portions48and54. In some embodiments, the rocker inner reinforcement member40and rocker outer reinforcement member42may be connected together via connections with a front pillar inner lower member58, e.g., by spot welding, bolting, structural adhesive, etc. The rocker inner reinforcement member40, rocker outer reinforcement member42and front pillar inner lower reinforcement member58may be formed of the same or of different materials, such as aluminum and steel and formed by any suitable method, such as extrusion, drawing, stamping and/or machining.

The lower front pillar region34includes a front pillar lower reinforcement member60. The front pillar lower reinforcement member60includes a generally vertical or upwardly extending pillar portion62and a generally horizontal or lengthwise extending rocker portion64forming somewhat of an L-shape. The pillar portion62includes a generally vertically oriented face66, a front portion68extending inwardly from the face66in the vehicle widthwise direction and a rear portion70extending inwardly from the face66in the vehicle widthwise direction, forming somewhat of a U-shape cross-section. The rocker portion64includes a generally vertically oriented face74and an upper portion76extending inwardly from a top of the face74in the vehicle widthwise direction. In some embodiments, the front pillar lower reinforcement member60may be connected to the rocker outer reinforcement member42and side body outer panel31, e.g., by spot welding, bolting, structural adhesive, etc. The front pillar lower reinforcement member60may be formed of any suitable materials, such as aluminum and steel and formed by any suitable method, such as extrusion, drawing, stamping and/or machining.

Referring toFIG. 3, a lower reinforcement assembly100without the side body outer panel31includes the front pillar lower reinforcement member60and the rocker outer reinforcement member42connected together. Referring also toFIG. 4, the rocker inner reinforcement member40may be received within the rocker outer reinforcement member42. The front pillar lower reinforcement member60includes the upwardly extending pillar portion62and the lengthwise extending rocker portion64. The face74of the rocker portion64extends generally in the vehicle lengthwise and vertical direction downwardly to a lower edge104that extends a majority of a total length LTat the bottom of the rocker portion64measured from a front facing terminal end106to a rear facing terminal end108of the rocker portion64(FIG. 3).

A lower wrap reinforcement structure110extends downwardly beyond the lower edge104of the face74. The lower wrap reinforcement structure110can extend downwardly along the face50of the rocker outer reinforcement member42and over a corner112that connects the face50and inwardly extending lower portion54of the rocker outer reinforcement member42(FIG. 4). In this manner, the lower wrap reinforcement structure110may include a generally vertical or downwardly extending portion120and a generally widthwise or inwardly extending portion122extending at an angle α (e.g., between about 90 degrees and about 170 degrees) to the downwardly extending portion120. As can be seen byFIG. 4, the lower wrap reinforcement structure110extends or is wrapped around the corner112, also forming a corner130in the lower wrap reinforcement structure110. The inwardly extending portion122of the lower wrap reinforcement structure110terminates at an end134. The end134may be located between and spaced from the corner112and a lower flange132of the rocker outer reinforcement member42that extends generally downward from the inwardly extending portion122and connects to the front pillar inner lower reinforcement member58and one or more rocker inner panels136(e.g., by welds).

Referring again toFIG. 3, the lower wrap reinforcement structure110is of limited extent in the vehicle lengthwise direction along the total length LTof the rocker portion64. Without wishing to be bound by theory, during a front small overlap collision event, the side body outer panel31(FIG. 1) that forms the general outer shape of the front pillar14and rocker assembly18may tend to shear away from the rocker outer reinforcement member42at a location between the front pillar14and rocker assembly18, or with reference toFIG. 3, at a location between the pillar portion62and the rocker portion64or the front pillar reinforcement member60. In some embodiments, a length LRof the lower wrap reinforcement structure110measured between edges140and142of the lower wrap reinforcement structure110may be selected to extend from or near the front facing terminal end106, while wrapping around the rocker outer reinforcement member42, as described above. In some embodiments, the length LRof the lower wrap reinforcement structure110may be at least about 50 mm, such as at least about 75 mm, such as at least about 100 mm. In some embodiments, the length LRmay be no greater than about 200 mm, such as no greater than about 150 mm, such as between about 50 mm and 200 mm, such as between about 75 mm and 150 mm. In some embodiments, length LRmay be about 50 percent or less of length LT, such as between about 25 percent and about 50 percent.

The front pillar lower reinforcement member60may be connected directly to the rocker outer reinforcement member42using, at least in part, the lower wrap reinforcement structure110. Referring particularly toFIG. 4, in some embodiments, the downwardly extending portion120and/or the inwardly extending portion122of the lower wrap reinforcement structure110may be welded (e.g., spot welded) to the rocker outer reinforcement member42by welds146and148. In some embodiments, the length LRof the lower wrap reinforcement structure110may be selected to allow for multiple welds (e.g., two or more) to be provided in the downwardly extending portion120and the inwardly extending portion122, spaced-apart in the vehicle lengthwise direction, connecting the lower wrap reinforcement structure110to the rocker outer reinforcement member42, as shown byFIG. 3.

Referring toFIG. 5, another embodiment of a front pillar lower reinforcement member160includes a lower wrap reinforcement structure162having a forward located edge164that is spaced from a front facing terminal end166of the front pillar lower reinforcement member160. The lower wrap reinforcement structure162extends downwardly beyond a lower edge168of face170. The lower wrap reinforcement structure162can extend downwardly along the face50of the rocker outer reinforcement member42and over a corner112that connects the face50and inwardly extending lower portion54of the rocker outer reinforcement member42. The lower wrap reinforcement structure162may include a generally vertical or downwardly extending portion172and a generally widthwise or inwardly extending portion174extending at an angle α to the downwardly extending portion172. Further, the downwardly extending portion172and the inwardly extending portion174of the lower wrap reinforcement structure162may be welded (e.g., spot welded) to the rocker outer reinforcement member42by welds176and178. In some embodiments, multiple welds (e.g., two or more) may be provided in the downwardly extending portion172and the inwardly extending portion174, spaced-apart in the vehicle lengthwise direction, connecting the lower wrap reinforcement structure162to the rocker outer reinforcement member42.

The above-described front pillar assemblies include front pillar lower reinforcements having lower wrap reinforcement structures that can provide additional reinforcement and inhibit or reduce shearing of components of the front pillar assemblies, such as side body outer panels. The lower wrap reinforcement structures can be an integral part of the front pillar lower reinforcements and can include a downwardly extending portion and an inwardly extending portion that are welded directly to the rocker outer reinforcement member, for example, by spot welds. In some embodiments, the downwardly extending portion and the inwardly extending portion may be welded to the rocker outer reinforcement member at multiple locations that are spaced apart from each other in the vehicle lengthwise direction. Additionally, the lower wrap reinforcement structure may be of limited extent in the vehicle lengthwise direction along the total length of the rocker portion of the front pillar reinforcement member. For example, the lower wrap reinforcement member may extend no more than about 50 percent of the total length of the rocker portion.

Directional terms used herein—for example widthwise, lengthwise, vertical, up, down, right, left, front, back, top, bottom, upper, lower—are made only to supply directional context. For example, the terms “extending vertically” or “extending generally vertically” are not meant to exclude a vertically and horizontally extending component.