Claims:We claim:

1. A multipurpose integrated long-member for improving the joinery thereof with the body-in-white (BIW) in automobiles, wherein the long-member comprises:

- a side quarter panel welded by means of spot welds to the flange of the body side inner on the BIW;

- at least one suspension mounting bracket integrally formed on the long-member; and

wherein the integrated long-member is stamped from a sheet-metal with an open section of a predetermined variable cross-section welded to the trailing arm inner reinforcement by means of spot welding.

2. Multipurpose integrated long-member as claimed in claim 1, wherein the suspension mounting bracket is configured on the lower flange of the hat-like section of the long-member.

3. Multipurpose integrated long-member as claimed in claim 1, wherein the open section is a hat-like section having a substantially flat crown disposed in a vertical plane and having flanges connected to the flat crown and tapering outwards from the crown section and having extension on either side disposed parallel to and disposed away from the flat crown thereof.

4. Multipurpose integrated long-member as claimed in claim 1, wherein the thickness of the variable cross-section is in a range of 1.5 mm to 2 mm, preferably approximately 1.8 mm.

5. Multipurpose integrated long-member as claimed in claim 1, wherein the variable cross-section is spot welded to the trailing arm inner reinforcement by means of 2T spot welding.

6. Multipurpose integrated long-member as claimed in claim 1, wherein the open-section long-member displays a substantially higher torsional stiffness with respect to the comparable closed-section long-member, preferably the open-section long-member is approximately three times stiffer than the closed-section long-member.

7. Multipurpose integrated long-member as claimed in claim 1, wherein the open-section long-member displays a substantially higher torsional stiffness in a range of 10 to 12 kN-m/degree, preferably approximately 11.5 kN-m/degree.

8. Multipurpose integrated long-member as claimed in claim 6, wherein the open-section long-member displays a substantially lower deflection with respect to the comparable closed-section long-member, preferably the open-section long-member deflects approximately one-third of the closed-section long-member.

9. Multipurpose integrated long-member as claimed in claim 7, wherein the open-section long-member deflects in a range of 1.5 mm to 2.5 mm, preferably approximately 2 mm.

10. A multipurpose integrated long-member for improving the joinery thereof with the body-in-white (BIW) in automobiles, wherein the long-member comprises a side quarter panel welded by means of spot welds to the flange of the body side inner on the BIW; at least one suspension mounting bracket integrally formed on the lower flange of the hat-like section of the long-member, the hat-like section having a substantially flat crown disposed in a vertical plane and having flanges connected to the flat crown and tapering outwards from the crown section and having extension on either side disposed parallel to and disposed away from the flat crown thereof; and wherein the integrated long-member is stamped from a sheet-metal with an open section of a predetermined variable cross-section welded to the trailing arm inner reinforcement by means of spot welding.

Dated: this day of 12th January 2016. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT , Description:FIELD OF INVENTION

The present invention relates to the long-member of Body-In-White (BIW) for automotive vehicles. In particular, the invention relates to an integrated long-member of a BIW. More particular, the invention relates to imparting a global stiffness and structural durability to an integrated long-member of a BIW.

BACKGROUND OF THE INVENTION

In automotive vehicles, the joinery between the long members and body side inners is very critical to transfer the loads from the rear bump stop to the load bearing members. Therefore, the spot welds at these locations play a very critical role and are normally under tension load in the convention BIW design. The spot welds are weak under tensile loads and prove substantially stronger under shear loading.

The long-member is a critical component in any automobile, which supports the complete chassis and body of the vehicle, thus making it an important component from the strength, durability and safety point of view.

DISADVANTAGES WITH THE PRIOR ART

The conventional BIWs have a torsional stiffness of 3.19 kN-m / degree, which is way below the acceptance criteria of > 8 kN-m / degree.

In conventional Body-In-White, the long member is provided with mounting suspension and brackets. However, the torsional stiffness of such BIW is not satisfactory. Therefore, the structural durability of BIW is not enough.

Since, the conventional long-member is connected to body side panel and floor, the joinery of long member with BIW should be sufficiently improved in order to improve the global stiffness and structural durability. Therefore, it would be useful to configure a multipurpose integrated long-member, in which the spot welds are under shear load instead of tension as in existing designs.

DESCRIPTION OF THE PRESENT INVENTION

The multipurpose integrated long-member configured according to the present invention completely changes the conventional design.

Accordingly, the multipurpose integrated long-member is configured to subject the spot welds under shear loading. The Integrated long-member simultaneously connects the body side inner and floor of the vehicle to impart improved global stiffness and durability with comparatively lesser weight. It also serves as an outer trailing suspension mounting bracket, which is very easy to assemble in the vehicle assembly line.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide a light-weight long-member for body-in-white (BIW).

