Patent Publication Number: US-2005116506-A1

Title: Vehicle modular body and method of assembly thereof

Description:
BACKGROUND OF THE INVENTION  
      The present disclosure relates generally to a modular body for a vehicle, and particularly to a modular body for a passenger vehicle.  
      The framing of an automobile body prior to painting is referred to as body-in-white framing and includes the fixturing and joining of large body panels, components or subassemblies. An exemplary auto body frame includes an underbody with side panels welded thereto, and a top panel welded to the side panels. The combination of underbody, side panels, and top panel, defines an engine compartment, a passenger compartment, and a storage compartment. With the size of some vehicles being large, so too are the panels, which requires the use of large and multiple fixturing tools.  
      In an effort to assist with material handling and reducing tooling and fixturing costs, modular assemblies for the manufacturing of automobiles have been devised, which have included a separation between the passenger compartment and the engine compartment, and a separation between the passenger compartment and the storage compartment. However, such efforts may still result in the handling of large side panels. Accordingly, there is a need in the art for a vehicle modular body that overcomes these drawbacks.  
     SUMMARY OF THE INVENTION  
      A modular body for a vehicle includes a first module having a first B-pillar interface and a second module having a second B-pillar interface. The first and second modules are joined at the first and second B-pillar interfaces defining a B-pillar thereat.  
      A modular body for a vehicle includes a first module defining a first passenger compartment and having a first B-pillar interface, and a second module defining a second passenger compartment and having a second B-pillar interface. The first B-pillar interface is disposed proximate the second B-pillar interface defining a B-pillar thereat.  
      A method for assembling a vehicle body is disclosed. A first module having a first B-pillar interface is engaged with a second module having a second B-pillar interface such that the first and second B-pillar interfaces are disposed proximate each other. The first module defines a first passenger compartment and the second module defines a second passenger compartment. The first and second B-pillar interfaces are joined together defining a B-pillar thereat. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Referring to the exemplary drawings wherein like elements are numbered alike in the accompanying Figures:  
       FIG. 1  depicts an exemplary embodiment of a modular body for a vehicle in accordance with an embodiment of the invention;  
       FIG. 2  depicts the modular body embodiment of  FIG. 1  with the modular body components joined;  
       FIG. 3  depicts a side view of a block drawing representation of the modular body of  FIGS. 1 and 2 ;  
       FIG. 4  depicts a side view of a block drawing representation of an alternative modular body in accordance with an embodiment of the invention;  
       FIGS. 5-8  depict alternative modular body arrangements for a vehicle in accordance with an embodiment of the invention; and  
       FIGS. 9-11  depict alternative arrangements for implementing an embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      An embodiment of the invention provides a modular body for a vehicle that is segmented at the B-pillar. As used herein, the term B-pillar refers to a structural element that defines a separation between a first passenger compartment and a second passenger compartment, the term A-pillar refers to a structural element that defines a separation between an engine compartment and the first passenger compartment, and the term C-pillar refers to a structural element that defines a separation between the second passenger compartment and a storage compartment. In an exemplary embodiment, the first passenger compartment provides an environment for a front seat driver and/or passenger and the second passenger compartment provides an environment for a back seat passenger. While the embodiment described herein depicts an automobile as an exemplary vehicle, it will be appreciated that the disclosed invention is also applicable to other vehicles, such as a limousine, a sport utility vehicle, and a truck, for example.  
       FIG. 1  is an exemplary embodiment of a modular body  100  for a vehicle having a first module  105  with a first B-pillar interface  110 , and a second module  115  with a second B-pillar interface  120 . First module  105 , defining a first passenger compartment; includes two side portions  125 ,  130 , an underbody portion  135 , and optionally a top portion  140 . Second module  115 , defining a second passenger compartment, includes two side portions  145 ,  150 , an underbody portion  155 , and optionally a top portion  160 . Top portions  140 ,  160  may be absent in a vehicle configured as a convertible. First and second modules  105 ,  115 , fabricated and welded to form structural modules, are joined at B-pillar interfaces  110 ,  120  defining a B-pillar  200  thereat, best seen by referring to  FIG. 2 . In an embodiment, first B-pillar interface  110  is outboard of second B-pillar interface  120 , however, in an alternative embodiment the opposite arrangement of inboard/outboard interfaces may be employed.  
