FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
T I T L E “Modular side body wall structure for a vehicle”
APPLICANT
TATA MOTORS LIMITED
Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400001, Maharashtra, India
The following specification particularly describes the invention and the manner in which it is to be performed

FIELD OF THE INVENTION [0001] The present invention relates to the field of automotive engineering, particularly to a modular side body wall structure for a vehicle.
BACKGROUND OF THE INVENTION [0002] Vehicle side body structure is an integral part of vehicle. The various vehicle classes include hatch, sedan, UV and style. Most of the vehicles are based on same platform but each vehicle class has different side body assembly. The conventional vehicle body structure comprises right inner panel circumference, the outer panel, and different reinforcing plate welded parts. The vehicle side body assembly is big in size and has considerable amount of weight. As it defines the vehicle class, it changes from vehicle to vehicle even if two different vehicles are on the same platform. The FIG. 1 illustrates existing section of vehicles, according to prior arts The existing section has three sheet metal panels construction joined together with welding. The process of development of new models, due to changes in appearance, will inevitably lead to change the structural characteristics of the inner body panel. This need to develop the side body structure greatly increases the manufacturing cost.
[0003] Thus, it is desired to address the above mentioned disadvantages or other shortcomings or at least provide a useful alternative. Also, there remains a need for modular side body wall structure that can be modularized based the vehicle class requirement.
OBJECT OF THE INVENTION [0004] The principal object of the present invention is to provide a modular side body wall structure for a vehicle. The modular design of the proposed side body wall structure is light in weight and assist for easy design conversion to a new vehicle class on same platform.

[0005] Yet another object of the present invention is to provide the modular side body wall structure that comprises an A-pillar assembly of plastic material, an upper cover assembly of plastic material, a C-pillar assembly of plastic material, and a lower cover assembly of plastic material.
[0006] Yet another object of the present invention is to mount the A-pillar assembly, the C-pillar assembly, the upper cover assembly and the lower cover assembly on a sheet metal body structure of the vehicle forming a body front frame assembly.
[0007] Yet another object of the present invention is to provide the C-pillar assembly that is customizable based on a design of the vehicle.
SUMMARY OF THE INVENTION
[0008] In accomplishing the objects of the invention, there has been provided, according to one aspect of the invention, a modular side body wall structure for a vehicle. The modular side body wall structure comprises an A-pillar assembly of plastic material, an upper cover assembly of plastic material, a C-pillar assembly of plastic material, and a lower cover assembly of plastic material. The A-pillar assembly, the C-pillar assembly, the upper cover assembly and the lower cover assembly are mounted on a sheet metal body structure of the vehicle forming a body front frame assembly.
[0009] In an embodiment, the upper cover assembly is a roof side rail assembly or an upper beam assembly.
[0010] In an embodiment, the lower cover assembly is a sill cover or a lower beam assembly.
[0011] In an embodiment, the A-pillar assembly and the C-pillar assembly is fixed to the upper cover assembly to form the body front frame assembly.
[0012] In an embodiment, the A-pillar assembly, the C-pillar assembly, the upper cover assembly and the lower cover assembly are mounted on the sheet metal

body structure using at least one of weld stud, hex nut, bolts, rivets, and mechanical fasteners.
[0013] In an embodiment, the C-pillar assembly is customizable based on a design of the vehicle.
[0014] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF FIGURES
[0015] This system is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0016] The FIG. 1 illustrates existing section of vehicles, according to the prior art;
[0017] FIG. 2 illustrates an explored view of a customizable side body wall structure for a vehicle, according to an embodiment as disclosed herein;
[0018] FIG. 3 illustrates an assembled view of a customizable side body wall structure for a vehicle, according to an embodiment as disclosed herein;
[0019] FIG. 4 illustrates a section view at a roof side rail assembly or an upper beam assembly, according to an embodiment as disclosed herein;
[0020] FIG. 5 illustrates a section view at a sill cover rail area or a lower beam assembly, according to an embodiment as disclosed herein;

