Connection structure of vehicle body

A connection structure of a vehicle body includes a roof side rail member extending in a longitudinal direction of the vehicle body, a roof rear cross member extending in a transverse direction of the vehicle body, and having an end coupled to the roof side rail member, a rear pillar member extending in a vertical direction of the vehicle body, and having an upper portion coupled to the roof side rail member and aligned with the end of the roof rear cross member, wherein the upper portion of the rear pillar member and the roof side rail member are coupled to each other by an insertion protrusion and an insertion groove, and a cover bracket covering a portion where the roof side rail member, the roof rear cross member, and the rear pillar member are connected to each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Korean Patent Application No. 10-2019-0162906, filed on Dec. 9, 2019, which application is hereby incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to a connection structure of a vehicle body.

BACKGROUND

In the case of a conventional monocoque-type vehicle body, multiple components are coupled to each other in a complex structure to construct a vehicle body. Shapes and coupling structures of the components are different for each vehicle model.

Therefore, in order to construct a vehicle body of one vehicle model, multiple molds are required for the manufacture of components for constructing the vehicle body. Furthermore, since the molds cannot be used in common to construct a vehicle body of another vehicle model, another group of molds should be manufactured.

As described above, in the case of manufacturing a vehicle body according to different assembly structures for each vehicle model and using a plurality of components, workability is decreased.

SUMMARY

The present disclosure relates generally to a connection structure of a vehicle body. Particular embodiments relate to a connection structure of an upper portion of a rear pillar (C pillar).

Accordingly, embodiments of the present disclosure provide a connection structure of a vehicle body, the connection structure being configured such that a component corresponding to a rear pillar (C pillar) of a vehicle may be easily assembled to a roof and a floor of the vehicle, and may be connected thereto with excellent strength and rigidity, when a modularized space frame vehicle body is constructed.

According to one embodiment of the present disclosure, there is provided a connection structure of a vehicle body. The connection structure includes a roof side rail member extending in a longitudinal direction of the vehicle body, a roof rear cross member extending in a transverse direction of the vehicle body, and having an end coupled to a rear end of the roof side rail member, a rear pillar member extending in a vertical direction of the vehicle body, and having an upper portion coupled to the rear end of the roof side rail member while being aligned with the end of the roof rear cross member, and a cover bracket covering a portion where the rear end of the roof side rail member, the end of the roof rear cross member, and the upper portion of the rear pillar member are connected to each other, the cover bracket to be integrated with the portion in a single body, wherein the rear end of the roof side rail member and the upper portion of the rear pillar member may be coupled to each other by being fastened in an inserting manner by an insertion protrusion and an insertion groove.

An upper end of the rear pillar member may be provided as a reinforcement part that may be bent along a longitudinal direction of the roof side rail member, and the reinforcement part and the rear end of the roof side rail member may be coupled to each other by being fastened in the inserting manner.

The rear end of the roof side rail member may be coupled with a protruding bracket that may protrude to face the rear pillar member, the insertion protrusion may be integrally provided with the protruding bracket, a groove bracket may be engaged with the reinforcement part to protrude to face the roof side rail member, and the groove bracket may be provided with the insertion groove, so that the insertion protrusion may be engaged with the insertion groove in the inserting manner.

The insertion protrusion and the insertion groove may be engaged with each other, as an upper end of the rear pillar member is moved in the transverse direction of the vehicle body toward the rear end of the roof side rail member, and the rear pillar member may be restricted from being moved in the vertical direction and the longitudinal direction of the vehicle body by the engagement between the insertion protrusion and the insertion groove.

The insertion protrusion may include a neck portion and a locking portion, the neck portion protruding from the protruding bracket toward the rear pillar member, and the locking portion being provided at an end of the neck portion and having a sectional width relatively larger than that of the neck portion. The insertion groove may have a depressed shape corresponding to outer lines of the neck portion and the locking portion of the insertion protrusion.

A plurality of insertion protrusions and a plurality of insertion grooves may be provided in an arrangement in which the insertion protrusions and the insertion grooves may be respectively spaced apart from each other in a front to rear direction that may be the longitudinal direction of the roof side rail member.