Another object of the present invention is to provide a stronger long-member for BIW having greater torsional stiffness.

Still another object of the present invention is to provide an improved long-member for imparting greater structural durability to BIW.

Yet another object of the present invention is to provide an improved long-member whereby joinery of the long-member with BIW is substantially improved.

A further object of the present invention is to provide an improved long-member which obviates the need of a separate suspension mounting bracket.

A still further object of the present invention is to provide an improved long-member having spot-welds to improve its performance under shear stresses.

A yet further object of the present invention is to provide an improved long-member which also improves the aesthetic appeal of the BIW.

These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a multipurpose integrated long-member for improving the joinery thereof with the body-in-white (BIW) in automobiles, wherein the long-member comprises:

- a side quarter panel welded by means of spot welds to the flange of the body side inner on the BIW;

- at least one suspension mounting bracket integrally formed on the long-member; and

wherein the integrated long-member is stamped from a sheet-metal with an open section of a predetermined variable cross-section welded to the trailing arm inner reinforcement by means of spot welding.

Typically, the suspension mounting bracket is configured on the lower flange of the hat-like section of the long-member.

Typically, the open section is a hat-like section having a substantially flat crown disposed in a vertical plane and having flanges connected to the flat crown and tapering outwards from the crown section and having extension on either side disposed parallel to and disposed away from the flat crown thereof.

Typically, the thickness of the variable cross-section is in a range of 1.5 mm to 2 mm, preferably approximately 1.8 mm.

Typically, the variable cross-section is spot welded to the trailing arm inner reinforcement by means of 2T spot welding.

Typically, the open-section long-member displays a substantially higher torsional stiffness with respect to the comparable closed-section long-member, preferably the open-section long-member is approximately three times stiffer than the closed-section long-member.

Typically, the open-section long-member displays a substantially higher torsional stiffness in a range of 10 to 12 kN-m/degree, preferably approximately 11.52 kN-m/degree.

Typically, the open-section long-member displays a substantially lower deflection with respect to the comparable closed-section long-member, preferably the open-section long-member deflects approximately one-third of the closed-section long-member.

Typically, the open-section long-member deflects in a range of 1.5 mm to 2.5 mm, preferably approximately 2 mm.

In accordance with the present invention, there is also provided a multipurpose integrated long-member for improving the joinery thereof with the body-in-white (BIW) in automobiles, wherein the long-member comprises a side quarter panel welded by means of spot welds to the flange of the body side inner on the BIW; at least one suspension mounting bracket integrally formed on the lower flange of the hat-like section of the long-member, the hat-like section having a substantially flat crown disposed in a vertical plane and having flanges connected to the flat crown and tapering outwards from the crown section and having extension on either side disposed parallel to and disposed away from the flat crown thereof; and wherein the integrated long-member is stamped from a sheet-metal with an open section of a predetermined variable cross-section welded to the trailing arm inner reinforcement by means of spot welding.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings, which include:

Figure 1 shows a conventional Body-In-White (BIW) showing the long-member.

Figure 2 shows the conventional configuration of the long-member shown in Fig. 1.

Figure 3 shows the section of the long-member shown in Fig. 2.

Figure 4 shows the first method for welding the long-member section of the conventional Body-In-White (BIW) shown in Fig. 2.

Figure 5 shows second method for welding of the long-member section of the conventional Body-In-White (BIW) shown in Fig. 2.

Figure 6 shows the configuration of the Body-In-White (BIW) showing the modified long-member encircled in red color in accordance with the present invention.

Figure 7 shows the stamped long-member with integrated suspension mounting bracket configured in accordance with the present invention.

Figure 8 shows an enlarged view of BIW depicting the stamped long-member in accordance with the present invention.

Figure 9 shows the cross-section of the long-member depicted along the section line A - A in accordance with the present invention.

Figure 10 shows the typical method for welding of the hat-like section of the stamped long-member section depicted in Fig. 6.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, different embodiments of the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

Figure 1 shows a conventional Body-In-White (BIW) 10 depicting a typical configuration of the rear long-member 20.

Figure 2 shows the conventional configuration of the rear long-member 20 depicted in Figure 1, which is connected to body side panel and vehicle floor. It requires a separate mounting bracket 25 for supporting the suspension system (not shown).

Figure 3 shows the hydroform section 30 of the rear long-member 20 of Figure 2. One such typical hydroform section 30 includes, e.g. uniform section of 50 x 60 mm having 1.8 mm thickness. This requires a separate mounting bracket 25 (Figure 2) for the suspension system (not shown).

