Patent Description:
Vehicle body structures of vehicles are constantly being tested for responses to various types impact events. <CIT> discloses the preamble of independent claims <NUM>, <NUM> and <NUM>.

One object of the present disclosure is to attached a bracket to a side roof rail, a B-pillar and a roof bow with attachments between the bracket and the roof bow being more numerous and stronger than attachments between the side roof rail and the bracket such that the bracket collapses in an area adjacent to the side roof rail in response to side impact events.

In view of the state of the known technology, one aspect of the present disclosure is to provide a vehicle body structure with a side roof rail, a B-pillar and a bracket. The side roof rail has an inboard surface extending in a vehicle longitudinal direction. The B-pillar has an upper end portion that overlays a portion of the inboard surface of the roof rail, the B-pillar extending downward from the roof rail. The bracket has a first portion and a second portion. The first portion is fixedly attached to the upper end portion of the B-pillar. The bracket further has a first rib and a second rib spaced apart from the first rib. The first rib and the second rib extend from the first portion of the bracket upward toward the second portion of the bracket. The first portion of the bracket further defines a slot located between the first rib and the second rib.

Referring now to the attached drawings which form a part of this original disclosure:.

Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to <FIG>, a vehicle <NUM> having a vehicle body structure <NUM> is illustrated in accordance with a first embodiment.

The vehicle <NUM> includes many conventional features, such as suspension, steering, powertrain, electronic and passenger compartment components. Since these features and components are conventional features, further description is omitted for the sake of brevity.

As shown in <FIG>, a plurality of differing directions is defined relative to the vehicle <NUM>. Those directions include: a vehicle longitudinal direction DL; a vehicle inboard direction DI; and a vehicle outboard direction Do. The vehicle inboard direction DI and the vehicle outboard direction Do are defined relative to an imaginary center line of the vehicle <NUM>, where the imaginary center line extends in the vehicle longitudinal direction DL of the vehicle <NUM>. Reference to inboard and outboard directions, inboard facing surfaces and outboard facing surfaces in the following description are with respect to the above listed vehicle defined directions.

As shown in <FIG>, <FIG>, the vehicle body structure <NUM> of the vehicle <NUM> includes many structural elements, many of them welded to one another. The various structural elements of the vehicle body structure <NUM> define A-pillars <NUM>, B-pillars <NUM>, C-pillars <NUM> and a roof structure <NUM>. It should be understood from the drawings and the description herein that the A-pillars <NUM> include a plurality of metallic panels that are welded or otherwise fixed to one another to define each of the A-pillars <NUM>. Similarly, the B-pillars <NUM> and the C-pillars <NUM> each include a plurality of metallic panels that are welded or otherwise fixed to one another to define each of the B-pillars <NUM> and the C-pillars <NUM>. As well, the roof structure <NUM> further includes a plurality of panels welded or otherwise fixed together to define the roof structure <NUM>.

The features of the vehicle body structure <NUM> described herein below are located at intersecting areas <NUM> of the B-pillars <NUM> and the roof structure <NUM>. These features are configured to provide predetermined levels of strength and rigidity, and, provide predetermined characteristics in response to an impact event were impact to the vehicle <NUM> is located proximate one of the B-pillars <NUM>, as described in greater detail below. There are two such intersecting areas <NUM> of the vehicle body structure <NUM>, as shown in <FIG>. The structures within the intersecting areas <NUM> are identical to one another, except that they are symmetrical mirror images of one another, being on opposite sides of the vehicle <NUM>. Description of one of the intersecting areas <NUM> applies equally to the structures within each of the intersecting areas <NUM>. Therefore, description of the structures within only one of the intersecting areas <NUM> is provided below for the sake of brevity.

<FIG> show those elements of the vehicle body structure <NUM> within the intersecting area <NUM>. These elements include an inboard panel <NUM> of the B-pillar <NUM>, a side roof rail <NUM> of the roof structure <NUM>, a roof bow <NUM> of the roof structure <NUM> and a bracket <NUM> that is attached to the side roof rail <NUM>, the B-pillar <NUM> and the roof bow <NUM>, as is described in greater detail below.

It should be understood from the drawings and the description herein that the B-pillar <NUM> is constructed from a plurality of differing panels welded together in a conventional manner. For purposes of understanding the structures within the intersecting areas <NUM>, only the inboard panel <NUM> is described hereinbelow for the sake of brevity. Similarly, the roof structure <NUM> includes a plurality of differing conventional panels and structural elements that are connected to one another by, for example, welding techniques and/or mechanical fasteners. However, for purposes of understanding the structures within the intersecting areas <NUM>, only the side roof rail <NUM> and the roof bow <NUM> of the roof structure <NUM> are described hereinbelow for the sake of brevity.