The cover bracket may include a first cover bracket provided at an inside of the vehicle body to integrally cover the rear end of the roof side rail member, the end of the roof rear cross member, and the upper portion of the rear pillar member, a second cover bracket provided at an outside of the vehicle body to integrally cover the rear end of the roof side rail member and the end of the roof rear cross member, and a third cover bracket provided at the outside of the vehicle body to integrally cover the rear end of the roof side rail member and the upper portion of the rear pillar member.

The second cover bracket and the third cover bracket may be coupled to each other without a gap remaining therebetween, as the second cover bracket and the third cover bracket are in contact with each other at the roof side rail member outside the vehicle body and are connected to each other in a flat surface-contact manner.

The first cover bracket and the third cover bracket may be disposed to be overlapped with each other, thus providing a flange part having a predetermined area. The flange part may be disposed at a portion between the rear end of the roof side rail member and the upper portion of the rear pillar member.

The flange part of the cover bracket may be provided to integrally cover the protruding bracket having the insertion protrusion and the groove bracket having the insertion groove, in addition to the reinforcement part of the rear pillar member.

According to an embodiment of the present disclosure, when a modularized space frame vehicle body is constructed, the upper portion of the rear pillar member corresponding to a rear pillar (C pillar) of a vehicle is coupled to the rear end of the roof side rail member in the inserting manner by the insertion protrusion and the insertion groove, so that the rear pillar member and the roof side rail member are connected to each other with an easy assembly process and with excellent strength and rigidity. Accordingly, the connection structure of embodiments of the present disclosure can secure stronger coupling force, strength, and rigidity, and be improved in durability.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Hereinbelow, a connection structure of a vehicle body according to an exemplary embodiment of the present disclosure will be described with reference to the accompanying drawings.

FIG. 1is a view showing a modularized space frame vehicle body. Referring toFIG. 1, a floor assembly109includes a front apron assembly101, a dash assembly103, a center floor assembly105, and a rear floor assembly107. An upper assembly119includes a side assembly11, a quarter assembly113, a back assembly115, and a roof carrier117. When the floor assembly109and the upper assembly119are assembled, a skin assembly127, including a fender121, a side-outer123, and a roof panel125, is coupled thereto to construct the space frame vehicle body.

For reference, the above description of the drawing inFIG. 1is only for easy understanding of the configuration of the space frame vehicle body mentioned in the present disclosure, and it does not represent an assembly order of compartments constituting an actual space frame vehicle body. The actual assembly order may vary depending on various situations.

The roof carrier117includes roof side tubes129, a cowl131, middle roof rails133, and a rear roof rail135that form a space frame structure. The roof side tubes129are at opposite sides of a vehicle, and the cowl131, the middle roof rails133, and the rear roof rail135, which are provided between the roof side tubes129to connect the roof side tubes129to each other, are formed in a hollow closed tube structure. As the roof side tubes129are expanded and contracted in a longitudinal direction of a vehicle body, and the cowl131, the middle roof rails133, and the rear roof rail135are expanded and contracted in a transverse direction of the vehicle body, the roof carrier117may be easily transformed and applied to various vehicle types and various vehicle models.

The front apron assembly101, the dash assembly103, the center floor assembly105, and the rear floor assembly107, which are modularized so as to form the floor assembly109, are assembled by varying lengths or widths thereof. Thus, the floor assembly109is easily transformed and applied to various vehicle types and various vehicle models.

As the roof carrier117and the floor assembly109are transformed, other components may be assembled by adjusting shapes or sizes thereof. Accordingly, it is easy to develop a vehicle body suitable for a new type or model of a vehicle, so that the development of the new vehicle type may be easy, and the vehicle body structure may be effectively applied to small quantity batch production.

Meanwhile, the skin assembly127including the fender121, the side-outer123, and the roof panel125may be made of various materials such as carbon fiber reinforced plastics (CFRP) as well as conventional steel plastics. Thus, each shape of the components may be freely transformed depending on vehicle types or vehicle models so as to be applied to the above-described space frame, and various vehicles may be easily manufactured.

