U.S. patent application number 12/045937 was filed with the patent office on 2008-07-03 for structural system for an automotive vehicle.
This patent application is currently assigned to Specialty Vehicle Acquisition Corporation. Invention is credited to Mostafa Rashidy, James E. Robertson, Robert G. Storc, George Wolenter.
Application Number | 20080157567 12/045937 |
Document ID | / |
Family ID | 34933302 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080157567 |
Kind Code |
A1 |
Rashidy; Mostafa ; et
al. |
July 3, 2008 |
Structural System For An Automotive Vehicle
Abstract
A structural reinforcement system is provided for an automotive
vehicle. In another aspect of the present invention, a structural
beam is employed which extends in a cross-vehicle direction spaced
above a vehicle floor. A further aspect of the present invention
provides a cross-vehicle reinforcement beam inside another
structural member. Yet another aspect of the present invention uses
a structural reinforcement system in a convertible roof
vehicle.
Inventors: |
Rashidy; Mostafa; (West
Bloomfield, MI) ; Wolenter; George; (Dearborn
Heights, MI) ; Storc; Robert G.; (Rochester Hills,
MI) ; Robertson; James E.; (Rochester, MI) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
Specialty Vehicle Acquisition
Corporation
Los Angeles
CA
|
Family ID: |
34933302 |
Appl. No.: |
12/045937 |
Filed: |
March 11, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10979873 |
Nov 2, 2004 |
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12045937 |
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10822901 |
Apr 13, 2004 |
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10979873 |
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60499669 |
Sep 3, 2003 |
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Current U.S.
Class: |
296/202 ;
296/107.01; 296/203.01; 296/203.03 |
Current CPC
Class: |
B62D 21/157 20130101;
B62D 25/2036 20130101; B60R 2021/23153 20130101; B60J 7/04
20130101; B62D 25/00 20130101; B62D 25/025 20130101 |
Class at
Publication: |
296/202 ;
296/107.01; 296/203.01; 296/203.03 |
International
Class: |
B62D 25/04 20060101
B62D025/04; B60J 7/00 20060101 B60J007/00 |
Claims
1. An automotive vehicle apparatus comprising: a structural pillar
elongated in a substantially vertical direction behind a front door
opening; and a structural beam and a structural member surrounding
a majority of the structural beam, the structural beam and member
being elongated in a substantially horizontal direction and being
substantially parallel to each other; the structural beam and
member being coupled to the pillar.
2. The automotive vehicle apparatus of claim 1 further comprising:
a first passenger seating area, the front door opening located
laterally adjacent the first seating area; a second passenger
seating area located rearwardly of the first seating area; and a
second door opening located laterally adjacent the second seating
area, the second door opening being located on the same side as and
rearwardly of the first door opening; the structural beam and
member being located substantially between the first and second
seating areas.
3. The automotive vehicle apparatus of claim 2 further comprising a
convertible roof movable to a raised position, covering the front
and rear seating areas, to a retracted position.
4. The automotive vehicle apparatus of claim 1 further comprising a
first diagonal beam downwardly extending from and coupling a lower
side of the structural beam to the pillar.
5. The automotive vehicle apparatus of claim 4 further comprising a
second diagonal beam upwardly extending from and coupling an upper
side of the structural beam to the pillar.
6. The automotive vehicle apparatus of claim 1 wherein the
structural beam is substantially straight between outboard portions
of the vehicle.
7. The automotive vehicle apparatus of claim 1 further comprising
aesthetically pleasing interior trim substantially hiding and
substantially surrounding a majority of the structural beam and the
structural member.
8. The automotive vehicle apparatus of claim 1 wherein the
structural beam and structural member are elongated in a
cross-vehicle direction.
9. The automotive vehicle apparatus of claim 1 further comprising a
corrugated gusset diagonally extending from the structural
member.
10. The automotive vehicle apparatus of claim 1 wherein at least a
majority of the structural beam is spaced away from the structural
member.
11. The automotive vehicle apparatus of claim 1 further comprising:
at least three additional passenger door openings; and the pillar
is one of a pair of center pillars upwardly projecting between
adjacent pairs of the door openings, at least one of the structural
beam and the structural member being rigidly coupled to the
pillars; wherein the structural beam and the structural member
assist the vehicle in satisfactorily passing Federal Motor Vehicle
Safety Standard side impact test 214.
12. The automotive vehicle apparatus of claim 1 further comprising:
at least two front seats located in the front seating area, the
front seats being independently movable and not restrained by the
structural beam and the structural member; a central floor tunnel;
the structural beam and structural member being located at or below
a vehicular beltline, and above a vehicular floor, the structural
beam and structural member being coupled to the floor tunnel.
13. The automotive vehicle apparatus of claim 1 wherein the
structural beam is hydroformed metal of substantially circular
cross-sectional shape.
14. An automotive vehicle apparatus comprising: a structural,
primary beam being elongated in a cross-vehicle direction; a
structural, diagonal beam upwardly extending from the primary beam
and inclining away from a vehicular, fore-and-aft elongated
centerline.
