USOO7344186B1

(12) United States Patent (10) Patent No.: US 7,344,186 B1

Hausler et al. (45) Date of Patent: Mar. 18, 2008

(54) A-PILLAR STRUCTURE FOR AN Primary Examiner Joseph D Pape

AUTOMOTIVE VEHICLE (74) Attorney, Agent, or Firm—Fredrick Owens; Miller Law
(75) Inventors: Henry Hausler, Manchester, MI (US); Group, PLLC
John Reed, Hudson, OH (US)
(73) Assignee: Ford Global Technologies, LLC, (57) ABSTRACT
Dearborn, MI (US)
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 An A-pillar structure on an automotive vehicle is manufac
U.S.C. 154(b) by 0 days. tured from a formed tubular member that replaces the
conventional inner and inner reinforcement members. The
(21) Appl. No.: 11/650,751 door opening panel is formed with conventional flanges that
are welded or adhered to the tubular member to provide a
(22) Filed: Jan. 8, 2007 conventional uniform Surface against which the windshield
(51) Int. Cl. and front door seals can be supported. The door opening
B62D 25/00 (2006.01) panel flanges can be welded by one-sided welding tech
(52) U.S. Cl. ............................. 296/1870s. 296/19306 niques, such as laser stitch welding, to the tubular member.
(58) Field of Classification Search ........... 206/1870s.
296/193.06. 203.O2, 203.03.205, 187.03
As an option, the movement of the front door seal from the
ab flange to the front door can provide an opportunity to
s s 296f 87.09, 1871 form the tubular member with a still larger cross-section for
See application file for complete search history. enhanced strength. The distance dimension spanning the
opposing flanges to define the standard arc for maintaining
(56) References Cited binocular vision is retained while increasing the strength of
U.S. PATENT DOCUMENTS the A-pillar due to the enlarged cross-sectional configuration
provided by the tubular member.
7,168,756 B2 * 1/2007 Hasegawa et al. ..... 296,2O303
* cited by examiner 17 Claims, 2 Drawing Sheets
U.S. Patent Mar. 18, 2008 Sheet 1 of 2 US 7,344,186 B1
U.S. Patent Mar. 18, 2008 Sheet 2 of 2 US 7,344,186 B1
 US 7,344,186 B1
1. 2
A-PLLAR STRUCTURE FOR AN It is another object of this invention to maintain the
AUTOMOTIVE VEHICLE dimensional standards in the A-pillar for providing binocular
vision by the operator of the automobile.
FIELD OF THE INVENTION It is a feature of this invention that the conventional inner
member and the conventional reinforcement member of an
This invention relates generally to an A-pillar on an A-pillar are replaced by a tubular member shaped to Support
automotive vehicle and, more particularly, to a structural the flanges of the door operating panel.
configuration that will maximize the cross-sectional con It is another feature of this invention that laser stitch
figuration while maintaining binocular vision for the opera welding techniques, one-sided welding techniques and adhe
tor of the vehicle. 10 sive technologies can be utilized to secure the door operating
panel to the tubular A-pillar member.
BACKGROUND OF THE INVENTION It is an advantage of this invention that the strength of the
A-pillar is substantially increased over conventional A-pillar
The A-pillars on an automotive vehicle are the structural design.
members of an automotive frame positioned between the 15 It is another advantage of this invention that the dimen
windshield and the front doors. The A-pillars support the sions for maintaining binocular vision for the vehicle opera
roof structure as well and, therefore, must provide substan tor are not exceeded.
tial support in rollover events. At the same time, the A-pillar It is still another object of this invention to provide an
lies within the sight lines of the operator and needs to have A-pillar having maximum cross-section with little or no
a minimal profile to allow the operator to maintain binocular effect on vision requirements.
vision with respect to the A-pillar. Thus, the designers of It is still another feature of this invention that the tubular
automobiles are faced with conflicting requirements with member can be manufactured utilizing hydroforming tech
respect to the design of the A-pillars. To provide a strong niques.
structural member, the A-pillar needs to have a maximum It is still another advantage of this invention that the
cross-sectional configuration, yet maintain a minimal cross 25 manufacturing techniques other than hydroforming can be
section for vision purposes. used to form the tubular member, including roll-forming
To achieve maximum cross-section of a tubular inner techniques.
member for an A-pillar body structure, while maintaining It is yet another feature of this invention that the tubular
acceptable binocular vision standards, a traditional flange member is designed to fit behind the outer surface of the
formation and welding is restrictive. The flanges provide for 30
door opening panel.