The connection structure for a vehicle body may be configured to be applied to the space frame vehicle body that has the above-described configuration. As shown in the embodiment ofFIGS. 2 and 3, the connection structure for a vehicle body includes a roof side rail member10extending in a longitudinal direction of a vehicle body, a roof rear cross member20extending in a transverse direction of the vehicle body and having an end coupled to a rear end of the roof side rail member10, a rear pillar member30extending in a vertical direction of the vehicle body and having an upper portion coupled to the rear end of the roof side rail member10while being aligned with the end of the roof rear cross member20, and a cover bracket40formed in a plate, and covering a portion where the rear end of the roof side rail member10, the end of the roof rear cross member20, and the upper portion of the rear pillar member30are connected to each other, the cover bracket40to be integrated with the portion in a single body. The rear end of the roof side rail member10and the upper portion of the rear pillar member30are coupled to each other in an inserting manner by an insertion protrusion60and an insertion groove80.

That is, the roof side rail member10is interposed between the roof rear cross member20and the rear pillar member30, and the roof rear cross member20and the rear pillar member30are connected at right angles to the roof side rail member10, respectively. Further, the cover bracket40covers and reinforces the portion where the rear end of the roof side rail member10, the end of the roof rear cross member20, and the upper portion of the rear pillar member30are connected to each other, thereby constructing the connection structure of a vehicle body.

The roof side rail member10, the roof rear cross member20, and the rear pillar member30may all be formed as hollow tubes or pipes to construct the space frame structure.

InFIG. 1, the roof side rail member10may be a configuration corresponding to the roof side tubes129, and the roof rear cross member20may be a configuration corresponding to the rear roof rail135.

Further, the rear pillar member30may correspond to a component called a C pillar or a rear pillar of a general vehicle.

As shown inFIG. 1, the rear pillar member30may be aligned and connected to a portion at a rear end of the roof side tubes129, e.g., the portion to which the rear roof rail135is connected, and the cover bracket40may be coupled to the space frame structure to cover a connected portion where the above-mentioned three components are connected to each other.

In addition, the connection structure of a vehicle body may be used such that the rear pillar member30is coupled to an object such as the floor assembly109inFIG. 1.

That is, the connection structure may correspond to a structure in which a lower end of the rear pillar member30is coupled to a rear end of a side sill that is positioned at the side of the floor assembly109.

The floor assembly109as described above may be provided with a cross member that is different from the above-mentioned component and formed in the transverse direction of the vehicle body. Accordingly, by corresponding the cross member provided in the floor assembly109to the rear roof rail135provided in the roof carrier117inFIG. 1, the connection structure of a vehicle body inFIG. 2may be used as the same structure in which the rear pillar member30is coupled to the rear end of the side sill of the floor assembly109, while only a direction of the connection structure is changed up and down.

Practically, embodiments of the present disclosure are expressed with the concept including both when the rear pillar member30is coupled to the rear end of the roof side tubes129and when coupled to the rear end of the side sill of the floor assembly109, as described above. That is, the connection structure of a vehicle body of the present disclosure may be commonly used in structures in which the rear pillar member30formed in the vertical direction of the vehicle body is coupled to both an upper side and a lower side of the vehicle body.

According to an embodiment of the present disclosure, the roof rear cross member20is disposed in the transverse direction of the vehicle body perpendicular to the roof side rail member10. The end of the roof rear cross member20is connected to the roof side rail member10in a manner of being directly coupled to the rear end of the roof side rail member10.

Coupling between the roof rear cross member20and the roof side rail member10may be performed by welding, structural adhesives, or separate coupling members.

As the end of the roof rear cross member20and the rear end of the roof side rail member10are directly coupled to each other, a coupled portion between the roof rear cross member20and the roof side rail member10may provide sufficient strength and rigidity.

According to an embodiment of the present disclosure, the rear pillar member30is disposed at a right angle with respect to the roof side rail member10in the vertical direction of the vehicle body. The upper portion of the rear pillar member30may be coupled to the rear end of the roof side rail member10in a form in which the upper portion of the rear pillar member30is aligned with the end of the roof rear cross member20.