15. The apparatus of claim 14 further comprising a substantially
vertical body pillar, the diagonal beam being coupled to the
pillar.
16. The apparatus of claim 15 further comprising a substantially
vertically extending and structural pillar reinforcement located
inside of and affixed to the pillar, the diagonal beam and the
primary beam being affixed to the pillar reinforcement.
17. The apparatus of claim 15 wherein the pillar is a B-pillar
located between front and rear passenger door openings.
18. The apparatus of claim 14 further comprising a vehicle rocker
panel and a second, structural diagonal beam downwardly extending
from the primary beam and being coupled adjacent the rocker
panel.
19. The apparatus of claim 14 further comprising a raised vehicle
floor tunnel, the primary beam being straight between its ends and
attaching to the floor tunnel.
20. The apparatus of claim 14 further comprising at least one roll
bar coupled to at least one of the beams.
21. The apparatus of claim 14 further comprising an electronic
device coupled to at least one of the beams.
22. The apparatus of claim 14 wherein the beams are tubular
metal.
23. The apparatus of claim 14 wherein the primary beam includes a
rigid wall with a substantially closed cross-section filled with
foam.
24. The apparatus of claim 14 further comprising a vehicle floor,
wherein at least a majority of the primary beam is spaced above the
floor.
25. The apparatus of claim 14 further comprising: a convertible
roof movable from an open position behind the primary beam to a
closed position above the primary beam; and a front seating area
and a rear seating area, the primary beam being located
substantially between the seating areas.
26. An automotive vehicle apparatus comprising: a structural member
extending in a substantially cross-vehicle direction; and a
structural gusset extending from an outboard portion of the
structural member, the gusset having a corrugated
configuration.
27. The apparatus of claim 26 further comprising a diagonal member
upwardly and outwardly extending from the beam toward the same
outboard end portion of the beam as the gusset, the diagonal member
being structural, the beam being spaced above a vehicle floor.
28. The apparatus of claim 27 wherein the diagonal member is a
gusset cover plate with a substantially flat middle section.
29. The apparatus of claim 27 wherein the diagonal member is an
elongated and hollow tube.
30. The apparatus of claim 26 further comprising: a front door
opening; a rear door opening; and a structural pillar disposed
between the front and rear door openings; wherein the member
assists the vehicle in satisfactorily passing Federal Motor Vehicle
Safety Standard side impact test 214; and wherein at least one of
the member and the gusset are coupled to the pillar.
31. The apparatus of claim 26 further comprising a convertible roof
movable from a raised position to a retracted position
substantially below a plane defined by a vehicular beltline, the
structural member and gusset being located in a passenger
compartment of the vehicle.
32. The apparatus of claim 26 wherein the structural member is a
tubular beam.
33. The apparatus of claim 26 wherein the gusset has a
substantially triangular rear view shape and upwardly extends from
the structural member.
34. An automotive vehicle apparatus comprising: a first structural
beam being elongated in a substantially cross-vehicle direction; a
second structural beam being elongated in a substantially
cross-vehicle direction, the first and second beams being coaxially
aligned with each other; and a coupler receiving adjacent in-board
end portions of the first and second beams and maintaining the end
portions in structural alignment with each other, the coupler
allowing some cross-vehicle movement of the first beam relative to
the second beam but causing the end portion of the first beam to
abut into the end portion of the second beam during a side impact
condition.
35. The automotive vehicle apparatus of claim 34 further comprising
substantially vertically extending, structural pillars being
coupled to out-board end portions of the respective beams.
36. The automotive vehicle apparatus of claim 35 further
comprising: front door openings; and rear door openings; each of
the pillars being disposed between their respective front and rear
door openings; wherein the beams assist the vehicle in
satisfactorily passing Federal Motor Vehicle Safety Standard side
impact test 214.
37. The automotive vehicle apparatus of claim 34 further comprising
at least two front seats substantially located forward of the beams
and at least two rear seats being located rearward of the beams,
the seats being independently movable and not restrained by the
beams.
38. The automotive vehicle apparatus of claim 34 wherein the
coupler is attached to a central and structural floor tunnel.
39. The automotive vehicle apparatus of claim 34 further comprising
a diagonal beam upwardly extending from the first beam adjacent an
outboard end portion of the first beam, the first and second beams
being spaced above a vehicle floor.
40. An automotive vehicle apparatus comprising: a structural beam;
a structural floor; a structural pillar upwardly extending adjacent
an outboard portion of the floor; and a structural tunnel extending
in a substantially fore-and-aft elongated direction, the tunnel
being centrally joined to the floor; and a reinforcement attached
to the tunnel; the structural beam extending through at least one
of: the reinforcement and the tunnel, in a substantially
cross-vehicle direction and having an outboard end portion of the
beam coupled to the pillar.
41. The automotive vehicle of claim 40 wherein the beam is spaced
above the floor to allow foot room between the beam and the
floor.
42. The automotive vehicle of claim 40 further comprising: a front
door opening; and a rear door opening; the pillar being disposed
between the front and rear door openings; wherein the beam assists
the vehicle in satisfactorily passing Federal Motor Vehicle Safety
Standard side impact test 214.
