Fibrous composite structural assembly for a motor vehicle

Abstract

An assembly for a vehicle body includes the following components: a sill, roof frame, hinge pillar, outer shell and inner shell. The assembly is characterized by being very rigid and very firm, and having a high degree of structural possibilities whilst being relatively light in weight. The sill and the roof frame are formed by hollow profiles. The hinge pillar is made from an extruded fibrous composite. The sill, the roof frame and the hinge pillar are surrounded on the outer side and the inner side, at least partially, by the outer shell and the inner shell, such that the assembly components form a composite unit.

Claims

1. An assembly for a vehicle body, comprising: a sill; a roof frame; a hinge pillar provided separately from the sill and the roof frame; an outer shell; and an inner shell, wherein the sill and the roof frame are formed by hollow profiles extending along a longitudinal direction of the vehicle body in a vicinity of the hinge pillar, the hinge pillar is made of an extruded fibrous composite, and the sill, the roof frame, and the hinge pillar are at least partially surrounded on an outer side by the outer shell and on an inner side by the inner shell such that the sill, the roof frame, the hinge pillar, the outer shell, and the inner shell form a composite unit.

2. The assembly according to claim 1, wherein the hollow profiles are formed of a wound, grated, or extruded fibrous composite.

3. The assembly according to claim 2, wherein the fibrous composite is a carbon fiber composite material.

4. The assembly according to claim 1, wherein the outer and inner shells are formed of a fibrous composite.

5. The assembly according to claim 4, wherein the fibrous composite is a carbon fiber composite material.

6. The assembly according to claim 4, wherein the fibrous composite has a fiber structure or fiber fabric, or is formed at least partially from a metallic material.

7. The assembly according to claim 4, wherein fibers in the fibrous composite of the outer and inner shells are oriented, continuous fibers, said oriented, continuous fibers being aligned in a main loading direction of the assembly.

8. The assembly according to claim 1, wherein the extruded fibrous composite of the hinge pillar is a carbon fiber composite material having fibers with a fiber length from 8-40 mm.

9. The assembly according to claim 1, wherein the extruded fibrous composite of the hinge pillar is a carbon fiber composite material having fibers with a fiber length from 10-30 mm.

10. The assembly according to claim 1, further comprising high-strength adhesive bonds connecting the sill, roof frame, hinge pillar, outer shell, and inner shell together.

11. The assembly according to claim 1, wherein the composite unit is designed to have a ductility sufficient to absorb energy in an event of a crash and to ensure connection of the sill, roof frame, hinge pillar, outer shell, and inner shell assembly components even upon a partial destruction of an individual one of the assembly components.

12. The assembly according to claim 1, wherein the hinge pillar is configured to have a meandering shape.

13. The assembly according to claim 12, wherein the hinge pillar comprises further components.

14. The assembly according to claim 13, wherein the further components comprises one or more of fixtures for door hinges, door checks, wire harness feedthroughs, equipment components and fastening elements for interior trim components.

15. The assembly according to claim 1, wherein the assembly forms an A-pillar of the vehicle body.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a simplified side view of a left A-pillar of a motor vehicle seen from the outside;

(2) FIG. 2 is a simplified side view of a left A-pillar of a motor vehicle seen from the vehicle interior;

(3) FIG. 3 shows an overview of the sectional views of the A-pillar of FIGS. 4 to 6 seen from the outside;

(4) FIG. 4 is a vertical section view through an A-pillar behind the hinge pillar,

(5) FIG. 5 is a vertical section view through an A-pillar at the height of the hinge pillar; and

(6) FIG. 6 is a horizontal section view through an A-pillar between an upper and lower hinge plane.

DETAILED DESCRIPTION OF THE DRAWINGS

(7) In the figures, only the parts of the assembly for a motor vehicle body which are of interest here are represented; all other elements are omitted for the sake of clarity. Furthermore, like reference characters represent the same components.

