GB2640425A

GB2640425A - Pillar sub-assembly

Info

Publication number: GB2640425A
Application number: GB2405435.5A
Authority: GB
Inventors: Sanghera Rashpal; Chivu George-Eugen
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2024-04-18
Filing date: 2024-04-18
Publication date: 2025-10-22
Also published as: WO2025219132A1; GB202405435D0

Abstract

A pillar 10b (figure 1) sub-assembly for a vehicle 1 (figure 1) comprising a plurality of metal elements 22, 24, 26, fixed together to form a pillar structure. At an edge portion of the pillar structure the plurality of metal elements form a respective plurality of layers, wherein there may be adhesive provided between the layers. A first one of the layers extends beyond one or more of the other layers for abutment with a trim 30; due to this the trim can be free of adhesive, squeak and rattle can be reduced, there is a consistent gap to the front windshield 5, and a cleaner abutment with the trim. Also disclosed is a vehicle comprising the pillar sub-assembly and a method of forming the pillar sub-assembly.

Description

PILLAR SUB-ASSEMBLY

TECHNICAL FIELD

The present disclosure relates to a pillar sub-assembly. Aspects of the invention relate to a pillar sub-assembly, a vehicle comprising the sub-assembly, and to a method of forming the pillar sub-assembly.

BACKGROUND

A vehicle body comprises a frame assembly, which includes a main frame (to be welded to a chassis), roof, and a plurality of pillars extending generally upwardly from the main frame to a roof of the frame assembly.

Windows / windscreens are attached between the pillars, and doors are mounted between adjacent pillars.

The pillars typically include "A" pillars (the front-most pillars, to either side of the front windscreen), "B" pillars (between the front doors and rear doors in a five-door vehicle, and "C" pillars (the rear-most pillars, to either side of a rear windscreen).

Following a body-in-white manufacturing stage, internal trims are added to the vehicle, including to the pillars.

In the case of the "A" pillar, when fitting a pillar trim to the pillar, it is conventionally very difficult to control the gap to the front windscreen glass and to provide a robust contact to the body in white. This tends to result in variable gaps (gaping) between the front windscreen and the trim, and squeak and rattle (S&R) issues. These problems stem partly from the use of adhesives on the body in white, the residue of which can interfere with a clean contact between the trim and the "A" pillars.

It is an aim of the present invention to address one or more of the disadvantages associated with the prior art, and in particular to provide a consistent gap to the front windscreen, reduce squeak and rattle, and provide better firmness and feel to the trim upon touch by a user.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a pillar sub-assembly, a vehicle comprising the subassembly, and to a method of forming the pillar sub-assembly as claimed in the appended claims.

According to an aspect of the invention, there is provided a pillar sub-assembly for a vehicle, comprising: a plurality of metal elements, fixed together to form a pillar structure; wherein at an edge portion of the pillar structure the plurality of metal elements form a respective plurality of layers; wherein a first one of the layers extends beyond one or more of the other layers for abutment with a trim of the vehicle.

In this way, a part of the first layer for abutment with the trim can be free of adhesive (because it extends beyond an adjacent layer and the adhesive is provided between layers), enabling a cleaner abutment with the trim.

The first one of the layers may have a castellated edge for abutting the trim. The castellated edge may comprise alternating projections and gaps. The projections of the castellation may extend greater than approximately 1mm from the edge, and preferably are approximately 1.5mm in length. The adhesive in this case is able to spill into the gaps between the projections, rather than onto the projections themselves (which are to contact the trim). This further reduces the likelihood of adhesive interfering with the contact between the pillar sub-assembly and the trim.

The pillar sub-assembly may be considered to comprise the trim, the trim being attached to the pillar structure and abutting the first one of the layers. The pillar sub-assembly as distinct from the trim may be considered part of the body-in-white of the vehicle.