As shown in <FIG> and <FIG>, the side roof rail <NUM> of the roof structure <NUM> has an inboard surface <NUM> that extends in the vehicle longitudinal direction DL. As viewed from within the passenger compartment of the vehicle body structure <NUM>, the inboard surface <NUM> is slightly concaved and is inclined relative to vertical such that a lower edge of the inboard surface <NUM> is located outboard of an upper edge of the inboard surface <NUM>. The lower edge of the side roof rail <NUM> includes a pair of protrusions 34a and 34b. As shown in <FIG>, when the inboard panel <NUM> of the B-pillar <NUM> is attached to the side roof rail <NUM>. the inboard panel <NUM> is located between the protrusions 34a and 34b.

The inboard panel <NUM> of the B-pillar <NUM> has an upper end <NUM> that is shaped and dimensioned to fit between the protrusions 34a and 34b and overlay a portion of the inboard surface <NUM> of the side roof rail <NUM>. The upper end <NUM> of the inboard panel <NUM> of the B-pillar <NUM> is welded to the side roof rail <NUM> in a conventional manner. As shown in <FIG>, the B-pillar <NUM> extends downward from the side roof rail <NUM>. The upper end <NUM> of the inboard panel <NUM> can be provided with a distal portion 36a that is angularly offset from the remainder of the upper end <NUM> to cover and contact the lower edge of the side roof rail <NUM>. The distal portion 36a is welded to the side roof rail <NUM>. As described below, the bracket <NUM> is connected to the distal portion 36a via welds.

A description of the bracket <NUM> is now provided with initial reference to <FIG>. The bracket <NUM> has a first portion <NUM>, a central portion <NUM> and a second portion <NUM>. The first portion <NUM> includes a first rib <NUM> and a second rib <NUM> spaced apart from the first rib <NUM>. The first rib <NUM> and the second rib <NUM> extend from and along the first portion <NUM> of the bracket <NUM> upward toward the second portion <NUM> of the bracket <NUM>. The first portion <NUM> of the bracket <NUM> further defines an opening or slot <NUM> located between the first rib <NUM> and the second rib <NUM>. The slot <NUM> of the first portion <NUM> of the bracket <NUM> is dimensioned to provide a predetermined rigidity to the bracket <NUM> in response to side impacting forces acting on a lateral side of the vehicle <NUM>, proximate the B-pillar <NUM>. Changes to the overall size of the slot <NUM> attenuates the overall strength of the first portion <NUM> and the central portion <NUM>.

The first portion <NUM> is fixedly attached to the upper end <NUM> (upper end portion) of the B-pillar <NUM> as shown in <FIG>, <FIG> and <FIG>. In the depicted embodiment, a lower section 40a of the first portion <NUM> overlays and is fixedly attached to the distal portion 36a of the upper end <NUM> of the B-pillar <NUM> via four welds W, as shown in <FIG>. As shown in <FIG>, <FIG> and <FIG>, the bracket <NUM> has an overall arcuate or curved shape such that the first portion <NUM> and the second portion <NUM> of the bracket <NUM> are angularly offset from one another.

The central portion <NUM> of the bracket <NUM> overlays the inboard surface <NUM> of the side roof rail <NUM> but has limited connection thereto. The central portion <NUM> includes first bends 41a (bent or curved sections of the central portion <NUM>) and second bends 41b. One of the first bends 41a and one of the second bends 41b are located on a forward portion of the bracket <NUM> adjacent to the first rib <NUM>. The others of the first bends 41a and the second bends 41b are located on a rearward portion of the bracket <NUM> adjacent to the second rib <NUM>.

As shown in <FIG>, surfaces of the central portion <NUM> that define each of the first bends 41a are angularly offset from one another by an obtuse angle that is approximately <NUM> degrees (plus or minus <NUM> degrees). The surfaces of the central portion <NUM> at the second bends 41b are also angularly off set from one another by an obtuse angle that is approximately <NUM> degrees (plus or minus <NUM> degrees).

The central portion <NUM> is welded to the inboard surface <NUM> of the side roof rail <NUM> via a single weld W located adjacent a rearward edge of the central portion <NUM> and the second rib <NUM> below the first and second bent sections 41a and 41b, as shown in <FIG>. The purpose of the first bends 41a and the second bends 41b is described below.