a sealing relationship with respect to both the windshield
and the front door that are supported on the A-pillars. BRIEF DESCRIPTION OF THE DRAWINGS
Typically, the elastomeric seals for both the windshield and
the adjacent portion of the front doors are mounted on the The advantages of this invention will become apparent
flanges of the A-pillars. The door opening panel is typically 35
upon consideration of the following detailed disclosure of
welded on the outside of the A-pillar structure to provide a the invention, especially when taken in conjunction with the
uniform surface against which the front door can close. accompanying drawings wherein:
The conventional A-pillar structure is reflected in FIG. 2, FIG. 1 is schematic perspective view of an automotive
which is a cross-sectional view of the A-pillar corresponding vehicle having an A-pillar Supporting the windshield and
to lines A-A of FIG.1. The A-pillar 10 is formed of a shaped 40
front door assembly, and incorporating the principles of the
inner member 12 that is formed with opposing vertically instant invention;
extending flanges. A reinforcement member 15 having mat FIG. 2 is a cross-sectional view of the conventional
ing flanges is welded at the flanges to the outer side of the A-pillar structure, corresponding to lines A-A of FIG. 1, the
inner member 12 to form a generally vertically extending description of this prior art A-pillar structural configuration
beam 10. The door opening panel 16 is also formed with 45
being found in the Background of the Invention above:
mating flanges that are welded to the flanges of the rein FIG. 3 is a cross-sectional view of a first embodiment of
forcement member 15. The door opening panel 16 provides the A-pillar incorporating the principles of the instant inven
a uniform surface for support of the windshield 17 supported tion, the cross-sectional view corresponding to lines A-A of
in an elastomeric seal 18 against the welded flange 13, while FIG. 1;
the front door (not shown) closes against a seal (not shown) 50
FIG. 4 is a cross-sectional view of a second embodiment
typically mounted on the opposing welded flange 14. The of the A-pillar incorporating the principles of the instant
distance from the lateral ends of the opposing welded invention, the cross-sectional view corresponding to lines
flanges 13, 14 defines the arc of seven and a half degrees, or A-A of FIG. 1; and
less, relative to the position of the operator of the vehicle. FIG. 5 is cross-sectional view of a third embodiment of
It would be desirable to provide an A-pillar configuration 55
the A-pillar incorporating the principles of the instant inven
that has an increased cross-section and greater tube size to tion, the cross-sectional view corresponding to lines A-A of
provide a greater measure of strength for the A-pillar, while FIG 1.
maintaining dimensional standards for binocular vision by
the operator of the vehicle. DETAILED DESCRIPTION OF THE
60
SUMMARY OF THE INVENTION PREFERRED EMBODIMENT

It is an object of this invention to overcome the afore Referring to FIGS. 1-5, an A-pillar structure for an
mentioned disadvantages of the known prior art by provid automotive vehicle incorporating the principles of the
ing an A-pillar configuration that utilizes greater tube size 65 instant invention can best be seen. The automotive vehicle 5
and defines a larger cross-section than conventional A-pil is formed with an A-pillar 10 that supports the roof 6, the
lars on automotive vehicles. front door 7 and the windshield 17. FIG. 2 is a depiction of
 US 7,344,186 B1
3 4
the conventional prior art A-pillar structure over which the 061, filed on Aug. 22, 2006 by John Reed, et al and entitled
instant invention represents an improvement. The conven “Roll-Formed Structural Member with Internal Web”,
tional A-pillar structure is reflected in FIG. 2, which is a assigned to Ford Global Technologies, LLC, or by a hydro
cross-sectional view of the A-pillar corresponding to lines forming process. Such as is disclosed in U.S. patent appli
A-A of FIG. 1. The A-pillar 10 is formed of a shaped inner cation Ser. No. 11/416,299, filed on May 1, 2006 by James
member 12 that is formed with opposing vertically extend Lowe and entitled “Process for Forming a Hydroformed
ing flanges. A reinforcement member 15 having mating Automotive Component with Integrated Weld Flange',
flanges is welded at the flanges to the outer side of the inner assigned to Ford Global Technologies, LLC, the contents of