The trim may comprise a plurality of ribs, each rib being aligned with and abutting a projecting portion of the castellated edge. The provision of ribs means that the interface need be controlled only at the ribs, which is easier than seeking to contract a continuous interface along the pillar and trim.

The pillar sub-assembly may be an A-pillar sub-assembly. While the present technique may also be used for other vehicle pillars, it is particularly applicable to the A-pillar, since the other pillars are held securely in place by other means. This is in part due to the "floating" nature of the front edge of the trim, which is required to extend towards (but not quite touch) the windscreen.

An adhesive may be provided between the layers, with an overspill of the adhesive (due to its compression between layers) being inhibited from interfering with the abutment of the trim to the first one of the layers by the extension thereof. The metal elements may be welded and/or riveted together.

The plurality of metal elements may comprise an outer metal element proximate the windscreen, an inner metal element corresponding to the first layer, and an intermediate metal element disposed between the outer metal element and the inner metal element, wherein the inner metal element, the intermediate metal element and the outer metal element define the first layer and second and third layers respectively. The first layer may be approximately 1.5mm in thickness, the second layer may be approximately 1.5mm in thickness, and the third layer may be approximately 1mm in thickness. The third layer may extend continuously beyond the second layer. The first layer may extend beyond the third layer.

According to another aspect, there is provided a vehicle comprising the pillar sub-assembly according to the above. A windscreen of the vehicle may be adhered to the outer (third) layer of the assembly. The trim may comprise a first edge which extends towards a windscreen of the vehicle. The trim may be formed of a plastics material. A fabric may cover a surface of the trim facing away from the pillar structure, wherein the fabric wraps around the first edge.

According to another aspect, there is provided a method of forming a pillar sub-assembly for a vehicle, the method comprising: fixing together a plurality of metal elements to form a pillar structure, wherein at an edge portion of the pillar structure the plurality of metal shells form a respective plurality of layers, and wherein a first one of the layers extends beyond one or more of the other layers; and abutting a trim of the vehicle to the first one of the layers.

Embodiments of the present technique seek to provide an improved pillar location strategy to front glazing (windscreen). Embodiments seek to locate the A pillar trim directly to the closing panel on the body in white by creating local castellations, with the interface being controlled by adding ribs on the abutment surface of the trim (to abut the castellations). The advantage of this is avoiding the body-in-white adessive between panels interfering with an abutment between the pillar and the trim, and more robust general dimension and tolerance (GD&T) for the system.

More specifically, whereas with existing assembly techniques the interface between A pillar trim and the body-in-white is not controlled robustly because of the adhesive flowing on the metal panels (which affects the proper location of the parts in relation to windshield), by extending the element of the A-pillar which is to be abutted the trim beyond the adjacent layer(s), preferably adding small castellations to accommodate defects, and preferably modifying the ribs on the trim, it becomes possible to achieve a more accurate location of the parts relative to each other, and to the windshield. As a result, by controlling the pillar trim in relation to the body-in-white it is possible to solve the gap problems, and to have improved firmness and feel, and reduced squeak and rattle.

From the above, it will be appreciated that embodiments of the present technique relate to the contact between the trim and the body in white of the A-pillar. It is important that the gap between the trim and the windscreen is accurately controlled, and also important that the contact between the trim and the body does not give rise to rattle and squeak, and uniformly resists deformation under pressure. The body in white is made up of multiple shells which are fixed together, generally by welding or riveting. An adhesive is provided between the shells, to inhibit water ingress, soundproof etc. At an edge portion of the A pillar bodyin-white, these joined shells form a plurality of (in this example 3) layers. The adhesive between the layers tends to get squeezed out, forming a mess of adhesive at the edges. This mess of adhesive makes a neat abutment of the trim difficult. One known technique is to cut away the excess adhesive, but this is expensive. The present technique provides an inner layer of the body-in-white edge which extends beyond the middle (and optionally outer) layers, but not continuously -in other words a castellated projecting edge is provided. The projections of the castellation abut ribs provided on the trim. The projections define a longer length to abut the ribs, providing greater stability. The gaps between the projections receive the excess adhesive squeezed out from between the layers of the body-in-white, and since these gaps do not abut the trim, the adhesive does not interfere with the contact between the body-in-white (of the pillar sub-assembly) and the trim.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination.