      In an embodiment, first and second B-pillar interfaces  110 ,  120  are slidably engaged with each other via interlocking rails  165 , which may include channels and tabs for example. Once slidably engaged, as depicted in  FIG. 2 , B-pillar interfaces  110 ,  120  may be joined together by mechanical, adhesive, adhesive-mechanical, metallurgical, or adhesive-metallurgical bonding. In an embodiment, B-pillar interfaces  110 ,  120  are welded together.  
      Referring to  FIG. 3 , a side view of a block drawing representation of the modular body  100  of FIGS. I and  2  is depicted, which in an embodiment may be representative of a four-door automobile. Here, modular body  100  includes first and second modules  105 ,  115  having first and second B-pillar interfaces  110 ,  120  similar to  FIGS. 1 and 2 , a third module  170  defining an engine compartment, and a fourth module  175  defining a storage compartment. Included in first module  105  is a first A-pillar interface  180 , included in third module  170  is a second A-pillar interface  185 , included in second module  115  is a first C-pillar interface  190 , and included in fourth module  175  is a second C-pillar interface  195 . In the assembled state, first and third modules  105 ,  170  are joined at A-pillar interfaces  180 ,  185  defining an A-pillar  205  thereat, and second and fourth modules  115 ,  175  are joined at C-pillar interfaces  190 ,  195  defining a C-pillar  210  thereat. Similar to B-pillar  200 , A-pillar interfaces  180 ,  185  and C-pillar interfaces  190 ,  195  may be slidably engaged with each other and then welded together.  
      Referring to  FIG. 4 , a side view of a block drawing representation of an alternative modular body  101  is depicted, which in an embodiment may be representative of a limousine-type automobile. Here, modular body  101  includes a first module  106  (similar to first module  105  of  FIG. 3 ), a second module  107 , a third module  116  (similar to second module  115  of  FIG. 3 ), a fourth module  171  (similar to third module  170  of  FIG. 3 ), and a fifth module  176  (similar to fourth module  175  of  FIG. 3 ). First, second and third modules  106 ,  107 ,  116  define passenger compartments, with passenger compartments defined by modules  107 ,  116  optionally being configured as one large passenger compartment. First and fourth modules  106 ,  171  include A-pillar interfaces  180 ,  185 ; first and second modules  106 ,  107  include B-pillar interfaces  110 ,  220 ; second and third modules  107 ,  116  include B-pillar interfaces  225 ,  120 ; and, third and fifth modules  116 ,  176  include C-pillar interfaces  190 ,  195 . In the assembled and joined state, A-pillar interfaces  180 ,  185  define an A-pillar  205  thereat, C-pillar interfaces  190 ,  195  define a C-pillar  210  thereat, B-pillar interfaces  110 ,  220  define a first B-pillar  201  thereat, and B-pillar interfaces  225 ,  120  define a second B-pillar  202  thereat. Since first and second B-pillars  201 ,  202  segment passenger compartments defined by first, second and third modules  106 ,  107 ,  116 , they are referred to as B-pillars, as discussed previously.  
      In viewing  FIGS. 3 and 4 , it will be appreciated that the number of B-pillars  200 ,  201 ,  202 , is not limited to one or two, but may be any number suitable for the purpose of providing a modular body for a vehicle with reduced module size.  
      Referring to  FIG. 5 , a modular body  100  for a vehicle is depicted having a first module  105  defining a passenger compartment, a second module  115  defining another passenger compartment, and a fourth module  175  defining a storage compartment. In the assembled state, the underbody portions  135 ,  155 ,  235  of first, second and fourth modules  105 ,  115 ,  175 , respectively become one underbody when welds are applied there between. In an embodiment, third module  170  defining an engine compartment becomes a portion of the finished modular body. In an alternative embodiment, third module  170  may be assembled to a chassis  230  along with assembly of other modules to the chassis. As used herein, the term “chassis” refers to that structure of the vehicle that includes the frame, powertrain and suspension components, for example, which is depicted generally by numeral  230 .  