(8) In the figures, the assembly according to the invention is explained using the example of an A-pillar for a body for a motor vehicle. However, the assembly according to the invention may also be used for other body parts, such as a B and/or C pillar.

(9) According to FIG. 1, the assembly includes a sill 1, a roof frame 2 and a hinge pillar 3, as well as an outer shell 4 and an inner shell (not shown in FIG. 1). The outer shell 4 and the inner shell surround the sill 1, the roof frame 2 and the hinge pillar 3. The sill 1 and the roof frame 2 are formed as hollow profiles, which are preferably formed from a wound, braided or extruded fibrous composite, preferably a carbon fiber composite material.

(10) Through the enclosing of the outer shell 4 and the inner shell, a stable composite unit exists between the assembly components, which promotes a force transfer between the hollow profiles and the hinge pillar 3 formed from an extruded fibrous composite. This contributes to the stability of the assembly.

(11) The hinge pillar 3 formed from extruded fibrous composite is characterized by a high degree of design freedom (structural possibilities). Represented by way of example are door hinges 6, a wire harness feedthrough 7 and a door check 8. Other equipment elements and connecting elements may be integrated into the hinge pillar 3.

(12) The assembly components are advantageously connected with one another by use of a high-strength adhesive bond, which promotes a stable assembly component composite unit.

(13) The assembly shown in FIG. 2 corresponds in structure to the assembly illustrated in FIG. 1, but is seen from the rear side, thus from the vehicle interior. As a result, the inner shell 5 may be seen in addition to the sill 1, the roof frame 2 and the hinge pillar 3. The roof frame 2 is thus partially covered by the inner shell 5, which encloses together with the outer shell (not shown) the sill 1, the roof frame 2 and the hinge pillar 3, resulting in a stable assembly component composite unit.

(14) A speaker 9 is additionally shown as an exemplary equipment element. Other equipment or connecting elements may be provided.

(15) FIG. 3 provides an overview of the sectional views of FIGS. 4 to 6 of an A-pillar as has already been represented in FIG. 1, seen from the outside.

(16) Individually, FIG. 4 shows a vertical section through the A-pillar of FIG. 1 behind the hinge pillar 3. The hollow profile, from which the sill 1 is formed, is clearly visible. By way of example, the sill 1 is formed from four hollow profiles. However, this is not required. The roof frame 2 is formed by way of example by an elongated hollow profile.

(17) As has already been mentioned, for reasons of weight savings and better processability with the other assembly components, the hollow profile is preferably formed from a wound, braided or extruded fibrous composite. In view of rigidity and firmness, the hollow profile is advantageously formed from a carbon fiber composite material.

(18) On the hinge pillar 3 can, in turn, be seen two door hinges 6 and the door check 8.

(19) FIG. 5 shows a vertical section through the A-pillar of FIG. 1 at the height of the hinge pillar 3. In turn clearly visible is the roof frame 2 formed from a hollow profile, as well as the sill 1 formed from four hollow profiles. The inner shell 5 and the outer shell 4 enclose the sill 1, the roof frame 2 and the hinge pillar 3.

(20) Furthermore, it can be seen that the hinge pillar 3 is formed in a meandering shape, which ensures a positive connection to the inner shell 5 and outer shell 4.

(21) A speaker 9 is integrated into the hinge pillar 3 as an example of the integration of further equipment components. Other equipment components, fixing means and/or connecting elements may be provided.

(22) FIG. 6 is a horizontal section through an A-pillar as shown in FIG. 1, between an upper and lower hinge plane. Here again is clearly visible the meandering shape of the hinge pillar 3, which is in connection with the outer shell 4 and the inner shell 5. Further shown are additional attached molded parts, such as an end wall 10 and a footwell lining 11, which may likewise be integrated into the assembly according to the invention.

LIST OF REFERENCE CHARACTERS

(23) 1 sill 2 roof frame 3 hinge pillar 4 outer shell 5 inner shell 6 door hinge 7 wire harness feedthrough 8 door check 9 speaker 10 end wall 11 footwell lining

(24) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.