Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10, rule 13)

A BODY STRUCTURE OF A VEHICLE AND ITS MANUFACTURING METHOD THEREOF

By

MAHINDRA ELECTRIC AUTOMOBILE LTD, HAVING ADDRESS AT PLOT NO.41/1, MAHINDRA WORLD CITY, ANJUR, CHENGALPATTU – 603004, TAMILNADU, INDIA

The following specification particularly describes the invention and the manner in which it is to be performed

TECHNICAL FIELD OF THE INVENTION:
[001] The present invention relates to the field of structural engineering. Particularly, the present invention relates to a vehicle body structure. More particularly, the present invention relates to a quarter glass hand access scoop integrated into a C-pillar region of the vehicle body structure to facilitate a rear door handle operation and the quarter glass fitment.
BACKGROUND OF THE INVENTION:
[002] Automotive industry has witnessed significant advancements in vehicle design and technology, driven by the increasing demands of consumers for enhanced safety, comfort, and aesthetic appeal. One crucial aspect of vehicle design is the optimization of visibility within the cabin, addressing blind spots, and ensuring a comprehensive view for the driver. With the evolution of design trends and customer preferences, the focus on achieving 360-degree visibility inside the cabin has become a prominent feature in modern vehicle design.
[003] Quarter glasses, positioned behind the rear seats and next to the C-pillar, serve a dual purpose in vehicles. They contribute to the overall aesthetic appeal of the vehicle exterior and play a crucial role in providing additional visibility for the driver. These quarter glasses are strategically placed to minimize blind spots, enhancing the overall safety of the vehicle. Additionally, they serve as key elements in maintaining a cohesive design theme from the rear door to the side body outer, contributing to the vehicle's overall stylistic execution.
[004] As market demands evolve, the integration of quarter glasses has become a standard feature in passenger cars. The presence of quarter glasses not only improves visibility but also adds to the overall interior and exterior design continuity. Achieving the desired functionality and aesthetic appeal, however, poses challenges in the design and manufacturing processes. Though innovations in manufacturing techniques, materials science, and design methodologies have enabled automotive manufacturers to overcome many of these challenges, integrating the quarter glass seamlessly presents a conundrum for engineers.
[005] In most Body-in-White (BIW) structures, a C-pillar typically comprises a box section running from a bottom sill section to a cantrail section. This box-to-box connection ensures overall stiffness and torsional rigidity, critical for crashworthiness and handling. Challenges often arise in maintaining this structural stiffness while accommodating ergonomic considerations for rear door handle operation. Stiffness, the backbone of a car's structural integrity, weakens with a window in the C-pillar.
[006] Maintaining a sleek and stylish appearance while seamlessly integrating the window adds another layer of complexity. Traditionally, the fitment of quarter glasses has been approached through conventional methods that may not always align with the evolving design requirements. The need for improved solutions that seamlessly integrate quarter glasses into the vehicle body structure, ensuring both structural integrity and user-friendly design, has become apparent.
[007] In response to these challenges, the automotive industry continually seeks innovative approaches to enhance vehicle design, functionality, and safety. As the demand for 360-degree visibility and ergonomic design grows, there is a pressing need for inventions that redefine how quarter glasses are integrated into vehicle body structures, addressing both form and function.
OBJECTIVES OF THE INVENTION:
[008] The primary objective of the present invention is to design a body structure of a vehicle by integrating a quarter glass window into a C-pillar, providing improved visibility for the driver, particularly in rearward direction and blind spots.
[009] Another objective of the present invention is to design a body section in the C-pillar with the scoop-shaped recess for hand access to the rear door handle, providing ease of opening the rear door handle with comfortable and ergonomic hand access while maintaining a sleek appearance, structural integrity, and torsional rigidity of the vehicle body.
[0010] Another objective of the present invention is to utilize one or more reinforcement brackets and improved joineries strategically to divert torsional load from the lower C-pillar portion to the D-pillar, ensuring efficient load transfer and enhancing structural robustness.
[0011] Another objective of the present invention is to ensure sufficient depth and accessibility while minimizing the impact on the C-pillar section and vehicle aesthetics.