43. The automotive vehicle of claim 40 further comprising at least
two front seats located forward of the beam and at least two rear
seats located rearward of the beam, the seats being independently
movable and not restrained by the beam, and a structural outer
member being elongated in a cross-vehicle direction and surrounding
a section of the beam.
44. The automotive vehicle of claim 40 further comprising a
convertible roof movable from a raised position to a retracted
position substantially below a plane defined by a vehicular
beltline.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No.
10/979,873, filed Nov. 2, 2004, which is a continuation-in-part of
U.S. Ser. No. 10/822,901, filed on Apr. 13, 2004, which claims the
benefit of U.S. Provisional Application No. 60/499,669, filed on
Sep. 3, 2003. The disclosures of the above applications are
incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention generally relates to automotive
vehicle structure and more particularly to a cross-vehicle
structural reinforcement for an automotive vehicle.
[0003] Cross-vehicle body stiffness within automotive vehicles is
important in reducing torsional twist and vibration of the body,
but also improves the ride and handling of the vehicle. This issue
is especially important for convertible vehicles where the removal
of the traditional fixed roof structure further decreases vehicle
stiffness to the point where four door convertible roof vehicles
have been essentially impractical to achieve with conventional body
structure. Furthermore, U.S. Federal Motor Vehicle Safety Standard
("FMVSS") 214 relates to side impact collision protection for
vehicles. This governmental standard employs a moving barrier,
equivalent to a truck bumper, which impacts the vehicle generally
at and below a belt-line of the front door and B-pillar. FMVSS 214
puts an added premium on cross-vehicle stiffness.
[0004] U.S. Pat. No. 1,694,546 entitled "Motor Car," which issued
to Lancia on Dec. 11, 1928, and U.S. Pat. No. 5,788,322 entitled
"Body Structure for a Rear Carriage of a Convertible," which issued
to Wolf et al. on Aug. 4, 1998, have both attempted to provide some
cross-vehicle structure. It is noteworthy, however, that both
constructions are attached to a fixed seat back and/or passenger
compartment panel. Furthermore, the Lancia construction appears to
lack any cross-vehicle structural support that would significantly
resist side impacts or torsion, especially for a modern unibody
construction vehicle.
[0005] In accordance with the present invention, a structural
reinforcement system is provided for an automotive vehicle. In
another aspect of the present invention, a structural beam is
employed which extends in a cross-vehicle direction spaced above a
vehicle floor. A further aspect of the present invention provides a
cross-vehicle reinforcement beam inside another structural member.
A variety of structural beam-to-pillar mounting arrangements are
also provided in additional aspects of the present invention. Yet
another aspect of the present invention uses a structural
reinforcement system in a convertible roof vehicle.
[0006] The present invention is advantageous over conventional
constructions, in that the present invention significantly improves
cross-vehicle resistance to side impact collisions and provides
torsional stiffness sufficient for use with a large four door
vehicle, such as one having a convertible roof. Spacing the
structural beam away from the floor reduces "match boxing" of the
vehicle body as compared to traditional, floor mounted
reinforcements. Moreover, the beam-to-pillar mounting structures of
the present invention significantly enhance side impact resistance
as compared to prior constructions. Additional features and
advantages of the present invention will be shown and described
with reference to the following description and appended
figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side elevational view showing an alternate
embodiment automotive vehicle employing a structural reinforcement
system of the present invention, with a hard-top convertible roof
in a retracted position and with the left side doors removed;
[0008] FIG. 2 is a side elevational view showing an alternate
embodiment automotive vehicle employing a structural reinforcement
system, with the hard-top convertible roof in a raised position and
with the left side doors removed;
[0009] FIG. 3 is a perspective view as seen from behind the right
rear corner, showing an alternate embodiment automotive vehicle
employing a structure reinforcement system of the present
invention, with a slidably retracting roof in a raised
position;
[0010] FIG. 4 is a partially fragmentary, rear diagrammatic view,
as seen from line 4-4 of FIG. 1, showing the alternate embodiment
structural reinforcement system of the present invention;
[0011] FIG. 5 is a diagrammatic side view showing a first alternate
embodiment structural reinforcement system made by stamping;
[0012] FIG. 6 is a diagrammatic side view showing a second
alternate embodiment structural reinforcement system made by
hydroforming;
[0013] FIG. 7 is a perspective view showing a fragmentary third
alternate embodiment automotive vehicle employing a structural
reinforcement system of the present invention;
[0014] FIG. 8 is a diagrammatic, partially cross-sectional view,
taken along line 8-8 of FIG. 4, showing the second alternate
embodiment structural reinforcement system;
[0015] FIG. 9 is a diagrammatic, cross-sectional view, taken along
line 8-8 of FIG. 4, showing the first alternate embodiment
structural reinforcement system;