      Alternative embodiments of modular body  100  are depicted in  FIGS. 6-8 . While  FIGS. 5-8  depict A-pillar  205 , B-pillar  200  and C-pillar  210  as segmented regions, it will be appreciated that interfaces for A-pillar  205 , B-pillar  200  and C-pillar  210  may be applied in accordance with the earlier discussion relating to A-pillar interfaces  180 ,  185 , B-pillar interfaces  110 ,  120 , and C-pillar interfaces  190 ,  195 . For example, second and fourth modules  115 ,  175  may be slidably engaged with each other at C-pillar  210  via C-pillar interfaces  190 ,  195 , and then welded together.  
       FIGS. 6-8  are representative of alternative modular body arrangements  100 , such as a sedan automobile depicted in  FIG. 6 , a sport utility vehicle depicted in  FIG. 7 , and a truck depicted in  FIG. 8 .  
      In an exemplary assembly process, first module  105  is slidably engaged with second module  115  at B-pillar  200 , third module  170  is slidably engaged with first module at A-pillar, fourth module  175  is slidably engaged with second module  115  at C-pillar, and then the entire assembly is placed on chassis  230 . In view of the earlier discussion relating to alternative modular body arrangements, it will be appreciated that variations on the assembly process may be employed. During or upon completion of the assembly of modules  105 ,  115 ,  170  and  175  onto chassis  230 , attachment would be applied at strategic points for maintaining dimensional stability and for providing additional structural integrity.  
      While the respective mating parts of the pillar interfaces are disclosed as being slidably engaged with each other, it will be appreciated that the slidable engagement may be replaced with any suitable joining arrangement, such as an overlapping and welded interface arrangement, or a pipe-fitting arrangement, for example.  
      Referring now to  FIGS. 9-11 , alternative B-pillar structures are depicted, where  FIG. 10  is a cross section view through the B-pillar  200  of  FIG. 9 . In  FIGS. 9 and 10 , B-pillar  200  includes a bonding area  235  formed by shaped channels  240 ,  245 , and in  FIG. 11 , B-pillar  200  includes ports  250  for receiving projections  255 . Ports  250  and projections  255  may be arranged as a tube-to-tube fit, a sheet-to-sheet fit, a tube-to-sheet fit, or any other arrangement suitable for the purpose of joining two B-pillar sections. Any of the bonding techniques discussed previously may be employed for securing the mating portions of B-pillar  200 .As discussed earlier, the various modules ( 105 ,  115 ,  170  and  175  for example) include underbody, top, and side portions,  135 ,  140 ,  145  and  150 , which in an embodiment are pre-assembled into modules at the same or a different assembly facility. By modularizing the vehicle body, less floor space may be needed for assembling each module, smaller crating may be needed for transporting each module, and a higher packing density may be achievable in transporting the body modules. Also, by utilizing modules during the framing stage (that is, during the final assembly of the body modules to each other and to the chassis), fewer movable parts may need to be held in place via clamps, thereby providing easier access for installing or mounting additional components, and improving the dimensional accuracy between mating modules. While an embodiment of the invention has been disclosed for a vehicle having an engine compartment at the front of the vehicle, it will be appreciated that the scope of the invention is not so limited, and that a vehicle having a rear-engine or a mid-engine arrangement also falls within the scope of the invention.  
      As disclosed, some embodiments of the invention may include some of the following advantages: reduced tolerance stack up arising from part fabrication or assembled parts; improved dimensional accuracy at the subassembly (modules) and final assembly (framing) levels; improved dimensional accuracy at the full vehicle level; less required floor space at the subassembly level; higher packing density during transportation of the body modules; versatility in using standard body modules in multiple vehicle designs; smaller tooling and fixturing during the assembly and framing processes; lower cost tooling at the framing station; reduced number of different parts required to build the body-in-white; and, ability to build the body-in-white for a vehicle having versatile style and function.  
      While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.