[0012] Still another objective of the present invention is to facilitate fitment of the quarter glass window in the Y-direction, potentially streamlining the manufacturing and assembly process.
[0013] Further objective of the present invention is to enable the use of standard glass pasting sealant instead of requiring preformed dry sealants, potentially reducing costs and improving water sealing performance in the quarter glass zone.
SUMMARY OF THE INVENTION:
[0014] In one aspect of the present invention, a body structure of a vehicle is provided.
[0015] The body structure includes a C-pillar that has a cantrail section and a bottom sill section interconnected by a box section which is segmented into an upper C-pillar portion and a lower C-pillar portion.
[0016] The body structure further includes at least one reinforcement bracket for connecting C-pillar and D-pillar. The reinforcement bracket includes at least one reinforcement C-pillar member that is strategically positioned by an upper C-pillar portion and lower C-pillar portion; at least one reinforcement D-pillar member that is positioned atop the C-pillar cantrail section; and at least one cross-connecting member that is provided between the reinforcement C-pillar member and reinforcement D-pillar member, establishing a rigid connection to the reinforcement bracket.
[0017] The body structure further includes a scoop-shaped recess that is formed in the reinforcement C-pillar member, configured to provide access for opening a rear door handle of the vehicle.
[0018] In accordance with an embodiment of the present invention, the members of the reinforcement bracket are set in order to form a quarter panel window that diverts the direct torsional load from the lower C-pillar portion to the D-pillar through the cross-connecting member and the reinforcement D-pillar member, while allowing a minimal load to the reinforcement C-pillar member, thereby ensuring structural integrity of the vehicle body structure.
[0019] In accordance with an embodiment of the present invention, the body structure further includes a quarter glass that is mounted in the formed quarter panel window, facilitating fitment of the quarter glass in the vehicle Y-direction.
[0020] In accordance with an embodiment of the present invention, the quarter panel window is strategically formed with a larger cross-sectional area through the reinforcement bracket to maximize the section modulus, ensuring efficient load transfer. The amount of load transfer is directly proportional to the section modulus, which, in turn, is directly proportional to the cross-sectional area, thereby enhancing the structural robustness and load-bearing capacity of the vehicle body structure.
[0021] In accordance with an embodiment of the present invention, the scoop-shaped recess is formed within an outer surface of the reinforcement C-pillar member.
[0022] In accordance with an embodiment of the present invention, the body structure utilizes one or more improved joineries for connecting the C-pillar to other structural members of the vehicle body.
[0023] In accordance with an embodiment of the present invention, the improved joineries are selected from a group consisting of welding, adhesive, and fastening techniques.
[0024] In accordance with an embodiment of the present invention, the scoop-shaped recess is formed as an inwardly curved or tapered profile.
[0025] In accordance with an embodiment of the present invention, the scoop-shaped recess is formed with a flushed feature.
[0026] In another aspect of the present invention, a method for manufacturing a vehicle body structure is provided.
[0027] The method includes the steps of: forming a C-pillar with a cantrail section and a bottom sill section connected by a box section; segmenting the C-pillar into an upper C-pillar portion and a lower C-pillar portion; creating a scoop-shaped recess in the reinforcement C-pillar member, providing hand access for opening a rear door handle of the vehicle; providing the cross-connecting member between the reinforcement C-pillar member and reinforcement D-pillar member, establishing a rigid connection to the outer body structure; forming a quarter panel window by connecting the C-pillar to the D-pillar using at least one cross-connecting member; and positioning a quarter glass in the quarter panel window, facilitating fitment of the quarter glass in the vehicle Y-direction.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS:
[0028] The detailed description is described with reference to the accompanying figures.
