Ford Global Technolgoies, LLC

Frank J Day

John T Reed

Hikmat F Mahmood

James Wayne Lowe

Gregory S Frederick

Lou Ratsos

A body side rail construction for an automotive vehicle is formed in a dual cell configuration. A reversed C-shaped channel is welded to the closed section of the conventional roof side rail member to enable the body side rail member to be a smaller section that is less susceptible to buckling as the body side rail member transfers load to the front and rear corner pillars. The C-shaped cross-sectional configuration presents advantages for manufacturing as it can be shaped to provide the attaching brackets and horns for mounting the front header, roof bow, and rear header members to the body side rail without the addition of individual end items to serve this function. From a shipping density standpoint, this design gives maximum structure while maintaining good rack density that enables relatively straight parts to be nested together while still providing the increased section strength required for enhanced roof performance.

Dual cell body side rail for automotive vehicles

A dual cell rear corner pillar for the operator's compartment of a pick-up truck is formed with longitudinally oriented front and rear tubular members. The dual cell tubular construction increases section strength for the rear corner pillar while maintaining packaging constraints for the rear pillar design. The front tubular member is nested against the rear tubular member to provide support therefor longitudinally and vertically. The forward tubular member is welded to the door opening panel seal flange, while the rearward tubular member is welded to the window flange and the back panel flange. The forward and rearward tubular members are also welded to one another to form a strong pillar structure. The dual cell configuration resists buckling and shares loading. The rear tubular member wraps around the front tubular member and transitions into the roof rail area, shortening the unsupported moment arm of the rear tubular member.

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South Lyon, MI, United States of America

Frank J Day