The second portion <NUM> of the bracket <NUM> extends inboard of the side roof rail <NUM> and has two ribs, a third rib <NUM> and a fourth rib <NUM>. The third rib <NUM> and the fourth rib <NUM> extend in an outboard direction from a distal end of the second portion <NUM>,.

The first rib <NUM> includes a first opening <NUM> and the second rib <NUM> includes a second fastener opening <NUM> that are dimensioned to receive fasteners F<NUM>, as described in greater detail below. The first rib <NUM> also includes a smaller opening 56a that receives an alignment pin P<NUM> (<FIG>), as is also described further below.

A description of the roof bow <NUM> of the roof structure <NUM> is now provided with reference to <FIG>, <FIG> and <FIG>. The roof bow <NUM> is a structural element of the roof structure <NUM>. The roof bow <NUM> extends in a vehicle lateral direction (side to side direction) perpendicular to the vehicle longitudinal direction DL. There are a plurality of the roof bows <NUM> within the roof structure <NUM> of the vehicle body structure <NUM>. However, only the roof bow <NUM> that extends from one of the B-pillars <NUM> to the other of the B-pillars <NUM> is described herein.

As shown in <FIG>, <FIG>and <FIG>, the roof bow <NUM> is an elongated member extending from one lateral side of the vehicle <NUM> to the other lateral side of the vehicle supporting a roof panel or roof panels of the roof structure <NUM>. The roof bow <NUM> is formed with a pair of ribs <NUM> and <NUM>. The ribs <NUM> and <NUM> extend the entire length of the roof bow <NUM> but are wider at outboard ends of the roof bow <NUM>, as shown in <FIG>. The rib <NUM> includes an opening 60a and threaded nut N. The nut N can be welded to the rib <NUM> above and axially aligned with the opening 60a. Similarly, the rib <NUM> includes an opening 62a and threaded nut N. The nut N can be welded to the rib <NUM> above and axially aligned with the opening 62a. The rib <NUM> also defines an alignment opening 60b. As shown in <FIG>, an alignment pin P<NUM> is force fitted into the opening 56a of the third rib <NUM> of the second portion <NUM> of the bracket <NUM>. When the roof bow <NUM> is installed to the bracket <NUM>, the alignment pin P<NUM> extends through the opening 60b making it easier to align the fasteners F<NUM> with the nuts N and thread the fasteners F<NUM> into the nuts N. along with the fasteners F1, the outer side flanges of the roof bow <NUM> are welded via welds W to outer side flanges of the bracket <NUM>, as shown in <FIG>. Thus, the fasteners F<NUM> and the two welds W attach the roof bow <NUM> to the bracket <NUM>. The fasteners F<NUM> are located outboard of the welds W. In other words, the fasteners F<NUM> and the welds W are not required to be aligned with one another, but, in an alternative embodiment can be in line with one another. In the depicted embodiment, the welds W are offset from the fasteners F<NUM> in the inboard/outboard directions, as shown in <FIG>. Specifically, the fasteners F<NUM> are located inboard of the welds W.

When the roof bow <NUM> is installed to the bracket <NUM>, the rib <NUM> overlays a portion of the upper surface of the third rib <NUM> of the second portion <NUM> of the bracket <NUM>. Similarly, the rib <NUM> overlays a portion of the upper surface of the fourth rib <NUM> of the second portion <NUM> of the bracket <NUM>. As shown in <FIG>, the width of the rib <NUM> at the nut N is a distance D<NUM>. The width of the rib <NUM> is identically dimensioned at the nut N, as shown in <FIG>. The width of the rib <NUM> at the nut N (and fastener F<NUM>) is a distance D<NUM>, as shown in <FIG>. The width of the rib <NUM> at the nut N is also the distance D<NUM>. Consequently, at the fastener F<NUM> and the nut N, the rib <NUM> and rib <NUM> (as well as the rib <NUM> and rib <NUM>) only mate along horizontal surfaces. The upwardly extending surfaces of the rib <NUM> are spaced apart from adjacent upwardly extending surfaces of the rib <NUM>. Similarly, the upwardly extending surfaces of the rib <NUM> are spaced apart from adjacent upwardly extending surfaces of the rib <NUM>.

Hence, the ribs <NUM> and <NUM> of the roof bow <NUM> overlay but do not mate with the ribs <NUM> and <NUM> of second portion <NUM> of the bracket <NUM>.