That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a schematic representation of a vehicle formed from the body in white and sub-assembly of the present technique; Figure 2 shows a schematic cross section through a pillar sub-assembly and trim; Figure 3 shows another schematic view of the pillar sub-assembly and trim; Figure 4 shows another schematic view of the pillar sub-assembly and trim; Figure 5 shows a schematic view of the trim; and Figure 6 shows a schematic cross section through the pillar sub-assembly and trim.

DETAILED DESCRIPTION

A pillar sub-assembly, a vehicle comprising a pillar sub-assembly and a method of forming a pillar sub-assembly in accordance with embodiments of the present invention are described herein with reference to the accompanying figures 1 to 6.

With reference to Figure 1, there is illustrated a simplified top view of an automobile 1 comprising front windshield 5, a first "A' pillar 10a to one side of the front windshield 5 and a second "A" pillar 10b to the other side of the front windshield 5. Each of the "A" pillars 10a, 10b extends from roof 7 of the vehicle 1, downwardly along the side of the windshield 5, and to a main body 9 of the vehicle 1. The windshield 5 is fixed (glued) to the first and second "A" pillars 10a, 10b, and to portions of the roof 7 and main body 9 of the vehicle 1.

With reference to Figure 2, there is illustrated a cross-sectional view through the second "A' pillar 10b. Visible in Figure 2 is a dashboard 12, the windshield 5, first, second and third metal elements (shells) 22, 24, 26, fixed together to form a pillar sub-assembly structure 20, and a trim 30. At the cross-section shown in Figure 2, the metal elements 22, 24, 26 can be seen to be fixed together at two portions A and B. At these portions they form a layered structure with no distance between the layers. Between the portions A and B the metal elements 22, 24, 26 can be seen to be separated from each other, to form a hollow structure. The first 22, second 24 and third 26 metal elements may be described as an outer metal element 26 proximate the windscreen, an inner metal element 22 to which the trim 30 is attached, and an intermediate metal element 24 disposed between the outer metal element 26 and the inner metal element 22. The inner metal element 22, the intermediate metal element 24 and the outer metal element 26 can be considered to define a first layer, second layer and third layer respectively. The trim 30 is attached to the pillar sub-assembly structure 20 internally of the vehicle 1, at the inner metal element 22. The trim 30 comprises a set of ribs 32 which contact an edge portion of the pillar structure 20 at various positions along the length of the trim 30 and pillar structure 20. Only two ribs 32 are clearly visible in Figure 2, but in practice further ribs will be provided spaced along the trim 30.

The metal elements 22, 24, 26 are welded and/or riveted together at the portions A and B. Additionally, an adhesive is provided between the layers of metal elements 22, 24, 26 at the portions A and B, which prevents or at least reduces water ingress, and reduces the transmission of airborne noise. The pillar sub-assembly structure 20, as part of the vehicle frame and before the trim 30 has been attached, is part of the "body in white" (BIVV) of the vehicle 1.

Due to the presence of the adhesives in the sub-assembly 20, there is a tendency for some of the adhesive, initially deposited between the layered elements 22, 24, 26, to be expelled when the layers are compressed together and joined (by welding/riveting). In previous designs, this results in the expelled adhesive being present (in hardened form) at an edge of the pillar structure (at the portion A of the metal elements), at which the plurality of metal elements 22, 24, 26 form the respective plurality of layers referred to above.

Conventionally, this edge contacts the trim, and so the presence of adhesive results in an inferior locating/positioning of the trim and the pillar sub-assembly (body in white) with respect to each other. In particular, the interface between the A pillar trim and the body in white (metal parts of the A-pillar) is not controlled robustly because of the adhesive flowing onto and around the edges of the metal panels, which affects the proper location of the parts in relation to the windshield. This may result in gaping, and squeak and rattle.