[0016] FIG. 10 is a cross-sectional view taken along line 10-10 of
FIG. 4, showing the second alternate embodiment structural
reinforcement system;
[0017] FIG. 11 is a cross-sectional view taken along line 10-10 of
FIG. 4, showing the first alternate embodiment structural
reinforcement system;
[0018] FIG. 12 is a diagrammatic rear view, as seen from line 4-4
of FIG. 1, showing a fourth alternate embodiment structural
reinforcement system of the present invention;
[0019] FIG. 13 is a diagrammatic rear view, as seen from line 4-4
of FIG. 1, showing a fifth alternate embodiment structural
reinforcement system of the present invention;
[0020] FIG. 14 is a perspective view showing the fifth alternate
embodiment structural reinforcement system of the present
invention;
[0021] FIG. 15 is a diagrammatic rear view, as seen from line 4-4
of FIG. 1, showing a sixth alternate embodiment structural
reinforcement system of the present invention;
[0022] FIG. 16 is a diagrammatic top view showing a seventh
alternate embodiment structural reinforcement system of the present
invention;
[0023] FIG. 17 is a diagrammatic side view showing an eighth
alternate embodiment structural reinforcement system of the present
invention;
[0024] FIG. 18 is a diagrammatic, perspective view showing another
alternate embodiment system of the present invention but with a
soft top convertible roof;
[0025] FIG. 19 is a bottom elevational view showing a first
preferred embodiment of the structural system of the present
invention;
[0026] FIG. 20 is a fragmentary and perspective view showing the
first preferred embodiment structural system;
[0027] FIG. 21 is a fragmentary and rear, elevational view showing
the first preferred embodiment structural system;
[0028] FIG. 22 is a diagrammatic side elevational view showing the
first preferred embodiment structural system;
[0029] FIG. 23 is a diagrammatic top elevational view showing the
first preferred embodiment structural system;
[0030] FIG. 24 is a fragmentary and perspective view showing the
first preferred embodiment structural system;
[0031] FIG. 25 is a cross-sectional view, taken along line 25-25 of
FIG. 22, showing the first preferred embodiment structural
system;
[0032] FIG. 26 is a cross-sectional view, taken along line 26-26 of
FIG. 23, showing the first preferred embodiment structural
system;
[0033] FIG. 27 is a fragmentary and perspective view showing a
second preferred embodiment of the structural system of the present
invention;
[0034] FIG. 28 is a rear, diagrammatic view showing the second
preferred embodiment structural system;
[0035] FIG. 29 is a top diagrammatic view showing the second
preferred embodiment structural system;
[0036] FIG. 30 is a rear diagrammatic view showing a ninth
alternate embodiment of the present invention structural
system;
[0037] FIG. 31 is a cross-sectional view, taken along line 26-26 of
FIG. 23, showing a portion of the preferred embodiment structural
system;
[0038] FIG. 32 is a cross-sectional view, like that of FIG. 31,
showing a tenth alternate embodiment of the present invention
structural system;
[0039] FIG. 33 is a cross-sectional view, like that of FIG. 31,
showing an eleventh alternate embodiment of the present invention
structural system;
[0040] FIG. 34 is a rear perspective view showing a twelfth
alternate embodiment of the structural system of the present
invention;
[0041] FIG. 35 is a fragmentary and front, perspective view showing
the twelfth alternate embodiment structural system;
[0042] FIG. 36 is a rear, diagrammatic view showing the twelfth
alternate embodiment structural system;
[0043] FIG. 37 is a rear, diagrammatic view showing a thirteenth
alternate embodiment of the present invention structural
system;
[0044] FIG. 38 is a rear, diagrammatic view showing a fourteenth
alternate embodiment of the present invention structural
system;
[0045] FIG. 39 is a fragmentary, perspective view showing the
fourteenth alternate embodiment structural system;
[0046] FIG. 40 is a fragmentary, perspective view, like that of
FIG. 39, showing the fourteenth alternate embodiment structural
system with a structural cover plate removed;
[0047] FIG. 41 is a cross-sectional view, taken along line 41-41 of
FIG. 39, showing the fourteenth alternate embodiment structural
system;
[0048] FIG. 42 is a fragmentary, perspective view showing a
fifteenth alternate embodiment of the structural system of the
present invention;
[0049] FIG. 43 is a cross-sectional view, taken along line 43-43 of
FIG. 42, showing the fifteenth alternate embodiment structural
system;
[0050] FIG. 44 is a fragmentary, rear perspective view showing a
sixteenth alternate embodiment of the present invention structural
system; and
[0051] FIG. 45 is a fragmentary and diagrammatic rear view showing
a seventeenth alternate embodiment of the present invention
structural system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] An automotive vehicle according to the present invention has
a body, a convertible roof and a structural reinforcement system
19. In an alternate embodiment of vehicle 21, shown in FIGS. 1 and
2, the convertible roof is a retractable hard-top roof including a
front hard-top section 23, a middle hard-top section 25 and a rear
hard-top section 27. The hard-top sections are interconnected by a
linkage assembly (not shown) driven by an automatic actuator 29,
such as an electric motor or hydraulic cylinder. The convertible
roof is movable from a raised and closed position above front
passenger seats 31 and rear passenger seats 33 in a passenger
compartment 35, as shown in FIG. 2, to a retracted and open
position within a roof storage compartment 37, as shown in FIG. 1.
