BODY STRUCTURE


  1. CONSTRUCTION


    1. Impact Absorbing Structure for Frontal Collision


      1. A structure that ensures collision energy absorption efficiency, dissipates impact and minimizes cabin deformation during a frontal collision has been achieved.


        • A frame construction which effectively transmits the impact load to the vehicle body parts during a frontal collision is used.

        • Ultra high strength sheet steel (Tensile Strength: 590 MPa class) rocker panel outer (*1 in illustration) and rocker panel reinforcement No. 1(*2 in illustration) are provided to help reduce the deformation of the rocker during a frontal collision.

        • Ultra high strength sheet steel (Tensile Strength: 590 MPa class) front body pillar reinforcement upper (*3 in illustration) and roof side rail outer (*4 in illustration) are used. The deformation of the front body pillars has been reduced during a frontal collision by overlapping the points at where the load concentrates most on the front body pillars during a frontal collision to provide further reinforcement.

        • The impact load is transmitted to the non-impacted side during an offset frontal collision to help reduce the vehicle deformation amount by providing a front bumper reinforcement No. 5 (*6 in illustration) within the cross section of the front bumper reinforcement sub-assembly (*7 in illustration).

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          *1 Rocker Panel Outer *2 Rocker Panel Reinforcement No. 1
          *3 Front Body Pillar Reinforcement Upper *4 Roof Side Rail Outer
          *5 Front Body Pillar Inner *6 Front Bumper Reinforcement No. 5
          *7 Front Bumper Reinforcement Sub-assembly - -
          *a A - A Cross Section *b B - B Cross Section
          *c C - C Cross Section - -
          B005L0G Front Impact Energy B005L08 Dissipate

        • The frame sub-assembly deformation pattern during a frontal collision is controlled to move the suspension tower, dash panel and pedals away from the passengers, reducing their level of injury.

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          *a Side View *b Plane View
          *c Step 1: Extension Bucking *d Step 2: Side Rail Collapsing Below Suspension Tower
          *e Step 3: Side Rail Collapsing *f Bucking
          *g Longitudinal Collapsing *h Lateral Collapsing
          *i Kick Region *j Deformation of the side-rail "kick" portionis controlled to reduce the deformation amount of the suspension tower, dash panel and pedals, reducing impact load delivered to the passengers during a collision.

    2. Impact Absorbing Structure for Side Collision


      1. A structure that ensures collision energy absorption efficiency, dissipates impact and minimizes cabin deformation during a side collision has been achieved.


        • A frame construction which effectively disperses the impact load during a side collision is used.

        • On double cab models, ultra high strength sheet steel (Tensile Strength: 590 MPa class) rocker panel outer (*1 in illustration) is provided to help reduce the deformation of the rocker during a side collision.

        • On double cab models, during the initial operation of the airbags, the rocker extension outer (*3 in illustration) and rocker panel reinforcement No. 4 (*2 in illustration) transmits the impact load to the floor to help reduce vehicle body deformation during a side collision.

        • On double cab models, the center body pillar is provided with an ultra high strength sheet steel (Tensile Strength: 590 MPa class) center body pillar reinforcement upper (*4 in illustration) to help reduce the deformation of the center body pillar during a side collision.

          Figure 1. Double Cab

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          *1 Rocker Panel Outer *2 Rocker Panel Reinforcement No. 4
          *3 Rocker Extension Outer *4 Center Body Pillar Reinforcement Upper
          *a A - A Cross Section *b B - B Cross Section
          B005L0G Side Impact Energy B005L08 Dissipate

        • On smart cab models, ultra high strength sheet steel (Tensile Strength: 590 MPa class) rocker panel outer (*1 in illustration) and ultra high strength sheet steel (Tensile Strength:590 MPa class) access panel Inside panel reinforcement (*4 in illustration) are provided to help reduce the deformation of the rocker during a side collision.

        • On smart cab models, during the initial operation of the airbags, the rocker extension outer (*2 in illustration) and rocker panel reinforcement No. 4 (*3 in illustration) transmits the impact load to the floor to help reduce vehicle body deformation during a side collision.

          Figure 2. Smart Cab

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          *1 Rocker Panel Outer *2 Rocker Extension Outer
          *3 Rocker Panel Reinforcement No. 4 *4 Access Panel Inside Panel Reinforcement
          *a A - A Cross Section *B B - B Cross Section
          B005L0G Side Impact Energy B005L08 Dissipate

        • On single cab models, ultra high strength sheet steel (Tensile Strength: 590 MPa class) rocker panel outer (*1 in illustration) is provided to help reduce the deformation of the rocker during a side collision.

        • On single cab models, during the initial operation of the airbags, the rocker extension outer (*2 in illustration) and rocker panel reinforcement No. 4 (*3 in illustration) transmits the impact load to the floor to help reduce vehicle body deformation during a side collision.

          Figure 3. Single Cab

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          *1 Rocker Panel Outer *2 Rocker Extension Outer
          *3 Rocker Panel Reinforcement No. 4 - -
          *a A - A Cross Section - -
          B005L0G Side Impact Energy B005L08 Dissipate

    3. Reduction Pedestrian Head Injury


      1. The following shape is used for around the front body, thus maintaining necessary rigidity and aiming for a reduction of impact against a pedestrian in a collision with a pedestrian.


        • The hood sub-assembly (*1 in illustration) uses a structure that places a sufficient space between the hood panel (*2 in illustration) and hood panel inner (*3 in illustration) to ensure an impact absorption stroke (*b in illustration) in order to reduce the impact to the head of a pedestrian during a collision.

          Figure 4. Hood Sub-assembly (The illustration shows an example)

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          *1 Hood Sub-assembly *2 Hood Panel
          *3 Hood Panel Inner - -
          *a A - A Cross Section *b Impact Absorption Stroke

        • The hood sub-assembly (*1 in illustration) uses a structure that places a sufficient space between the hood panel (*4 in illustration) and engine compartment parts (*5 in illustration) to ensure an impact absorption stroke (*b in illustration) in order to reduce the impact to the head of a pedestrian during a collision.

        • Deformation points (*c in illustration) are placed on the hood lock hook reinforcement No. 2 (*3 in illustration) to create an easily collapsible structure that can absorb the impact load effectively when a pedestrian collides with the hood lock area in order to reduce the impact to the head of a pedestrian.

          Figure 5. Hood Sub-assembly (The illustration shows an example)

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          *1 Hood Sub-assembly *2 Hood Panel Reinforcement
          *3 Hood Lock Hook Reinforcement No. 2 *4 Hood Panel
          *5 Engine Compartment Parts - -
          *a A - A Cross Section *b Impact Absorption Stroke
          *c Deformation Point *d Head Form

        • The cowl top panel inner (*1 in illustration) uses a crushable structure that has deformation points (*b in illustration) to improve the rate of energy absorption from the estimated collision direction when a pedestrian collides with the windshield glass (*2 in illustration) to reduce the impact to the pedestrian whose head, etc., struck the area.

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          *1 Cowl Top Panel Inner *2 Windshield Glass
          *a A - A Cross Section *b Deformation Point
          *c Head Form - -

        • An impact absorption brackets (fender apron reinforce plate: *1 in illustration and front fender apron reinforcement RR: *2 in illustration) are provided around the front fender apron sub-assembly (*3 in illustration) to absorb impact load during a collision and collapse, forming a structure which reduces the impact to the pedestrian whose head, etc., struck the fender.

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          *1 Fender Apron Reinforce Plate *2 Front Fender Apron Reinforcement RR
          *3 Front Fender Apron Sub-assembly - -
          *a A - A Cross Section - -