With reference to Figure 3, there is illustrated a close-up view of the ribs 32 of the trim 30, and its contact with part of the sub-assembly structure 20. In particular, it can be seen that the first metal element (layer) 22 extends beyond one or more of the other layers (in this case beyond both the second and third metal elements 24, 26) for abutment with the trim 30. More particular, in the present embodiment the layer 22 has a castellated edge for abutting the trim 30. The castellated edge comprises alternating projections (castellations) 29 and gaps. The projections 29 of the castellated edge extend greater than approximately 1mm from the edge, preferably to approximately 1.5mm in length. Each rib 32 of the trim 30 is aligned with and abuts a projecting portion 29 of the castellated edge.

It can be seen from Figure 3 that each rib 32 abuts both an end face 29a of a projection 29 and also a lower face 29b of the projection 29. The rib 32 is shaped to have a cut-out dimensioned to achieve this dual abutment.

In Figure 4 a further view (similar to that of Figure 2) of the assembled "A" pillar is shown. The first, second and third metal elements 22, 24, 26 can be clearly seen, as can the layered structure formed at first and second ends of the elements, where they are immediately proximate and fixed together. The gap between the first and second metal elements 22, 24 can be seen to form a cavity 52, while the gap between the second and third metal elements 24, 26 can be seen to form a cavity 54. Also visible in Figure 4 is a strip of adhesive 40 which bonds the windscreen 5 to the outer layer 26 of the pillar structure.

It can be seen clearly from Figure 4 that a distance between the trim 30 and the windscreen 5 is relatively small. A small gap is desirable to provide an aesthetic interior finish, but does require a narrow tolerance in the accuracy of attachment of the trim 30 to the pillar structure 20, because if the gap reduces too much the trim 30 may come into contact with the windscreen 5, which may cause rattle as vibrations pass through the vehicle 1.

By controlling the position of the pillar trim 30 in relation to the pillar structure 20 of the body in white, the gap can be kept small with a low risk of squeak and rattle. An improved degree of firmness and feel (that is, how much the trim 30 moves and deflects when pressed on by a vehicle occupant) may also be achieved.

Figure 5 shows a view of the trim 30. In Figure 5 the trim 30 can be seen to comprise two parts: a first part 31, which provides structural rigidity, and includes both the main body of the trim 30, and also the ribs 32, is formed of a plastics material. A second part 33 is a fabric part which covers a surface of the trim 30 facing away from the pillar structure 20, and which wraps around an edge of the trim 30 proximate the windshield 5.

The overall thickness (excluding the ribs 32) of the trim 30 for the majority of its periphery about the pillar structure 20 is in this example approximately 3.2mm, of which 0.5mm is the fabric covering 33 and 2.7mm is the plastic part 31. The fabric part 33 can be seen to comprise cut-outs around the ribs 32.

In Figure 6, the contact between the trim 30 and the pillar structure 20 is shown in greater detail. Figure 6 represents a section A-A through Figure 5 (at the position of a rib 32), and its interaction with the corresponding portion of the pillar structure 20. The adhesive 40 and the gap between the trim 30 and the windscreen 5 are clearly visible in Figure 5.

In the present implementation, the inner layer 22 is approximately 1.5mm in thickness, the outer layer 26 is approximately 1mm in thickness and the intermediate layer 24 is approximately 1.5mm in thickness. However, in alternative implementations these thicknesses may vary. Further, in other implementations a greater or fewer number (no less than two) of layers may be present.