Roof storage compartment 32 is a trunk with a dual opening decklid,
or a bootwall, forward and separated from a trunk, covered by an
automatically openable tonneau cover. Such a hard-top roof and
linkage assembly is disclosed in U.S. patent Ser. No. 10/245,973,
now U.S. Pat. No. 6,695,386, entitled "Vehicle Retractable Hardtop
Roof," which was invented by Michael T. Willard and filed on Sep.
18, 2002, which is incorporated by reference herein.
[0053] Referring to FIG. 18, a soft top convertible roof 41 is also
usable with the present invention, and is disclosed in U.S. patent
Ser. No. 10/403,362, now U.S. Pat. No. 6,695,385, entitled "Vehicle
Convertible Roof," which was invented by Eric W. Lange and filed on
Mar. 31, 2003; this disclosure is incorporated by reference herein.
Soft top roof 41 includes a top stack mechanism including left and
right, front, center and rear side rails, 42, 43 and 44,
respectively, with four spanning roof bows 45 and multiple linkages
48. An electric motor or hydraulic actuator 46 automatically drives
the mechanism and a pliable roof cover 47 is attached to and covers
roof bows 45. More preferably, an in-folding soft top convertible
roof is employed, such as that disclosed in U.S. Ser. No.
60/612,384, entitled "In-Folding Convertible Roof" which was filed
on Sep. 23, 2004, and invented by Dilluvio; this application is
incorporated by reference herein. Furthermore, FIG. 3 shows
multiple sliding roof panels and a slidably retracting backlite or
back window, which are employed with the present invention in
another alternate embodiment. This is disclosed in PCT Publication
No. WO 02/096685 entitled "Automotive Vehicle with Open Air System"
which was invented by Doncov et al. and published on Dec. 5, 2002;
this disclosure is also incorporated by reference herein.
[0054] Returning to the alternate embodiment of FIGS. 4-6,
structural reinforcement system 19 is made up of multiple
cross-vehicle upper and lower beams 51 and 53, respectively, and
interconnected diagonal and vertical beams 55 and 57, respectively.
Upper beam 51 is positioned adjacent a beltline 61 of the vehicle
and lower beam 53 is attached to a sheet metal floor pan 63 of the
vehicle. The outboard vertical beams 57 are welded, riveted or
otherwise secured to B-pillars 65 of the vehicle. Beams are
integrally hydroformed as a single steel piece, as shown in FIGS.
4, 6, 8, 10, 12, 13 and 15. In another embodiment, beams are
integrally stamped from sheet metal as a single piece, as shown in
FIGS. 5, 9 and 11. Gussets 91 are attached to a center tunnel 93 of
vehicle and to outboard rocker panels 95 of the unibody vehicle.
Alternately, separated created beams can be welded together.
[0055] Reference should be made to FIGS. 7 and 8 where a polymeric
center, floor trim console 101 extends from a front passenger area
107, through a recess 103 in upper beam 51 and into a rear seating
area 109, between bucket front seats and bucket rear seats.
Polymeric trim panels 105 also cover the exterior of structural
system 19. Door hinge hardware 121 can be secured directly to
reinforcement system 19 by bolts, rivets or welding. A decorative
B-pillar facia 123 is attached to structural system 19 in an
alternate embodiment. An electronic entertainment system 141, such
as including an audio or video compact disc player, movie player,
radio or the like, is located in a central pocket of each side of
structural system 19 for use by the rear seat passengers.
Furthermore, an inflatable air bag system 151 (see FIG. 12) may be
provided in each pocket of structural system 19, the beams of which
are angled to properly channel the deployment forces into the floor
and B-pillars. Moreover, roll bars 161 (see FIG. 4) are optionally
secured to upper beam 51 on each side of the vehicle's fore-and-aft
centerline 162.
[0056] FIG. 13 illustrates a fifth alternate embodiment structural
reinforcement system 19 of the present invention. This exemplary
structural reinforcement system 19 includes an upper beam 161, a
lower beam 163, and pairs of crossing diagonal beams 165 and 167
spanning between the upper and lower beams outboard of a middle,
recess 169 where upper and lower beams 161 and 163 converge. Ends
of upper and lower beams 161 and 163 are directly affixed to
adjacent and generally vertical B-pillars 65 and rocker panels 95,
without supplemental vertical beams. A simulated bumper 171,
according to FMVSS 214, is shown adjacent to the vehicle beltline
which is generally aligned with the intersection between upper beam
161 and B-pillar 65.
[0057] FIG. 14 shows structural reinforcement system 19 with a
floor-mounted, trim console 101 centrally extending in a
fore-and-aft centerline direction of the vehicle. In this
variation, console 101 extends between bucket front seats 173 and
either is interrupted by, passes above or passes below beam recess
169. The rear end of console 101 terminates forward of a bench rear
seat 175.
[0058] A sixth alternate embodiment system 19 is shown in FIG. 15.