Figure 1 depicts a body structure of a vehicle, in accordance with an aspect of the present disclosure;
Figure 2A depicts an outer body structure of a vehicle, in accordance with an aspect of the present disclosure;
Figure 2B depicts an inner body structure of a vehicle, in accordance with an aspect of the present disclosure;
Figure 3A depicts a body structure of a vehicle without fitment of quarter glass, in accordance with an aspect of the present disclosure;
Figure 3B depicts a body structure of a vehicle with quarter glass fitment, in accordance with an aspect of the present disclosure;
Figure 4 depicts a lowest Y-section of vehicle body structure, in accordance with an aspect of the present disclosure;
Figures 5A and 5B depicts a cross-sectional view of Y-section of a rear door equipped with a rear door handle, in accordance with an aspect of the present disclosure;
Figure 6 depicts a travel direction of torsional load from C-pillar to D-pillar of vehicle body structure, in accordance with an aspect of the present disclosure;
Figure 7A depicts a first configuration of an average torsional stiffness of vehicle body structure with a tabular and graphical representation, in accordance with an aspect of the present disclosure;
Figure 7B depicts a second configuration of an average torsional stiffness of vehicle body structure with a tabular and graphical representation, in accordance with an aspect of the present disclosure;
Figure 8 depicts a stress plot in Accelerated Durability Test (ADT) cycle for the vehicle body structure (100), in accordance with an aspect of the present disclosure; and
Figure 9 depicts a method for manufacturing a body structure of a vehicle, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION:
[0029] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of the invention as defined by the description. It includes various specific details to assist in the understanding, but these are to be regarded as merely exemplary. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0030] The terms and words used in the following description are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of the present invention is provided for illustration purposes only.
[0031] It is to be understood that the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise.
[0032] Referring to Figure 1, according to an aspect, the present invention discloses a body structure (100) of a vehicle.
[0033] In accordance with an aspect of the present invention, the body structure (100) includes a C-pillar (102) which is a key structural element in a common Body-in-White (BIW) structure of the vehicle. The C-pillar (102) is formed in a way that it connects a cantrail section (104) and a bottom sill section (106) through a box section (107), as depicted in Figure 2B. This box section (107) of C-pillar (102) is adapted to connect a roof structure to the vehicle's body platform. Its design and construction significantly influences the overall structural integrity and torsional stiffness of the vehicle. During an impact, the box-to-box connection absorbs and distributes crash energy, protecting passengers in the rear seat.
[0034] In some aspects of the present invention, the box section (107) of the C-pillar (102) is segmented into an upper C-pillar portion (108) and a lower C-pillar portion (110), as depicted in Figures 2A and 2B, illustrating an outer and inner vehicle body structure (100). This depiction offers insight into the foundational structure of the vehicle, highlighting key elements such as the C-pillar (102), D-pillar (114), and the overall configuration of the body.
[0035] In accordance with an aspect of the present invention, the C-pillar (102) is connected to the D-pillar (114) through a reinforcement bracket (112), to serve as a vital component of the vehicle body structure (100). The reinforcement bracket (112) is engineered to effectively manage one or more torsional loads (128) within the vehicle body structure (100).
[0036] The C-pillar (102), typically located at the rear-most section of the vehicle, provides structural support and rigidity, while the D-pillar (114) forms part of the vehicle's framework, extending from the roof to the rear section. By connecting these pillars (102, 114), the reinforcement bracket (112) effectively distributes loads and torsional forces, optimizing the structural performance of the vehicle.
[0037] In some aspects of the present invention, the reinforcement bracket (112) includes at least one reinforcement C-pillar member (116), at least one reinforcement D-pillar member (118), and at least one cross-connecting member (120).
[0038] In some aspects of the present invention, the reinforcement C-pillar member (116) is strategically positioned by an upper C pillar portion and lower C pillar portion and integrates a scoop-shaped recess (122), as shown in Figures 1 to 4.
[0039] In some aspects of the present invention, the scoop-shaped recess (122) may be formed as an inwardly curved or tapered profile, configured to provide hand access for opening a rear door handle (124) of the vehicle.
[0040] In some aspects of the present invention, the scoop-shaped recess (122) may be formed with a flushed feature.
[0041] In some aspects of the present invention, the reinforcement D-pillar member (118) is positioned atop the C-pillar cantrail section (104), providing additional strength and support, and enhances the overall rigidity of the vehicle body structure (100).
[0042] In some aspects of the present invention, the cross-connecting member (120) is provided between the reinforcement C-pillar member (116) and reinforcement D-pillar member (118), establishing a rigid connection to the reinforcement bracket (112).