member 12 to form a generally vertically extending beam 10
both references patent applications being incorporated
10. The door opening panel 16 is also formed with mating herein by reference.
flanges that are welded to the flanges of the reinforcement As with the first embodiment depicted in FIG. 3, the
member 15. The door opening panel 16 provides a uniform flange 13 of the door opening panel 16 can be welded to the
surface for support of the windshield 17 supported in an landing 22 by one-sided welding techniques, including laser
elastomeric seal 18 against the welded flange 13, while the 15 stitch welding. The flange 14 of the door opening panel 16
front door (not shown) closes against a seal 19 typically and the support flange 24 of the tubular member 20 can be
mounted on the opposing welded flange 14. The distance welded by conventional two-sided welding techniques. As
from the lateral ends of the opposing welded flanges 13, 14 with the first embodiment, the formation of the landing 22
enables the tubular member 20 to provide an increased
defines the arc of seven and a half degrees, or less, relative cross-sectional area, represented by the gained cross-section
to the position of the operator of the vehicle. 25, as compared to the conventional prior art A-pillar
The first embodiment of the instant invention is shown in Structure.
FIG. 3. The inner member and the inner reinforcement
The fourth embodiment of the instant invention is shown
member are replaced by a tubular member 20 that is formed in FIG. 5. The tubular member 20 is formed with two
to include a first landing 22 against which the flange 13 of 25
landings 22 and 27. The first landing 22 Supports the flange
the door opening panel 16 is Supported. The flange 13 is
preferably welded to the landing 22 by one-sided welding 13 of the door opening panel 16, as described above. The
techniques, including laser Stitch welding. The incorporation second landing 27 Supports the opposing flange 14 of the
of the landing 22 enables the tubular member 20 to have an door opening panel 16 to provide a uniform surface against
increased size with the added cross-sectional area 25 30 which the front door 7 can seal. Since, however, the flange
increasing the size of the A-pillar structure 10. The opposing 14, as shown in FIG. 3, or the welded combination of flanges
flange 14 of the door opening panel 16 can be adhered with 14, 24, as depicted in FIG. 4, do not project outwardly from
modern adhesive technology, representatively identified at the body of the tubular member 20, the flange 14 cannot
23, to provide the necessary support for the door seal (not support the door seal. Therefore, the door seal would have
shown). Since the door opening panel 16 remains the same 35 to be moved to the front door 7. The flange 14 in this third
shape as in the conventional prior art door opening panel 16, embodiment, however, does provide a convenient location
the windshield 17 and the front door 7 have the same for welding the door opening panel 16 to the tubular member
uniform Surface against which to seal. One of ordinary skill 20 by one-sided welding techniques, such as laser Stitch
in the art will recognize that the tubular member 20 can be welding. By forming the tubular member 20 with the addi
formed efficiently with a hydroforming manufacturing pro 40
tional landing 27, the tubular member 20 has a further
CCSS,
increase in cross-sectional area by the area of gain 29.
The limit of the landing 22 of the tubular member 20 is Furthermore, neither the flange 13 nor the flange 14 project
defined by a lateral Surface 21 which is angled according to outwardly beyond the corresponding landing 22, 27 into the
the sight lines of the operator of the vehicle 5. Accordingly, sight lines of the operator of the automotive vehicle 5.
the tubular member 20 lies within the seven and a half 45
degree arc that will maintain binocular vision for the opera As noted above, the windshield side lateral surface 21 of
tor of the vehicle 5. The orientation of the windshield side the tubular member 20 is oriented along the sight lines of the
lateral surface 21 of the tubular member 20 is consistent operator of the vehicle 5 so as to be within a seven and
from this first embodiment to the other embodiments of the one-half degree arc for maintaining binocular vision for the
instant invention described below. One skilled in the art will 50 operator. The opposing door side lateral Surface 28 is
recognize that, because the operator is physically closer to oriented to provide an aesthetically desired surface for the
the driver's side A-pillar than the passenger side A-pillar, the A-pillar 10, and retain binocular vision for the operator. One
structural configuration of the driver's side A-pillar is more of ordinary skill in the art will recognize that the door side
restrictive with respect to maintaining binocular vision for lateral surface 28 could also be oriented along the sight lines
the operator than the structural configuration of the passen 55 of the operator and still retain binocular vision for the
ger side A-pillar. operator, while providing slightly more cross-sectional area
The second embodiment of the instant invention can be gain for the tubular member 20.
seen in FIG. 4. The tubular member 20 continues to be It will be understood that changes in the details, materials,
formed with the landing 22 in support of the flange 13 on the steps and arrangements of parts which have been described
door opening panel 16. The tubular member 20, however, is 60 and illustrated to explain the nature of the invention will
also formed with a support flange 24 that would underlie the occur to and may be made by those skilled in the art upon
flange 14 of the door opening panel 16, thus providing a reading of this disclosure within the principles and scope
essentially the same Support structure found in the conven of the invention. The foregoing description illustrates the
tional prior art A-pillar configuration depicted in FIG. 2. The preferred embodiment of the invention; however, concepts,
tubular member 20, in the second embodiment shown in 65 as based upon the description, may be employed in other
FIG. 4, can be formed through roll-forming techniques, such embodiments without departing from the scope of the inven
as is disclosed in U.S. patent application Ser. No. 1 1/508, tion.