In this embodiment, a generally straight and horizontal upper beam
181 is connected to a lower beam 183 by multiple branching,
intermediate beams 185. Lower beam 183 has a raised central segment
187 to circumvent the floor tunnel. Beams 181 and 183 are attached
to B-pillars 65 and rocker panels 95. A central, component cluster
assembly 189 is mounted to system 19 within an aperture between the
beams for use by the rear seat passengers. Component cluster
assembly 189 includes audio and video entertainment systems 191,
heating/ventilating/air conditioning ducts and controls 193, a
storage compartment 195, communications devices 197, and the
like.
[0059] Referring to FIG. 16, a seventh alternate embodiment of a
structural reinforcement system 251 includes a structural beam 253
extending in a primarily cross-vehicle direction. Ends 255 of beam
253 are welded or otherwise fastened to B pillars 257. Beam 253 has
a pair of arcuately curved segments 259 joining at a forwardly
extending central segment 261 which can be optionally secured to a
floor panel 263 or fore-and-aft extending tunnel attached thereto,
by a generally vertical bracket or gusset. A front seat 265 is
located forward of each curved segment 259 and each seat back may
have a top view curve conforming with the adjacent curved shape of
beam 253. A floor mounted, interior trim console (such as that
shown in FIG. 14) may be provided between seats 265 and can either
extend above center segment 261 for use by both front and rear seat
passengers, may extend below central segment 261 such that the
center portion of beam 253 creates an aesthetic styling element in
the vehicle as well as providing a functional reinforcement, or a
two-piece console may sandwich central segment 261 of beam 253. The
rear view shape of beam 253 can extend straight across the vehicle
or may have a central depression such as that shown in FIGS. 4 and
7.
[0060] FIG. 17 illustrates an eighth alternate embodiment
structural reinforcement system 301 of the present invention. In
this embodiment, a structural beam 303 extends in a generally
straight (when viewed from the top and rear) orientation between
the B-pillars or other upstanding structural members of the
automotive vehicle adjacent the rocker panels. Beam 303 is an
enclosed and hollow polygon, here shown with four sides when viewed
in cross-section, which can be created from and extruded or
hydroformed steel. Rear sections 305 of metal seat tracks 307 are
attached to beam 303 by welded or riveted brackets 309. Front
sections 311 of seat tracks 307 are attached to a metal floor panel
313 by welded, riveted or bolted on brackets. Front seats 315, or
other passenger seats, and their respective seat movement
mechanisms 317 are attached to seat tracks 307. Exemplary seat
movement mechanisms 317 are disclosed in U.S. Pat. No. 5,575,531
entitled "Vehicle Power Seat Adjuster with End Driven Lead Screw
Actuation" which issued to Gauger, et al. on Nov. 19, 1996, and is
incorporated by reference herein. Space is provided below beam 303
and the adjacent portion of seat tracks 307 so as to maximize
passenger compartment leg room and foot room. Beam 303 is secured
to the vehicle well below a belt line area but may be useful in
trucks, vans, sport utility vehicles and other situations that
serve to add the required vibrational stiffness, minimize
cross-vehicle and diagonal twisting of the vehicle body, while also
improving crashworthiness during side impact. Thus, beam 303
advantageously serves as a multifunctional part.
[0061] A first preferred embodiment of the structural system of the
present invention is shown in FIGS. 19-26. FIG. 19 illustrates
supplemental bracing of underbody 331 of an automotive vehicle 333,
which includes a structural floor pan 335 and rocker panels 337 and
339. The supplemental bracing includes a pair of inwardly angled
front braces 341 and 343, a pair of oppositely expanding V-shaped
middle braces 345 and 347, a generally flat central brace 349
extending fore and aft of middle braces 345 and 347, and a pair of
inwardly angled rear braces 351 and 353.
[0062] Referring now to FIGS. 21-25, a center or B-pillar 361
upwardly projects in a generally vertical manner between front and
rear door openings 363 and 365, respectively, from each rocker
panel 337 on the outboard sides of floor pan 335. Each B-pillar has
an inner, stamped steel panel 367, an outer, stamped steel panel
369 and an exterior, polymeric trim molding 371. Inner and outer
panels 367 and 369 are welded together at flanges 373 and 375, and
define an elongated hollow area 377 therebetween. Rocker panel 337
is similarly constructed with an inner, stamped steel panel 381 and
an outer, stamped steel panel 383, welded together at pinch weld
flanges 385 and defining a fore-and-aft elongated hollow area 387
therebetween.
[0063] A generally vertical, steel reinforcing tube 391 is welded
to each center pillar 361, within hollow 377, and is attached to a
generally fore-and-aft elongated and horizontal reinforcing steel
tube 393 which is welded to rocker panel 337 in hollow 387. A
reinforcement cross beam 401 is welded to a middle segment of
vertical reinforcement tube 391 and is elongated in a generally
straight, cross-vehicle and horizontal orientation projecting
inwardly between the B-pillars 361. Cross beam 401 is a structural
steel tube. An upper diagonal reinforcement tube 403 upwardly and
outwardly extends from cross beam 401 and is welded onto an upper
segment of vertical reinforcement tube 391, which is considered
herein to be part of the B-pillar. A lower diagonal reinforcement
tube 405 downwardly and outwardly extends from cross beam 401 and
is welded to a lower segment of vertical reinforcement tube 391
and/or rocker reinforcement tube 393. Both B-pillar reinforcement
systems are similarly constructed in mirrored symmetry to each
other and are connected by the continuous cross beam 401.