[0043] In some aspects of the present invention, the members (116, 118, 120) are configured to form a quarter panel window (126), as shown in Figures 1 to 3A, facilitating load transfer/ distribution from C-pillar (102) to D-pillar (114), i.e., the members (116, 118, 120) of the reinforcement bracket (112) are arranged in a way to direct the direct torsional load (128) away from the lower C-pillar portion (110) towards the D-pillar (114), via the cross-connecting member (120) and the reinforcement D-pillar member (118), as shown in Figure 6, ensuring optimal load-bearing capacity and structural robustness of the vehicle body structure (100).
[0044] The design of the reinforcement bracket (112) is carefully optimized to achieve load diversion while minimizing stress on the reinforcement C-pillar member (116). This strategic distribution of torsional load helps maintain the overall structural integrity of the vehicle body structure (100), ensuring that critical components such as the C-pillar (104) remains resilient under various driving conditions. By allowing only a minimal or no load to be borne by the reinforcement C-pillar member (116), the reinforcement bracket (112) effectively mitigates potential points of weakness and enhances the overall stability of the vehicle body structure (100).
[0045] The reinforcement bracket (112) may be selected from a group consisting of steel alloys, aluminum alloys, composite materials, magnesium alloys, and other hybrid materials. The selection of materials for the reinforcement brackets (112) may depend on various factors, including, but not limited to, structural requirements, manufacturing feasibility, cost considerations, and the overall design objectives of the vehicle.
[0046] In accordance with an aspect of the present invention, the body structure (100) includes a quarter glass (130) mounted within the quarter panel window (126), which is formed by the C-pillar (102) and the reinforcement brackets (112). The quarter glass (130) may preferably be made of a transparent material, providing improved visibility for the driver.
[0047] The structural design of the C-pillar (102), along with the strategic placement of the members (116, 118, 120) of the reinforcement brackets (112), facilitate fitment of the quarter glass (130) in the vehicle Y-direction, ensuring a seamless and efficient installation process.
[0048] In some aspects of the present invention, the quarter panel window (126) may be formed with a larger cross-sectional area, facilitated by the reinforcement bracket (112) to maximize the section modulus. The section modulus is a fundamental parameter in structural engineering that measures a section's resistance to bending and torsional loads. It is directly proportional to the cross-sectional area of the component, indicating that a larger cross-sectional area results in a higher section modulus.
[0049] By maximizing the section modulus of the quarter panel window (126) through strategic design choices, such as cross connecting member (120)placement, the present invention ensures efficient load transfer within the vehicle body structure (100). This efficient load transfer mechanism is essential for enhancing structural robustness and load-bearing capacity. The amount of load transfer is directly proportional to the section modulus, meaning that an increase in the section modulus results in a more effective distribution of loads throughout the vehicle body structure (100).
[0050] In accordance with an aspect of the present invention, maximizing the section modulus of the quarter panel window (126) through the cross connecting member (120) allows the vehicle body structure (100) to withstand higher loads and stresses without compromising its integrity. This is particularly crucial in areas prone to torsional loads, such as the C-pillar section (102) where the quarter panel window (126) is located. By enhancing the structural robustness and load-bearing capacity of the vehicle body structure (100), the present invention contributes to overall vehicle safety and performance.
[0051] In accordance with an aspect of the present invention, the vehicle body structure further includes one or more improved joineries (not shown) that connects the C-pillar (102) to one or more structural members or elements of the vehicle body. The improved joineries may be selected from a group consisting of welding, adhesive, and fastening techniques. Aspects of the present disclosure are intended to include or otherwise cover any type of joineries, including known, related art, and/or later developed technologies, facilitating connection between the C-pillar (102) to one or more structural members or elements of the vehicle body.
[0052] Referring to Figure 3A, according to an aspect, illustrates the vehicle body structure (100) without the fitment of a quarter glass (130), providing a clear visual representation of the vehicle's skeletal framework.