Figure 4 shows the first method for welding the rear long-member section 30 of 50 x 60 mm with 1.8 mm thickness for the conventional Body-In-White (BIW) 10 as shown in Figure 2. Here, only CO2 seam welding is possible for sub-assemblies, e.g. the trailing arm inner bracket 32; because it is a closed section 30 with more overlap with the trailing arm inner reinforcement 40. However, seam welding is not advisable for smaller thickness components.

Figure 5 shows second method for welding of the rear long-member section 30 of the conventional Body-In-White (BIW) 10 as shown in Figure 2. In this configuration, the spot-welds 50 made by CO2 seam welding between the trailing arm inner reinforcement 40 and the rear long member 30 are possible with lesser overlap for trailing arm inner reinforcement 40. The bottom spot welds 52 CO2 made by seam welding between the trailing arm inner reinforcement 40 and the rear long member 30 are in tension here. This configuration has been proven to be disadvantageous and therefore a comparatively weaker design.

Figure 6 shows the configuration of the floor riser 100 showing the modified long-member 120 which is a component stamped in accordance with the present invention.

Figure 7 shows the stamped long-member 120 configured with integrated suspension mounting bracket in accordance with the present invention, which includes a body side quarter panel 102 and an integral trailing arm mounting bracket 104 configured for supporting the suspension system. The hat-like section along the section line A – A is depicted in more details in Figure 9.

Figure 8 shows an enlarged view of BIW 100 depicting the stamped long-member 120 of Figure 7 welded to the body side quarter panel 110 by means of 2T spot welds to the flange 102 of the body side inner. The stamped long-member 120 does not require a separate suspension mounting bracket, because it has an integral trailing arm mounting bracket 104 configured for supporting the suspension system.

Figure 9 shows the long-member 120 along the section line A - A depicting the typical hat-like stamped section 130 thereof, which is a sheet metal stamped part having a variable section with 1.8 mm thickness.

Figure 10 shows the method for welding of the long-member section 130 of the modified long-member 120 shown in Figure 6. It is made by spot-welding between the hat-like stamped section 130 of the long member 120 and the floor riser 100.

Therefore, this long member configuration is substantially stronger under shear stresses than under tension, making it preferable for BIW construction. The hat-like stamped section 130 is a sheet metal stamped part with a variable section, for example, with 1.8 mm thickness.

WORKING OF THE INVENTION:

The acceptance criterion under the mandatory torsional stiffness test is > 8kN-m/deg. A 3 kN-m moment is applied at the front end under this test. The force is calculated and applied at the ends of rigid bar in opposite directions.

The conventional configuration of Figures 1 to 5 exhibit a torsional stiffness value of just 3.19 kN-m/Degree with a deflection of 7.29 mm, whereas the modified configuration according to Figures 6 to 9 exhibit a torsional stiffness value of 11.54 kN-m/degree with a deflection of just 2.07 mm. This is a substantially improved performance with respect to the comparable conventional closed section design.

Therefore, the modified hat-like open section design of the long-member configured in accordance with the present invention is particularly suitable for small vehicles segment.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The multipurpose integrated long-member of Body-In-White configured in accordance with the present invention has the following advantages:

• Light in weight

• Stronger against torsional forces

• Impart greater structural durability to BIW

• Improves the joinery of the long-member with BIW

• Does not require separate suspension mounting brackets

• Spot-welds improve long-member performance under shear stresses

• Improves aesthetic appeal of BIW.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps. In the claims and the description, the terms “containing” and “having” are used as linguistically neutral terminologies for the corresponding terms “comprising”.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention. Furthermore, the use of the term “one” shall not exclude the plurality of such features and components described.

The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention. The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification.

In the previously detailed description, different features have been summarized for improving the conclusiveness of the representation in one or more examples.

However, it should be understood that the above description is merely illustrative, but not limiting under any circumstances. It helps in covering all alternatives, modifications and equivalents of the different features and exemplary embodiments.

Many other examples are directly and immediately clear to the skilled person because of his/her professional knowledge in view of the above description.

Therefore, innumerable changes, variations, modifications, alterations may be made and/or integrations in terms of materials and method used may be devised to configure, manufacture and assemble various constituents, components, subassemblies and assemblies according to their size, shapes, orientations and interrelationships.

While considerable emphasis has been placed on the specific features of the preferred embodiment described here, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

The exemplary embodiments were selected and described in order to be able to best represent the principles and their possible practical application underlying the invention. Thereby, the skilled persons can optimally modify and use the invention and its different exemplary embodiments with reference to the intended use.