As described above, the rear end of the roof side rail member10and the end of the roof rear cross member20may be coupled to each other by welding, and the rear end of the roof side rail member10and the upper portion of the rear pillar member30may be coupled to each other by welding. However, in an embodiment of the present disclosure, coupling between the rear end of the roof side rail member10and the upper portion of the rear pillar member30is performed in an inserting manner by the insertion protrusion60and the insertion groove80rather than welding.

That is, as shown inFIGS. 2 to 5, an upper end of the rear pillar member30is bent along a longitudinal direction of the roof side rail member10to provide a reinforcement part31. The reinforcement part31and the rear end of the roof side rail member10are coupled to each other by being fastened in the inserting manner.

As the upper end of the rear pillar member30is bent in an L shape along the longitudinal direction of the roof side rail member10to form the reinforcement part31, a coupled portion between the upper portion of the rear pillar member30and the rear end of the roof side rail member10may provide sufficient strength and rigidity.

The coupling structure between the insertion protrusion60and the insertion groove80will be described in detail. A protruding bracket50is coupled to the rear end of the roof side rail member10to protrude toward the rear pillar member30, and the insertion protrusion60is integrally provided with the protruding bracket50. Further, a groove bracket70is coupled to the reinforcement part31of the rear pillar member30to protrude toward the roof side rail member10, and the insertion groove80is provided in the groove bracket70, so that the insertion protrusion60is inserted into the insertion groove80.

Of course, it is possible to apply a structure in which the insertion protrusion60and the insertion groove80are engaged with each other as a configuration opposite to the above-described embodiment of the present disclosure, when the protruding bracket50provided with the insertion protrusion60is provided at the upper end of the rear pillar member30, and the groove bracket70provided with the insertion groove80is provided at the rear end of the roof side rail member10.

The insertion protrusion60and the insertion groove80are engaged with each other in the insertion manner, as the upper end of the rear pillar member30is moved in the transverse direction of the vehicle body toward the rear end of the roof side rail member10. Further, the rear pillar member30is restricted from being moved in the vertical direction and the longitudinal direction of the vehicle body by the engagement between the insertion protrusion60and the insertion groove80.

The insertion protrusion60of an embodiment of the present disclosure includes a neck portion61protruding from the protruding bracket50toward the rear pillar member30, and a locking portion62being provided at an end of the neck portion61and having a sectional width relatively larger than that of the neck portion61.

The neck portion61has a shape in which two sections face each other while being overlapped, and has a relatively narrower sectional width than that of the locking portion62. The locking portion62has a rectangular sectional shape extending from the neck portion61, and has a relatively larger sectional width than that of the neck portion61.

The insertion groove80has a shape corresponding to outer lines of the neck portion61and the locking portion62, and is formed in a depressed shape on the groove bracket70.

Accordingly, in order to couple the upper portion of the rear pillar member30to the rear end of the roof side rail member10, the protruding bracket50is first coupled to a lower surface of the rear end of the roof side rail member10by using a coupling member91such as a bolt or a screw or structural adhesives. Next, the groove bracket70is coupled to an upper surface of the reinforcement part31of the rear pillar member30by using a coupling member92such as a bolt or a screw or structural adhesives. Then, when the groove bracket70of the rear pillar member30is moved in the transverse direction of the vehicle body toward the protruding bracket50of the roof side rail member10, the insertion protrusion60and the insertion groove80are engaged with each other in the inserting manner.

As described above, when the upper end of the rear pillar member30and the rear end of the roof side rail member10are coupled to each other by the insertion protrusion60and the insertion groove80, the rear pillar member30is brought into a restricted state in which the rear pillar member30cannot be moved in the vertical direction and the longitudinal direction of the vehicle body with respect to the roof side rail member10. In this state, the cover bracket40is used to cover a coupled portion between the insertion protrusion60and the insertion groove80, the portion including the reinforcement part31, and then welding is performed or structural adhesives or a coupling member such as a bolt or a screw is used in the coupled portion to fix the insertion protrusion60and the insertion groove80.

According to an embodiment of the present disclosure, a plurality of insertion protrusions60and a plurality of insertion grooves80are provided in an arrangement in which the insertion protrusions60and the insertion grooves80are respectively spaced apart from each other in a front to rear direction, that is, the longitudinal direction of the roof side rail member10. Thus, the roof side rail member10and the rear pillar member30may have a stronger coupling force, and may be improved in strength, rigidity, and durability.