[0053] Referring to Figure 3B, according to an aspect, illustrates the vehicle body structure (100) with the quarter glass (130) fitment, showcasing the integration of the quarter glass (130) into the vehicle body structure (100). With the quarter glass (130) in place, the design achieves a harmonious balance between visibility requirements, design continuity, and structural integrity. The quarter glass (130) fitment serves as a key feature enhancing the overall appeal and functionality of the vehicle, catering to both practical and stylistic considerations.
[0054] Referring to Figure 4, according to an aspect, illustrates lowest Y-section of the vehicle body structure (100). This Y-section of the vehicle body structure may play a pivotal role in supporting the overall integrity and functionality of the vehicle. In the present invention, the quarter glass (130) is integrated into the quarter panel window (126), facilitating fitment of the quarter glass (130) in the vehicle Y-direction which is optimized to meet stringent performance standards while accommodating scoop-shaped recess (122) in the C-pillar (102) of the vehicle body structure (100).
[0055] Referring to Figures 5A and 5B, according to an aspect, illustrates a cross-sectional view of Y-section of a rear door, showcasing the integration of a rear door handle (124). In some aspects of the present invention, the rear door handle (124) may be strategically arranged between the quarter glass (130) and a rear door frame, ensuring optimal functionality and ease of operation to users (138). In some aspects of the present invention, the positioning of the quarter glass (130) edge relative to the support of the rear door handle (124) is carefully considered, highlighting the meticulous attention to detail in the design process.
[0056] In some aspects of the present invention, the vehicle body structure (100) may further include a body side assembly (134) and a rear door assembly (136). The body side assembly (134) is adapted to contribute to the seamless integration of one or more body panels, ensuring a cohesive and visually appealing exterior design, whereas the rear door assembly (136) is configured to encompass one or more components essential for rear door operation, including, but not limited to, hinges, latches, and handles, facilitating smooth access to the vehicle's interior.
[0057] Referring to Figures 7A and 7B, according to an aspect, illustrates a visual representation of the quantitative data derived from comprehensive testing and simulation methods employed to assess the torsional stiffness of the vehicle body structure (100), according to a first and second configurations of an average torsional stiffness.
[0058] The torsional stiffness is a critical parameter in vehicle design, as it determines the vehicle's resistance to twisting forces that may occur during dynamic maneuvers or uneven road conditions. A higher torsional stiffness indicates greater rigidity and stability, leading to improved handling, ride comfort, and overall vehicle performance.
[0059] In some aspects of the present invention, the first configuration incorporates one or more structural components such as Body-in-White (BIW), windshield, Front End Carrier (FEC), and front and rear bumper beams, and excludes battery for assessing the vehicle's torsional stiffness.
[0060] In some aspects of the present invention, the second configuration incorporates one or more key components such as Body-in-White (BIW), windshield, Cross-Car Beam (CCB), front frame, Front End Carrier (FEC), front and rear bumper beams, and battery for assessing the vehicle's torsional stiffness.
[0061] Referring to Figure 8, according to an aspect, illustrates a stress plot, highlighting the areas of the vehicle body structure (100) that experience significant stress concentrations during Accelerated Durability Test (ADT) cycle. This stress plot indicates the stress experienced by the vehicle body structure (100) due to torsional loads, indicating the load travels from C-pillar portion (102) to the D-pillar (114) via the cross-connecting member (120) and the reinforcement D-pillar member (118), whereas only a minimal load travels through the reinforcement C-pillar member (116).
[0062] Referring to Figure 9, according to an aspect, the present invention discloses a method (200) for manufacturing vehicle body structure (100). The method (200) includes an initial step (202), wherein a C-pillar (102) is formed with a cantrail section (104) and a bottom sill section (106) connected by a box section (107). In the next step (204), the C-pillar (102) is segmented into an upper C-pillar portion (108) and a lower C-pillar portion (110). In further step (206), a scoop-shaped recess (122) is formed in the reinforcement C-pillar member (116), providing hand access for opening a rear door handle (124) of the vehicle. In further step (208), the cross-connecting member (120) is provided between the reinforcement C-pillar member (116) and reinforcement D-pillar member (118), establishing a rigid connection to the outer body structure (112). In further step (210), a quarter panel window (126) is formed by connecting the reinforcement C-pillar member (102) to the reinforcement D-pillar member (118) by at least one cross-connecting member (120), and in last step (212), a quarter glass (130) is positioned in the quarter panel window (126), facilitating fitment of the quarter glass (130) in the vehicle Y-direction.
