The E-Class Body Structure A rigid platform with these benefits: • A solid platform for the suspension, contributing to superb handling! • Mercedes-Benz patented passenger safety frame and crumple zones - front and rear! • An industty benchmark for durability and noise reduction! The E-Class' monocoque HSLA steel shown in red - Crumple Zones High-strength/Low-alloy Multiple-step Sheet-metal OVerview The front and rear sections are Fabrication (HSLA) Steel Monocoque Structure A large proportion of the sheet designed to crumple or deform HSLA steel (shown in red) is an The E-Class' monocoque (meaning metal is rolled or stamped in multi- in a programmed fashion during alloy that is up to three times "one shell") construction incorpo- ple steps to maintain strength and an impact. Crumpling helps to stronger than lower-carbon steel of rates the body and frame in the the same dimension. HSLA steel is integrity over the entire surface. dissipate as much impact force same sheet metal. This technology as possible before reaching the used in parts of the monocoque Bends and arcs in the body have provides one of the strongest steel that are critical for strength and passenger cabin. a wide radius wherever possible. automobile bodies for its weight. rigidity (20.0 percent of the overall Full, wide curves reduce cutting E-Class structure). A rigid body and crimping that could weaken supports the chassis systems and the steel and make it more suscep- helps protect the passenger cabin. tible to rust and corrosion. Exterior 7 1999 E·CLASS PRESENTATION GUIDE
II Bulkhead Crossmember An HSLA-steel crossmember at the forward bulkhead connects the in- ner forks of the three-prong forked members. This transverse link in- creases body strength and trans- verse rigid ity. In certain full-frontal impacts, the front bulkhead crossmember will deform to help absorb some impact forces. o Wheel Housings Reinforced areas over the front wheels afford greater protection in impacts with objects that hit the car above the front bumper, help- ing to reduce intrusion into the passenger cabin. o Front Structure In addition to reducing noise and o road vibration, the subframe Longitudinal Members increases chassis rigidity, adding to Running from the bumper to the Transverse Member body strength and durability. passenger cabin, these frame rails Behind the bumper, a transverse II are made of HSLA steel. The two member ties together the two members increase in height and Three-prong Forked longitudinal members. The trans- cross section from the bumper to Members verse member is made of high- the cabin. This design helps them As the longitudinal members strength steel and is bolted and to deform at a programmed, uni- approach the cabin, they divide strongly welded to the longitudinal form rate, absorbing some impact into three prongs, leading to the members. The member is designed forces before they reach the cabin. transmission tunnel, the rocker to channel impact energy to the o panels, and the A-pillars. The side opposite a frontal, offset colli- prongs' purpose is to channel Subframe sion so that both sides are involved some impact energy around the The front subframe serves a in absorbing some impact energy. passenger cabin instead of into it, number of purposes. Besides being helping to protect the occupants the mounting point for engine and reduce injury. and chassis components, it is a o structural member. Double Bulkhead The subframe is made of rigid high- Two bulkheads separate the engine strength steel, and its front cross- compartment from the passenger member acts as an additional cabin. Their benefits are: (A) They transverse member connecting the protect the electrical and brake two longitudinal members. The components housed between rear crossmember's mounts are them from dust and engine heat. designed to break away from the (B) They add an additional barrier longitudinal members in an impact, to engine noise and heat, helping allowing the longitudinal members to prevent them from entering the to deform along a greater portion passenger cabin. (C) They add of their length. By breaking away, strength to the bod y. the subframe carries the engine and chassis components that are mounted to it backward and poten- tially under the passenger cabin. 8 Exterior 1999 E-CLASS PRESENTATION GUIDE 7
o Cabin Structure Floor Crossmembers Safety Frame The rocker panels are connected A rigid steel frame surrounds the by three HSLA-steel crossmem- E-Class' passenger cabin, helping bers, which make the floor pan to protect occupants in an impact. stronger and increase body rigidity. Body pillars, crossmembers, and The transmission tunnel has three longitudinal members form a braces that help the tunnel to safety frame around the cabin in resist collapsing in a side impact. the floor, around the doors, and in (Compression would reduce inte- the roof_ HSLA steel (shown in rior occupant space.) red) makes up a large part of the D safety frame. D Cowl Crossmember A tubular, high-grade, HSLA-steel Sandwich Body Pillars cowl crossmember ties together The A-, B-, and C-pillars each the A-pillars. It helps to resist crush- consist of three pieces of steel ing in a side impact that strikes the sandwiched together (one of them cowl area. This crossmember also HSLA steel). Crossmembers tie assists in holding back the steering together the A- and B-pillars, and column, climate-control unit, and an HSLA-steel longitudinal roof other components that are housed member extends from the A-pillar o behind the dashboard, helping to the C-pillar. This construction Bonded Front and Rear to prevent intrusion in frontal provides not only strength and Windshields Rear Bulkhead impacts. The E-Class' fixed glass is held in rigidity for a quality feel, but affords A steel bulkhead separates the II place by a quick-drying adhesive increased protection for the occu- passenger cabin from the trunk. that bonds the glass solidly to the pants from various types of impacts. Doors and Hinges Besides protecting occupants in body. The strong bonding makes A steel beam inside each door the cabin from trunk con tents, it The B-pillars extend into the the glass a part of the body struc- presents a barrier to side-impact also improves overall structural HSLA-steel rocker panels for added ture, adding to its rigidity and forces, helping to reduce intrusion. rigidity to resist body fleXing. strength, benefiting safety. (Some safety. Strong hinges attach the doors to competitors weld the bottoms of the A-and B-pillars. The hinges and the B-pillars to the tops of the the wedge design of the door rocker panels.) latches help to allow the doors to be opened after an impact. 1999 E-CLASS PRESENTATION GUIDE Exterior 9
Corrosion Protection II Galvanization Much of E-Class' body is electro- galvanized, coating 48.0 percent of the body with zinc. linc covers the steel uniformly, making it resis- tant to corrosion. linc protects steel by "sacrificing" itself when the steel is scratched, rather than allowing the steel to corrode or rust. The benefit of galvanizing is increased body durability, ensuring long-lasting strength. Rust Inhibitors Seams and crimped body parts most subject to corrosive influ- ences are sealed with polyvinyl chloride (PVC) to help prevent corrosion. The wheel arches underside of the floor, and A:pillars receive particular attention. The critical attachment points of the A-pillars and the body are sealed by hand, affording long life and strength. Rear Structure Reinforced Structure [:320 o 'Iv, Jor Decklid Construction Structural enhancements by cross- Part of the decklid is preassembled Transverse Member members in the Wagon's roof and using a "clinching" process. As in the front, a high-strength passenger-cabin! cargo-area floor as Clinching joins the two parts of steel transverse member ties well as a steel frame surrounding the decklid through a pressurized together the longitudinal members. the tailgate opening help to ensure indentation of the metal. The join- In an offset collision, the transverse rigidity and integrity even when ing is done without damage to the member helps channel some fully loaded with seven passengers decklid's corrosion protection and impact energy to the opposite and/or cargo. without heat distortion, adding to side, for improved safety. the decklid's quality construction. o Clinching allows the use of two Fuel Tank different metals that cannot be One of the safest locations for the welded together - steel for the fuel tank is over the rear axle, an outer shell and framing made of area protected from rear impacts aluminum fittings and brackets. by the rear body structure and the rear part of the chassis_ The E-Class sedan's fuel tank is located there. The Wagon's fuel tank is located under the floor pan. 10 Exterior 1999 E-CLASS PRESENTATION GUIDE p
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