Tubular B-Pillar to Stamped Rocker Joint and Method of Assembling The Same

Abstract

A pillar to rocker joint assembly comprising a tubular pillar having a pinched flange near a lower end of the pillar is joined to a rocker assembly including a side sill and rocker reinforcement. A method of making a pillar to rocker joint assembly that comprises a vehicle structural support is formed by welding a structural support pillar to an outer body panel through an access opening in the pillar and welding a rocker reinforcement to a side sill. The rocker reinforcement is welded to the pillar through an access opening in the side sill, an access hole in the body outer panel, and an access opening in the pillar that is vertically spaced relative to the first access opening. A bottom flange of the B-pillar is welded to a lower edge flange of the rocker reinforcement and a lower edge flange of the side sill.

1 . A method of making a pillar to rocker joint assembly, the rocker joint assembly having a rocker reinforcement, a side sill, and an outer body panel, the method comprising:
 forming a tubular pillar having a pinched flange proximate a lower end, a first access opening along an inner wall of the pillar and an second access opening vertically spaced relative to the first access opening along an outer wall of the pillar;   welding the pillar to the outer body panel through a first access opening;   welding the rocker reinforcement to the side sill;   welding the rocker reinforcement to the pillar through the second access opening in the pillar; and   welding the pinched flange of the pillar to a bottom flange of the rocker reinforcement and a bottom flange of the side sill.   
     
     
         2 . The method of  claim 1  further comprising welding the pinched flange together prior to welding the pillar to the body outer panel. 
     
     
         3 . The method of  claim 2  further comprising removing a single wall thickness along the pinched flange to provide a single wall thickness of the pillar that is welded to a bottom side sill flange and a bottom rocker reinforcement flange. 
     
     
         4 . The method of  claim 3  wherein the weld of the pinched flange, the bottom side sill flange, and the bottom rocker reinforcement flange is formed below the location where the pinched flange is welded together. 
     
     
         5 . The method of  claim 1  wherein the step of welding the rocker reinforcement to the side sill forms a tubular reinforcement assembly. 
     
     
         6 . The method of  claim 1  wherein the pillar is welded to an outer side of the rocker reinforcement, wherein the side sill is welded to an inner side of the rocker reinforcement thereby forming a joint in which the rocker reinforcement is sandwiched between the pillar and the side sill. 
     
     
         7 . The method of  claim 1  wherein the welding steps are performed in a resistance welding operation. 
     
     
         8 . The method of  claim 1  wherein the pillar has a box-shaped cross-section above the pinched flange. 
     
     
         9 . The method of  claim 1  wherein the rocker reinforcement is welded to the pillar through an access area in the body outer panel and an access opening in the side sill. 
     
     
         10 . The method of  claim 1  wherein the tubular pillar is hydro-formed. 
     
     
         11 . A method of making a vehicle structural support comprising:
 hydro-forming a pillar having a box shaped cross-section and a pinched double flange adjacent a lower end of the pillar;   stamping a body outer panel;   welding the pillar to the body outer panel;   stamping a rocker reinforcement;   stamping an side sill;   welding the side sill to an inner side of the rocker reinforcement; and   welding the pillar to an outer side of the rocker reinforcement.   
     
     
         12 . The method of  claim 11  further comprising removing a single wall thickness in the along the pinched double flange to provide a single wall thickness of the pillar that is welded to a side sill flange and a rocker reinforcement flange. 
     
     
         13 . The method of  claim 11  wherein the pillar is welded to an outer side of the rocker reinforcement, wherein the side sill is welded to an inner side of the rocker reinforcement thereby forming a joint in which the rocker reinforcement is sandwiched between the pillar and the side sill. 
     
     
         14 . The method of  claim 11  further comprising removing a single wall thickness of the pillar in multiple vertically spaced locations to form an upper access hole and a lower access hole, wherein an inner surface of the pillar is welded to the rocker reinforcement through the upper access hole and a side sill access hole in the side sill and an access hole in the body outer panel, and wherein an outer surface of the pillar is welded to the body outer panel through the lower access hole in the inner surface of the pillar before the rocker reinforcement and side sill are assembled to the pillar. 
     
     
         15 . The method of  claim 11  wherein hydro-formed pillar has a first box-shaped cross-section located above a second elongated cross-section. 
     
     
         16 . A method of making a structural support for a vehicle, comprising:
 forming a first subassembly by welding an outer panel to an outer wall of a pillar;   forming a reinforcement assembly by welding a side sill to a rocker reinforcement; and   welding the reinforcement assembly to the first subassembly, such that the first subassembly is disposed outboard of the reinforcement assembly.   
     
     
         17 . The method of  claim 16  further comprising the step of:
 hydro-forming the pillar as a tubular pillar. 
 
     
     
         18 . The method of  claim 16  further comprising the steps of:
 forming a first access opening on an inner wall of the pillar and a second access opening defined on the outer wall of the pillar; 
 forming a third access opening; 
 welding the outer panel to the pillar through the first access opening; and 
 welding the reinforcement assembly to the pillar along the inner wall of the pillar through the second opening and the third opening. 
 
     
     
         19 . The method of  claim 18  further comprising the steps of:
 forming an fourth access opening along a pinched flange located adjacent a lower end of the pillar; and 
 welding the first subassembly to the reinforcement assembly through the fourth access opening. 
 
     
     
         20 . The method of  claim 16  wherein the reinforcement assembly is a tubular assembly extending in a longitudinal direction of the vehicle.