, Claims:We Claim:
1. A body structure (100) of a vehicle, comprising:
a C-pillar (102) having a cantrail section (104) and a bottom sill section (106) interconnected by a box section (107) which is segmented into an upper C-pillar portion (108) and a lower C-pillar portion (110);
at least one reinforcement bracket (112) connecting C-pillar (102) and D-pillar (114), said reinforcement bracket (112) comprising:
at least one reinforcement C-pillar member (116) that is positioned within the upper C-pillar portion (108);
at least one reinforcement D-pillar member (118) that is positioned atop the C-pillar cantrail section (104); and
at least one cross-connecting member (120) that is provided between the reinforcement C-pillar member (116) and reinforcement D-pillar member (118), establishing a rigid connection to the reinforcement bracket (112),
a scoop-shaped recess (122) formed within the upper C-pillar portion (108), configured to provide hand access for opening a rear door handle (124) of the vehicle;
wherein the members (116, 118, 120) of the reinforcement bracket (112) are set-in order to form a quarter panel window (126), diverting the direct torsional load (128) from the lower C-pillar portion (110) to the D-pillar (114) through the cross-connecting member (120) and the reinforcement D-pillar member (118), while allowing a minimal load to the reinforcement C-pillar member (116) ensuring structural integrity of the vehicle body structure (100),
a quarter glass (130) mounted in the formed quarter panel window (126), facilitating fitment of the quarter glass (130).
2. The body structure (100) of the vehicle as claimed in claim 1, wherein the quarter panel window (126) is formed with a larger cross-sectional area through the reinforcement bracket (112) to maximize section modulus, ensuring efficient load transfer, thereby enhancing structural robustness and load-bearing capacity of vehicle body structure (100).
3. The body structure (100) of the vehicle as claimed in claim 1, wherein the scoop-shaped recess (122) is formed within an outer surface of the upper C-pillar portion (108) without changing the profile of the upper C-pillar portion (108) in the vehicle cabin.
4. The body structure (100) of the vehicle as claimed in claim 1, wherein the body structure (100) utilizes one or more improved joineries for connecting the C-pillar (102) to other structural members of the vehicle body.
5. The body structure (100) of the vehicle as claimed in claim 3, wherein the improved joineries are selected from a group consisting of welding, adhesive, and fastening techniques.
6. The body structure (100) of the vehicle as claimed in claim 1, wherein the scoop-shaped recess (122) is formed as an inwardly curved or tapered profile.
7. The body structure (100) of the vehicle as claimed in claim 1, wherein the scoop-shaped recess (122) is formed with a flushed feature.
8. The body structure (100) of the vehicle as claimed in claim 1, wherein the members (116, 118, 120) of the reinforcement bracket (112) facilitate fitment of the quarter glass (130) in the vehicle Y-direction.
9. A method for manufacturing a body structure (100) of a vehicle, the method comprising the steps of:
forming a C-pillar (102) with a cantrail section (104) and a bottom sill section (106) connected by a box section (107);
segmenting the C-pillar (102) into an upper C-pillar portion (108) and a lower C-pillar portion (110);
creating a scoop-shaped recess (122) in a reinforcement C-pillar member (116) for providing hand access for opening a rear door handle (124) of the vehicle;
disposing at least one cross-connecting member (120) between the reinforcement C-pillar member (102) and reinforcement D-pillar member (118);
forming a quarter panel window (126) by connecting the C-pillar (102) to the D-pillar (114) using at least one reinforcement bracket (112); and
positioning a quarter glass (130) in the quarter panel window (126), facilitating fitment of the quarter glass (130) in the vehicle Y-direction.

Dated this 28th day of March, 2024

For MAHINDRA ELECTRIC AUTOMOBILE LTD
By their Agent

(GIRISH VIJAYANAND SHETH) (IN/PA 1022)
KRISHNA & SAURASTRI ASSOCIATES LLP