[0021] FIG. 6 illustrates an example customizable side body wall structure mounted a vehicle, according to an embodiment as disclosed herein;
[0022] FIG. 7a illustrates an example customizable side body wall structure for a hatch-type vehicle, according to an embodiment as disclosed herein;
[0023] FIG. 7b illustrates an example customizable side body wall structure for a sedan-type vehicle, according to an embodiment as disclosed herein;
[0024] FIG. 7c illustrates an example customizable side body wall structure for a Multi-Purpose Vehicle (MPV)-type vehicle, according to an embodiment as disclosed herein; and
[0025] FIG. 7d illustrates an example customizable side body wall structure for a sport utility vehicle (SUV)-type vehicle, according to an embodiment as disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION [0026] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0027] Embodiments herein discloses a modular side body wall structure for a vehicle. The modular side body wall structure comprises an A-pillar assembly of plastic material, an upper cover assembly of plastic material, a C-pillar assembly of plastic material, and a lower cover assembly of plastic material. The A-pillar assembly, the C-pillar assembly, the upper cover assembly and the lower cover assembly are mounted on a sheet metal body structure of the vehicle forming a body front frame assembly.
[0028] Unlike the conventional systems, the proposed modular side body wall structure is light in weight and assist for easy design conversion to new vehicle on same platform. The proposed customizable side body wall structure reduces the vehicle weight and also modularizes side body assembly for any type of vehicle. The modular side body wall structure comprises a body set outer panel made of a plastic/composite material mounted on a sheet metal body layout with the help of an inner plastic/composite material substructure. It is to be noted that the inner substructure is joined with the inner panel using weld stud and hex nut combination.

Further, the inner substructure may be joined with the outer panel by using mechanical fasteners. It is observed that the trims parts provide an advantage to customize the side body panel areas as per customer demands, market trends and vehicle variants. The trim parts may be made removable at customer/dealer end to get a new look for the same vehicle without changing the inner substructure of the vehicle body.
[0029] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
[0030] Referring now to the drawings, and more particularly to FIGS. 2 through 4, there are shown preferred embodiments.
[0031] FIG. 2 illustrates an explored view of a modular side body wall structure for a vehicle, according to an embodiment as disclosed herein. The modular side body wall structure comprises an A-pillar assembly (102) of plastic material, an upper cover assembly (104) of plastic material, a C-pillar assembly (106) of plastic material, and a lower cover assembly (108) of plastic material. The A-pillar assembly (102), the C-pillar assembly (106), the upper cover assembly (104) and the lower cover assembly (108) are mounted on a sheet metal body structure of the vehicle forming a body front frame assembly. In an embodiment, the upper cover assembly (104) is a roof side rail assembly or an upper beam assembly. In an embodiment, the lower cover (108) assembly is a sill cover or a lower beam assembly. In an embodiment, the C-pillar assembly is customizable based on a design of the vehicle. The sheet metal body structure act as an inner panel and the customizable side body

wall structure act as an outer panel mounted on the sheet metal body structure with the help of inner Plastic/composite material to form the body front frame.
[0032] FIG. 3 illustrates an assembled view of a customizable side body wall structure for a vehicle, according to an embodiment as disclosed herein. When assembled, the A-pillar assembly (102) and the C-pillar assembly (106) is fixed to the upper cover assembly (104) to form the body front frame assembly. The A-pillar assembly (102), the C-pillar assembly (106), the upper cover assembly (104) and the lower cover assembly (108) are mounted on the sheet metal body structure using at least one of weld stud, hex nut, bolts, rivets, and mechanical fasteners.
[0033] Unlike the conventional side wall structure, the complete assembly is divided based on its functions as aesthetic skin panels and strength carrying members. The strength carrying members have all body side inner panels made from sheet metal to retain same stiffness for passenger safety and the aesthetic skin panels are the A-pillar assembly (102) of plastic material, the upper cover assembly (104) of plastic material, the C-pillar assembly (106) of plastic material, and the lower cover assembly (108) of plastic material.
[0034] FIG. 4 illustrates a section view at a roof side rail assembly or an upper beam assembly, according to an embodiment as disclosed herein. The A-pillar assembly, the C-pillar assembly, the upper cover assembly and the lower cover assembly are mounted on the sheet metal body structure using at least one of weld stud, hex nut, bolts, rivets, and mechanical fasteners. Unlike the conventional systems, following are advantages over the conventional systems:

Construction Hybrid construction with plastic or composite outer layer
Joining Process Mechanical fasteners, weld stud, hex nut and combination thereof
Interchangeability Replaceable at user end
Common parts Modular for same platform vehicles

[0035] FIG. 5 illustrates a section view at a sill cover rail area or a lower beam assembly, according to an embodiment as disclosed herein.
[0036] FIG. 6 illustrates an example customizable side body wall structure mounted a vehicle, according to an embodiment as disclosed herein. The illustrated structural and rigidity function serving panels are made up of Body in White (BIW). Aesthetic skin panels such as the A-pillar assembly, the C-pillar assembly, the cant rail and the sill cover are converted to plastics, together forming the complete body side wall structure assembly.
[0037] Converting sheet metal to plastic offers significant weight advantage, making assembly lightweight with same structural rigidity. Plastic parts have unique advantage of having better style, finish over the BIW components. As per latest trends in automobiles, vehicle sides along with roof panel are decorated with various colorful patterns. Trims parts give big advantage to customize these areas as per customer demands, market trends and vehicle variants. The trim parts can be made removable at customer/dealer end to get a new look for the same vehicle.
[0038] In the conventional systems, it is to be noted that although Original Equipment Manufacturer (OEM) uses same platform to make vehicles of different class (such as hatch, sedan, SUV, MPV), conventional body side assembly is different for each class of vehicle due to different styling. In the proposed invention, as complete body side assembly is split into sub-assemblies, common assemblies to be used for different vehicles. Effective change to be kept around the C-pillar assembly (106) to define each vehicle class & style as shown in the FIGS. 7a-7d. As illustrated in the FIGS. 7a-7d, the pillar assembly (101), the upper cover assembly (104) and the lower cover assembly (108) are common. The change is limited for the C-pillar assembly only resulting in saving in capex on tooling, manufacturing, supplier, design costs compared to the conventional systems. Further, this enables the vehicle body side wall/trim assembly changeable/customization at customer/dealer end to make alternatives and meet the customer requirements.

[0039] For example, FIG. 7a illustrates an example modular side body wall structure for a hatch-type vehicle, according to an embodiment as disclosed herein. The C-pillar assembly (106) is customized based on a design of hatch-type of the vehicle. FIG. 7b illustrates an example modular side body wall structure for a sedan-type vehicle, according to an embodiment as disclosed herein. The C-pillar assembly (106) is customized based on a design of sedan-type of the vehicle. FIG. 7c illustrates an example modular side body wall structure for a MPV-type vehicle, according to an embodiment as disclosed herein. The C-pillar assembly (106) is customized based on a design of MPV-type of the vehicle. FIG. 7d illustrates an example modular side body wall structure for a SUV-type vehicle, according to an embodiment as disclosed herein. The C-pillar assembly (106) is customized based on a design of SUV-type of the vehicle.
[0040] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

STATEMENT OF CLAIMS
I/We Claim:
1. A modular side body wall structure for a vehicle, the structure comprises:
an A-pillar assembly (102) of a plastic material;
an upper cover assembly (104) of a plastic material;
a C-pillar assembly (106) of a plastic material; and
a lower cover assembly (108) of a plastic material,
wherein the A-pillar assembly (102), the C-pillar assembly (106), the upper cover assembly (104) and the lower cover assembly (108) are mounted on a sheet metal body structure of the vehicle forming a body front frame assembly.
2. The modular side body wall structure as claimed in claim 1, wherein the upper cover assembly (104) is a roof side rail assembly or an upper beam assembly.
3. The modular side body wall structure as claimed in claim 1, wherein the lower cover assembly (108) is a sill cover or a lower beam assembly.
4. The modular side body wall structure as claimed in claim 1, wherein the A-pillar assembly (102) and the C-pillar assembly (106) are fixed to the upper cover assembly (104) to form the body front frame assembly.
5. The modular side body wall structure as claimed in claim 1, wherein the A-pillar
assembly (102), the C-pillar assembly (106), the upper cover assembly (104) and
the lower cover assembly (108) are mounted on the sheet metal body structure
using at least one of weld stud, hex nut, bolts, rivets, and mechanical fasteners.
6. The modular side body wall structure as claimed in claim 1, wherein the C-pillar
assembly (106) is customizable based on a design of the vehicle.