[0064] A structural outer member 411 is best observed in FIGS. 21,
24 and 26. Structural outer member or supplemental cross beam 411
is preferably shown as two stamped, steel parts that are welded or
riveted together to encase or surround a majority of main cross
beam 401 therein between B-pillars 361. Alternately, structural
outer member 411 may consist of a circular-cylindrical tube or
rectangular cross-sectionally shaped reinforcement surrounding
cross beam 401. Preferably, cross beam 401 is inwardly spaced from
a majority of support outer member 411, and outer member 411 is
attached to B-pillars 361 and a floor tunnel 413 by diagonally
extending, structural gusset covers 415, 417 and 419. Structural
outer member 411 serves to reinforce and limit buckling of the
otherwise straight cross beam 401 during a side impact collision
and to further stiffen the vehicle body between the B-pillars 361
during extreme torsional operating forces of the vehicle.
[0065] FIG. 20 shows polymeric, interior trim panels 425 attached
to B-pillars 361 and structural outer member 411, which may have
fastening holes therein. Thus, cross beam 401, structural outer
member 411, the gusset covers and diagonal tubes 403 and 405 are
all aesthetically hidden by interior trim panels 425. Furthermore,
foot room clearance is provided between the underside of interior
trim panels 425, structural outer member 411 and cross beam 401,
relative to the spaced apart floor pan 335, as can be observed in
FIGS. 21 and 26. This structural system-to-floor spacing further
improves side impact resistance and torsional resistance of the
vehicle, especially when impacted by a truck or other raised bumper
of a colliding vehicle. Cross beam 401 is preferably of a hollow
and circular cross-sectional configuration, such as that shown in
FIGS. 26 and 31, or it may be filled with a solid yet somewhat
compressible foam, such as that shown in FIG. 32, filled with a
solid polymeric material (not shown), or may have a D-like cross
sectional shape such as that illustrated in FIG. 33.
[0066] A second preferred embodiment structural system of the
present invention is illustrated in FIGS. 27-29. This embodiment is
similar to the first preferred embodiment, however, a main cross
beam 451 is integrally formed as a single piece with upper diagonal
tube 453 and lower diagonal tube 455, such as by hydroforming or
sheet stamping. Additionally, fore-and-aft enlarged plates 457, 459
and 461 are welded onto their respective ends of tubes 453 and 455,
and beam 451. These plates 457, 459 and 461 are, in turn, screwed
or riveted onto box-like stamped or cast brackets 463, 465 and 467
which are secured to a generally vertically extending reinforcement
tube 469 welded inside of the center pillar. As an option, main
cross beam 451 can be bolted to a center tunnel 413 as shown in
FIG. 37.
[0067] FIG. 30 shows a ninth alternate embodiment structural system
of the present invention wherein a straight and circularly
sectioned cross beam 481 extends in a generally horizontal and
crosscar direction and is directly coupled to generally vertical
reinforcement tubes 483 welded within center pillars 361 and rocker
panels 337. The center of cross beam 481 is welded to or passes
above a centrally located and fore-and-aft elongated floor tunnel
485 of the vehicle. Diagonally extending upper and lower
reinforcement tubes 487 and 489 couple outboard segments of cross
beam 481 to pillar reinforcement tube 483 and a rocker
reinforcement tube 491. Interior trim panels 493, 495 and 497
aesthetically cover the top, front, back and bottom of cross beam
481, and diagonal upper and lower reinforcement tubes 487 and 489.
Front passenger seats 499 are located in front of and are
independently movable in a fore-and-aft direction and up-down
direction with regard to cross beam 481. Unlike with the first
preferred embodiment, no surrounding structural member (such as 411
shown in FIG. 21) is employed.
[0068] A twelfth alternate embodiment has a first sub-variation
shown in FIGS. 34 and 35. A vehicle body, cross beam 501,
structural outer reinforcement 502, upper and lower diagonal
reinforcement tubes 503 and 505, vertical pillar reinforcement
tubes 507 and rocker reinforcement tubes 509 are constructed like
that disclosed in the first preferred embodiment, specifically
FIGS. 21 and 26. Cross beam 501 and the surrounding structural
outer member 502, however, differ in that they project in a
generally straight line through floor tunnel 413 and are mounted
inside a coupler 511 secured to floor tunnel 413. Referring to FIG.
36, a second sub-variation of this embodiment provides for a single
cross beam 501' but without the supplemental structural outer
member. It is also noteworthy that in this embodiment, as well as
with the first preferred embodiment, additional structural,
cross-vehicle panels 513 and 515 are provided at the front
windshield header and between the rear wheel houses where the rear
seat back panel is located.