 US 7,344,186 B1
5 6
Having thus described the invention, what is claimed is: lines of an operator of said automotive vehicle, said
1. A structural member for use as an A-pillar in an tubular member also being formed with a door side
automotive vehicle to support a windshield seal and a front flange member, said door seal Support flange of said
door seal, comprising: door opening panel being affixed to said door side
a shaped tubular member having a first landing Surface flange member, said door seal being mounted on door
corresponding to said windshield Seal and a second side flange member and said door seal Support flange.
landing Surface spaced from said first landing Surface; 8. The automotive vehicle of claim 7 wherein said tubular
and member is formed through a hydroforming process.
a door opening panel having a windshield Support flange 9. The automotive vehicle of claim 7 wherein said wind
mounted on said first landing Surface and a door seal 10 shield Support flange is welded to said first landing Surface
Support flange affixed to an opposing side of said through one-sided welding techniques.
tubular member from said first landing surface, neither 10. The automotive vehicle of claim 7 wherein said door
said door seal Support flange nor said windshield Sup seal Support flange is affixed to an opposing side of said
port flange project beyond the corresponding said first tubular member from said first landing surface by adhesives.
and second landing Surfaces relative to operator sight 15 11. The automotive vehicle of claim 7 wherein said
lines. tubular member is formed with a second landing Surface,
2. The structural member of claim 1 wherein said door said door seal Support flange of said door opening panel
seal Support flange is affixed to an opposing side of said being affixed to said second landing Surface.
tubular member from said first landing surface by adhesives. 12. The structural member of claim 11 wherein said door
3. The structural member of claim 2 wherein said tubular seal Support flange is affixed to said second landing Surface
member is formed with a windshield side lateral surface by one-sided welding techniques.
defining a lateral limit of said first landing Surface, said 13. The structural member of claim 12 wherein said door
windshield side lateral Surface being oriented along sight seal is supported on said front door.
lines of an operator of said automotive vehicle. 14. An automotive A-pillar member Supporting a wind
4. The structural member of claim 1 wherein said tubular 25
shield Seal and engagable with a front door, comprising:
member is formed with a door side flange member, said door a door opening panel having a windshield Support flange
seal Support flange of said door opening panel being affixed for engagement with said windshield seal, and an
to said door side flange member. opposing door seal Support flange positioned for
5. The structural member of claim 1 wherein said door
seal Support flange of said door opening panel is affixed to 30 engagement with said front door; and
said second landing Surface. a shaped tubular member having a first landing Surface on
6. The structural member of claim 5 wherein said wind which said windshield support flange is affixed, and a
shield Support flange and said door seal Support flange being windshield side lateral surface defining a limit of said first
affixed to said first and second landing Surfaces, respec landing Surface, said windshield side lateral Surface being
tively, by one-sided welding techniques. 35 oriented to align with operator sight lines, said tubular
7. In an automotive vehicle having a roof: a windshield member being formed with a door side flange member, said
including a windshield Seal on a perimeter thereof a front door seal Support flange of said door opening panel being
door including a door seal against which said front door affixed to said door side flange member.
seals when closed; and an A-pillar structural member Sup 15. The A-pillar member of claim 14 wherein said door
porting said windshield seal and said door seal, said A-pillar 40 seal Support flange is affixed to an opposing side of said
Supporting said roof and including a door opening panel tubular member from said first landing surface by adhesives.
having a windshield Support flange on which said wind 16. The A-pillar member of claim 14 wherein said tubular
shield Seal is supported and a door seal Support flange on member is formed with a second landing Surface, said door
which said door seal is mounted, the improvement compris seal Support flange of said door opening panel being affixed
1ng: 45 to said second landing Surface.
said A-pillar being formed with a shaped tubular member 17. The A-pillar member of claim 16 wherein neither of
having a first landing Surface on which said windshield said door seal Support flange nor said windshield Support
Support flange is affixed, said tubular member being flange project beyond the corresponding said first and sec
formed with a windshield side lateral surface defining ond landing Surfaces relative to operator sight lines.
a lateral limit of said first landing Surface, said wind 50
shield side lateral Surface being oriented along sight k k k k k