As is also shown in <FIG>, there are four welds W that fix the lower section 40a of the bracket <NUM> to the distal portion 36a of the upper end <NUM> of the B-pillar <NUM>. There is only one weld W along a side flange of the first portion <NUM> (adjacent to the second rib <NUM>) that fixes the bracket <NUM> to the roof side rail <NUM>. More specifically, the attachment between the bracket <NUM> and the B-pillar <NUM> is significantly stronger than the attachment between the bracket <NUM> and the roof side rail <NUM>. Further, the attachment between the upper section 40b of the bracket <NUM> and the roof rail <NUM> includes the two fasteners F1 and the two welds W. Hence, the attachment between the bracket <NUM> and the roof rail <NUM> is significantly stronger than the attachment between the bracket <NUM> and the roof side rail <NUM>. These differing strengths between the attachment locations of the bracket <NUM> to each of the B-pillar <NUM>, the side roof rail <NUM> and the roof bow <NUM> provides attenuates absorption of impact force by the bracket <NUM> during a side impact event where impact energy is applied to the side of the vehicle <NUM> proximate or in alignment with the B-pillar <NUM>.

Specifically, as shown <FIG>, during a side impact event where impact forces are applied to one of the B-pillars <NUM>, the impact force are at least partially transmitted through the B-pillar <NUM> and to the inboard panel <NUM> of the B-pillar <NUM>. Some of the transmitted impact forces is further transmitted to the bracket <NUM>. In response to the impact forces, the roof bow <NUM> receives a portion of the impact forces. Since the bracket <NUM> is only attached to the side roof rail <NUM> by a single weld W, the attachment bond between the bracket <NUM> and the side roof rail <NUM> has only a small degree of resistance to shear forces, as compared to the multiple welds between the inboard panel <NUM> and the side roof rail <NUM> and the lower section 40a of the bracket <NUM>. Further, the attachment bond between the upper section 40b of the bracket <NUM> and the roof bow <NUM> is significantly stronger that the single weld between the bracket <NUM> and the side roof rail <NUM>. As a result of these differing attachment strengths, the presence of the slot <NUM> and the first and second bends 41a and 41b of the bracket <NUM>, the bracket <NUM> can collapse along the first and second bends 41a and 41b bending in an accordion-like movement, as shown in <FIG>. Further, as indicated by the arrow representing horizontal impact forces Fs<NUM> and the arrow representing upwardly directed impact forces FU1, the horizontal impact forces FS1 include a majority the arrow representing upwardly directed impact forces FU1,.

There are advantages to this arrangement. The amount of overall deformation of the vehicle body structure <NUM> can be minimized and be confined to the intersecting area <NUM> in response to most side impact events. Such an arrangement can limit or minimize, and possibly eliminate any deformation to, for example, the roof structure <NUM>.

<FIG> shows an intersecting area of a vehicle that includes a side roof rail <NUM> and a bracket <NUM> where the bracket <NUM> is welded to the side roof rail <NUM> at a plurality of location making the bond strength of the attachment between the side roof bracket <NUM> and the bracket <NUM> significantly stronger than in the arrangement described above with reference to <FIG>. As shown in <FIG>, since the bracket <NUM> has a stronger attachment to the side roof rail <NUM>, upwardly directed impacting forces FU2 are much greater that horizontal impact forces FS2. Consequently, the roof bow <NUM> is deformed, in particular in a mid-portion (not shown) thereof, such that the outboard ends of the roof bow <NUM> bend upward in an inboard direction causing corresponding deformation to other elements of the roof structure of the depicted vehicle body structure.

The vehicle <NUM> includes many conventional components that are well known in the art. Since these conventional components are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

In understanding the scope of the present invention, the term "comprising" and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, "including", "having" and their derivatives. Also, the terms "part," "section," "portion," "member" or "element" when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment, the following directional terms "forward", "rearward", "above", "downward", "vertical", "horizontal", "below" and "transverse" as well as any other similar directional terms refer to those directions of a vehicle equipped with the vehicle body structure. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the vehicle body structure.

The term "configured" as used herein to describe a component, section or part that is constructed to carry out the desired function.

The terms of degree such as "substantially", "about" and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

Claim 1:
A vehicle body structure, comprising:
a side roof rail having an inboard surface extending in a vehicle longitudinal direction;
a B-pillar extending downward from the roof rail;
a bracket having a first portion and a second portion, the first portion being fixedly attached to an upper end portion of the B-pillar, the bracket further having a first rib, and a second rib spaced apart from the first rib, the first rib and the second rib extending from the first portion of the bracket upward toward the second portion of the bracket, the first portion of the bracket further defining a slot located between the first rib and the second rib; and
a roof bow that extends laterally inboard from the bracket and is fixedly attached to the second portion of the bracket,
characterized in that
the upper end portion of the B-pillar overlays a portion of the inboard surface of the roof rail.