[0069] A thirteenth alternate embodiment is depicted in FIG. 37
wherein two coaxially aligned cross beams 521 and 523 inwardly
project between B-pillars 361 and are coupled together by a
circular-cylindrically shaped and hollow coupler 525. Coupler 525
is secured to floor tunnel 413 internal to a steel, floor tunnel
reinforcement cap 527 attached to floor tunnel 413. Coupler 525
normally allows clearance of adjacent inboard ends 529 and 531 of
cross beams 521 and 523, respectively, such that normal
cross-vehicle tolerance variations and temperature induced
contraction and expansion are allowed by varied end-to-end spacing
of cross beams 521 and 523 within coupling 525. In a side impact
situation, however, significant inward movement of the initially
impacted cross beam will then cause its inboard end to abut against
the opposing inboard end of the other cross beam within coupling
525, thereafter acting as a single and unitary cross beam in
resisting the side impact collision.
[0070] A fourteenth preferred embodiment of the present invention
structural system is illustrated in FIGS. 38-41. A structural cross
beam 551 and structural outer member 553, surrounding cross beam
551 like that of the first preferred embodiment shown in FIG. 26,
are used with this embodiment. Cross beam 551 is welded to
vertically extending pillar reinforcement tube 555. Furthermore, a
corrugated and diagonally extending, structural gusset 557 upwardly
and outwardly projects from structural outer member 553 or
alternately, cross beam 551, and is welded or riveted to inner
panel 367 of B-pillar 361. Gusset 557 has a generally triangularly
shaped configuration when viewed from the rear and includes a pair
of attached corrugated and stamped steel panels 559 and 561 which
are in mirrored symmetry to each other. Panels 559 and 561 have
outer flanges 563 attached to the inner panel of the B-pillar, and
inner flanges 565 attached to a structural, stamped steel gusset
cover plate 567 (shown in FIGS. 39 and 41). The corrugations define
diagonally extending ribs or flutes within each plate to add
torsional stiffness. A box-like and generally diagonally extending
structural gusset 571 projects from structural outer member 553 in
a downward and outwardly angled manner to the bottom of center
pillar 361 and rocker panel 337.
[0071] Referring to FIGS. 42 and 43, a fifteenth alternate
embodiment structural system of the present invention is similar to
the configuration employed with the prior alternate embodiment of
FIGS. 38-41, except that a gusset cover plate is not employed and
the upper gusset has a differing configuration. More specifically,
an upper gusset 601 is defined by a pair of stamped steel gusset
plates 603 and 605 which are attached to the inner panel of
B-pillar 361. Gusset plates 603 and 605 are stamped in mirrored
symmetry and each has a generally L-shaped pillar section 607, with
an outwardly projecting pinch weld flange, and a corrugated or
ribbed section 609 which defines generally circular and hollow
flutes when the panels are joined together, thereby adding diagonal
structural rigidity between the attached structural outer member
611 and B-pillar 361. This diagonal gusset, as well as that of the
prior embodiment, are preferably covered by an aesthetically
pleasing, polymeric and/or carpeted interior trim panel.
[0072] As shown in FIG. 44, a sixteenth alternate embodiment
structural system of the present invention provides diagonally
extending upper reinforcement beams 651 and 653, of a tubular
configuration, which attach to either a tubular cross beam 655
and/or surrounding structural outer member 657 immediately adjacent
a center, floor tunnel area 659. An upper end of each diagonal
upper beam 651 and 653 attaches to a portion of each center pillar
631 adjacent beltline 61 (see FIG. 1) of the vehicle. The upper and
outer end of each diagonal tube 651 and 653 may additionally or
alternately be welded to a vertically extending pillar
reinforcement tube.
[0073] Moreover, FIG. 45 shows a seventeenth alternate embodiment
of the present invention structural system wherein an outer
coupling 701 has an enlarged flange 703 screwed or riveted to an
inner panel of center pillar 761. Coupling 701 also has a
cylindrical and hollow collar 705 which slidably receives an
outboard end of a tubular cross beam 707. Coupling 701 is
configured to allow cross-vehicle movement of the secured cross
beam 707 relative to pillar 361 to account for normal cross-vehicle
manufacturing tolerance variations. A lost motion screw or pin
fastener can optionally extend through an elongated slot in collar
705 and engage within a snug aperture in cross beam 707 to prevent
complete disengagement of cross beam 707 from coupling 701 yet
allow tolerance variations.
[0074] While various aspects of the structural reinforcement system
have been disclosed, it should be appreciated that variations may
be made which fall within the scope of the present invention. For
example, additional accessories can be attached to any of the
structural reinforcement beams disclosed herein such as folding
tables, lamps, telephones, computers and the like. Furthermore, the
beams can alternately be manufactured from composite materials such
as glass-filled polymers, metal inserts molded within polymers, and
the like. The cross-vehicle beams and reinforcements can also be
employed behind rear seats, in front of instrument panels or
between other vehicle pillars although various advantageous of the
present invention may not be fully achieved. Structural system 19
is preferably employed in a convertible vehicle having four, side
passenger doors 213 but may also be used in a stretch limousine
having four or more passenger doors and a stationary roof.
Bullet-proof armor is optionally mounted along a cross-car plane
parallel and internal to trim panels 105. Furthermore, it should be
appreciated that alternate beam shapes can be employed. It is
intended by the following claims to cover these and any other
departures from the disclosed embodiments that fall within the true
spirit of the invention.
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