The cover bracket40of an embodiment of the present disclosure includes a first cover bracket41provided at an inside of the vehicle body to integrally cover the rear end of the roof side rail member10, the end of the roof rear cross member20, and the upper portion of the rear pillar member30, a second cover bracket42provided at an outside of the vehicle body to integrally cover the rear end of the roof side rail member10and the end of the roof rear cross member20, and a third cover bracket43provided at the outside of the vehicle body to integrally cover the rear end of the roof side rail member10and the upper portion of the rear pillar member30.

That is, the first cover bracket41, the second cover bracket42, and the third cover bracket43provide support by covering connected portions between the rear end of the roof side rail member10, the end of the roof rear cross member20, and the upper portion of the rear pillar member30at all directions in a surface-contact manner. Thus, the connected portions may secure sufficient strength and rigidity.

An outer edge of the second cover bracket42and an outer edge of the third cover bracket43are in contact with each other at the roof side rail member10outside the vehicle body, and connected to each other in a flat surface-contact manner. The second cover bracket42and the third cover bracket43are coupled to each other without a gap remaining therebetween. Accordingly, the second cover bracket42and the third cover bracket43may have a stronger coupling force.

The first cover bracket41, the second cover bracket42, and the third cover bracket43that form the cover bracket40may be coupled to the connection structure by being fixed by welding, structural adhesives, or a coupling member such as a bolt or a screw, when the first cover bracket41, the second cover bracket42, and the third cover bracket43cover the connected portions where the end of the roof rear cross member20, the upper portion of the rear pillar member30, and the rear end of the roof side rail member10are coupled to each other.

The first cover bracket41and the third cover bracket43are disposed to be overlapped with each other, thus providing a flange part44that has a predetermined area. The flange part44is configured to be disposed at a portion between the rear end of the roof side rail member10and the upper portion of the rear pillar member30. Accordingly, the connected portion between the rear end of the roof side rail member10and the upper portion of the rear pillar member30may have improved strength and rigidity.

Further, the flange part44is provided to integrally cover the protruding bracket50provided with the insertion protrusion60and the groove bracket70provided with the insertion groove80, in addition to the reinforcement part31that is bent along the longitudinal direction of the roof side rail member10at the upper end of the rear pillar member30. Thus, the inserting portion between the rear pillar member30and the roof side rail member10may provide sufficient strength and rigidity.

The connection structure of a vehicle body of embodiments of the present disclosure as described above is configured such that the length of the rear pillar member30may easily vary and be coupled to the rear end of the roof side rail member10. Therefore, the connection structure of embodiments of the present disclosure may be easily applied to various structures of a vehicle body frame, as shown inFIGS. 6A-6C.

InFIGS. 6A-6C, various structures of a vehicle body frame are shown to be comparable to each other. In each structure of a vehicle body frame, circles A1and C1indicate joints provided to form each vehicle body frame. Among the circles, opposite ends of a component corresponding to the rear pillar member30of the present disclosure are indicated with solid circles C1, and the above-described connection structure of a vehicle body of the present disclosure may be applied to the solid circles C1.

That is, the connection structure of a vehicle body may be easily applied in common to the various vehicle types as shown inFIGS. 6A-6C, when the length variation of the rear pillar member30and the slight deformation are entailed. Accordingly, the development of new vehicle types may be carried out easily, and it is possible to provide technology infrastructure that may be effectively applied to small quantity batch production.

Hereinbefore, according to an embodiment of the present disclosure, in configuring a vehicle body structure of a modularized space frame type, the upper portion of the rear pillar member30that corresponds to a rear pillar (C pillar) of a vehicle is coupled to the rear end of the roof side rail member10in the inserting manner by the insertion protrusion60and the insertion groove80, so that the connection between the rear pillar member30and the roof side rail member10is performed with easy assembly performance and excellent strength and rigidity. Accordingly, the connection structure can secure stronger coupling force, strength, and rigidity, and be improved in durability.