As can be seen from Figure 6, the outer layer 26 extends continuously beyond the intermediate layer 24, by an amount d, which may for example be 1.5mm. The inner layer 22 extends (discontinuously) beyond the outer layer 26 by 1.5mm, giving a projection length (beyond the intermediate layer 24) D of 3mm. The trim 30 comprises a first edge which extends towards the windscreen 5 of the vehicle. A distance E between the first edge of the trim 30 and the windshield 5 is approximately 3mm. The present technique permits this distance to be accurately achieved.

By virtue of the above structure, and in particular the extension of the inner layer 22 beyond the intermediate layer 24, an overspill of the adhesive is inhibited from interfering with the abutment of the trim 30 to the (projected part of) the interior layer 22.

In general terms, a method of forming a pillar sub-assembly for a vehicle comprises fixing together a plurality of metal elements to form a pillar structure and then abutting a trim of the vehicle to the first one of the layers. The step of fixing together the metal elements comprises providing an adhesive between the metal elements in regions A and B (to be fixed), and then welding or riveting the metal elements together at or near regions A and B. In such a method, at an edge portion of the pillar structure the plurality of metal shells form a respective plurality of layers, and a first one of the layers 22 extends beyond one or more of the other layers 24, 26. As a result, the trim 30 may be abutted to the extended part of the layer 22, which can be expected to be relatively free of adhesive, since any adhesive expelled from the compression of the layers together will be less likely to flow as far as the portions of the extended parts 29 of the layer 22 to which the trim 30 is abutted.

It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

CLAIMS1. A pillar sub-assembly for a vehicle, comprising: a plurality of metal elements, fixed together to form a pillar structure; wherein at an edge portion of the pillar structure the plurality of metal elements form a respective plurality of layers; wherein a first one of the layers extends beyond one or more of the other layers for abutment with a trim of the vehicle.
2. A pillar sub-assembly according to claim 1, wherein the first one of the layers has a castellated edge for abutting the trim.
3. A pillar sub-assembly according to claim 2, wherein the castellated edge comprises alternating projections and gaps.
4. A pillar sub-assembly according to any preceding claim, comprising the trim, the trim being attached to the pillar structure and abutting the first one of the layers.
5. A pillar sub-assembly according to claim 4 as appendant on claim 2 or claim 3, wherein the trim comprises a plurality of ribs, each rib being aligned with and abutting a projecting portion of the castellated edge.
6. A pillar sub-assembly according to any preceding claim, wherein the pillar sub-assembly is an A-pillar sub-assembly.
7. A pillar sub-assembly according to any preceding claim, wherein an adhesive is provided between the layers, an overspill of the adhesive being inhibited from interfering with the abutment of the trim to the first one of the layers by the extension thereof.
8. A pillar sub-assembly according to any preceding claim, wherein the metal elements are welded and/or riveted together.
9. A pillar sub-assembly according to any preceding claim, wherein the plurality of metal elements comprises an outer metal element proximate the windscreen, an inner metal element corresponding to the first layer, and an intermediate metal element disposed between the outer metal element and the inner metal element, wherein the inner metal element, the intermediate metal element and the outer metal element define the first layer and second and third layers respectively.
10. A pillar sub-assembly according to claim 9, wherein the first layer is approximately 1.5mm in thickness, the second layer is approximately 1.5mm in thickness, and the third layer is approximately 1mm in thickness.
11. A pillar sub-assembly according to claim 9 or claim 10, wherein the third layer extends continuously beyond the second layer.
12. A pillar sub-assembly according to any one of claims 9 to 11, wherein the first layer extends beyond the third layer.
13. A vehicle comprising the pillar sub-assembly according to any preceding claim.
14. A vehicle according to claim 13, wherein a windscreen of the vehicle is adhered to the outer layer of the assembly.
15. A method of forming a pillar sub-assembly for a vehicle, the method comprising: fixing together a plurality of metal elements to form a pillar structure, wherein at an edge portion of the pillar structure the plurality of metal shells form a respective plurality of layers, and wherein a first one of the layers extends beyond one or more of the other layers; and abutting a trim of the vehicle to the first one of the layers.