BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary exploded perspective view of an A-pillar and roof rail shown in conjunction with adjacent parts of a vehicle.
FIG. 2 is a fragmentary front elevation view of the A-pillar and roof rail of the present invention;
FIG. 3 is a cross sectional view taken along line 3-3 in FIG. 1;
FIG. 4 is a cross sectional view taken along the line 4-4 in FIG. 1;
FIG. 5 is a cross-sectional view taken along the line 5-5 in FIG. 1; and
FIG. 6 is a diagrammatic cross sectional view showing a hydroformed support rail for a vehicle having a single thickness of material removed from the pinched flange portions thereof to facilitate welding.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring to FIG. 1, a combined roof rail and A-pillar 10 is shown in position relative to a windshield 12 and a roof 14. A front door opening 16 and rear door opening 18 are provided for doors (not shown) that will be installed adjacent to the roof rail and A-pillar 10.
The roof rail and A-pillar 10 includes a tubular body portion 20 that has a hollow cross section, a windshield support flange 22, a roof support flange 24, and a roof support surface 26. A door opening flange 28 including a front door portion 30 and a rear door portion 32 is also provided on the tubular body portion 20. The flanges are formed from the tubular blank that is also used to form the tubular body portion 20 in a hydroforming operation. The flanges are formed by pinching a portion of the tubular blank during the hydroforming process. A double wall metal thickness area formed by pinching the blank provides a robust and durable flange to which other body panels or brackets may be welded using a resistence welding operation.
Referring to FIG. 2, a front tube connector 36 that is integrally formed as part of the roof rail and A-pillar 10 at the front end 38 of the roof rail and A-pillar 10. First and second blind openings 40 and 42 are shown on the windshield support flange 20 and front door portion 30 of the door opening flange 28. A notch 44 is also shown as part of the front tube connector 36. The blind openings 40, 42 are provided to facilitate welding other components to the front tube connector 36 reducing the number of metal thicknesses to a maximum of three metal thicknesses. The notch 44 is provided to allow access to other components.
A rear tube connector 48 is generally indicated on FIG. 1 that may be formed in a manner similar to the front tube connector 36 including blind openings or a notch as required to provide access for welding the roof rail and A-pillar 10 to the vehicle at the rear end of the roof rail and A-pillar 10.
Referring to FIG. 3, a portion of the roof rail and A-pillar 10 is shown that includes the windshield support flange 22 and the front door portion 30 of the door opening flange 28.
Referring to FIG. 4, a cross sectional view of the roof rail and A-pillar 10 is shown above the front door opening 16 that includes the tubular body portion 20, a roof support flange 24 and the front door portion 30 of the door opening flange 28.
Referring to FIG. 5, a cross section of the roof rail and A-pillar 10 is shown that is located above the rear door opening 18. A rear door portion 32 of door opening flange 28 is illustrated on the lower portion of the roof rail and A-pillar 10. A roof support surface 26 is provided on the top of the roof rail and A-pillar 10. It should be noted that the height of the tubular body portion 20 is increased from the portion of the roof rail and A-pillar 10 shown in FIG. 3 so that it gradually increases as shown in FIG. 4 and to the maximum height shown in FIG. 5. Increasing the height of the hollow cross section of the roof rail and A-pillar 10 increases the strength of the roof rail and A-pillar 10 and improves roof crush performance. By reducing the cross section of the tubular section adjacent the windshield, a smaller A-pillar portion may be provided that offers improved styling possibilities.
Referring to FIG. 6, a support rail 48 is illustrated that has a generally rectangular shape and first and second oppositely oriented flanges 50, 52. The first flange 50 has a blind opening 54 through one thickness of the flange 50 to facilitate welding to a single thickness of metal 56 disposed adjacent to the flange 50. The other flange 52 has a blind opening 60 to facilitate welding the flange to two thicknesses of sheet metal 62, 64 that are disposed on opposite sides of the flange 52.
While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.
Patent Application
20080088157
