OVERVIEW
Because luxury-car feel and safety were priorities of the CL
project,
our engineers concentrated on optimizing the rigidity of the CL
unit
body structure to provide excellent crash protection, excellent
isolation from noise and vibrations, and rewarding ride comfort.
In developing the chassis, our engineers used the latest Finite Element Analysis and Modeling to achieve the highest rigidity levels at the lightest possible weight. An important tool in achieving these high rigidity targets was "IDEAS" software from the Structural Dynamics Research Corporation in Cincinnati. This tool allows chassis designers to quickly analyze and evaluate changes in a structure and find the best solution.
UNIT BODY STRUCTURE
The carefully designed structure is designed to keep the center
passenger section protected in the event of an impact. The
center
"safety cage" is specifically fortified with thickened
reinforcements
at such critical points as the floor tunnel, the side-sills, and the
center pillars. The thickened rear damper stiffeners are also
extended downward over the wheelhouses. In addition to
enhanced
impact protection, these fortifications contribute to overall body
rigidity and balance, imparting a quieter ride and a true luxury
feel.
RIGID STRUT TOWER BAR
By carefully matching a rigid front strut tower bar to the specific
characteristics of each CL engine, engineers were able to
enhance
both ride feel and steering response. In the event of a severe
frontal collision, the structure is designed to crush at the tower
bar center mounting bracket, helping to protect the integrity of the
passenger cabin.
REAR WHEEL ARCH EXTENSIONS AND FULL REAR
BULKHEAD
Greatly improving torsional rigidity are exclusive rear wheel arch
extensions. At each rear wheelhouse, this part creates a box
section
by connecting the side-sill box section with the
rear-damper-stiffener box section.
In addition, a large shear plate ties the left and right rear wheelhouses together with the floor and the parcel shelf. Combined with the rear wheel arch extensions, this full rear bulkhead integrates the entire rear structure of the CL into a single unit, helping eliminate weak points and enhancing structural rigidity.
POLYPROPYLENE IMPACT BOXES
To supplement the side-impact protection provided by the CL's
steel
door-impact beams, the sides of the CL are equipped with
polypropylene boxes that crush progressively and evenly in a
side
impact, helping to dissipate and distribute impact forces before
they
intrude into the passenger cabin. To reduce the likelihood of hip
injuries, there is one box inside the lower part of each door, and
one under each rear armrest. Additional side-impact protection
is
provided by polypropylene foam blocks in the upper part of each
door
and just above each rear side armrest. To reduce the likelihood
of
head injuries to rear-seat passengers in a side impact, special
crushable box sections are also built into each C-pillar.
SOUND INSULATION
While the structure effectively damps out annoying vibrations and
helps ensure a tight, rigid body, blocking out road noise is
accomplished by using sound deadening material in strategic
areas
throughout the body. A liberal amount of insulating material has
been
used in the engine compartment, the floorpan, the rear
bulkhead, the
rear wheelhouse, and the trunk to ensure a quieter passenger
cabin.
To reduce splashing and drumming noise, the CL is insulated
with a
rigid composite material in the rear quarter-panels and in the
rear
wheelhouses. Additional noise control is provided by a PVC
undercoating under the floor and in the wheel wells, and by a
fabric
insulator under the hood.
PAINT PROCESS
To ensure a lustrous, lasting finish, each CL undergoes an
exacting,
19-step painting procedure. The process begins by thoroughly
cleaning
the body of grease and other debris that might mar the final
finish
or prevent paint from properly bonding to the metal. The body is
then
put through an electrodeposition coating process, washed, and
then
dried.
At that point, the actual process of painting begins. Each successive coat of paint and the sealer coat is baked and washed.
To improve the durability of the CL's fine finish, engineers developed a special anti-chip primer that is applied to parts of the body at particular risk from small stones and other flying road debris (such as the front of the hood). Thanks to improved tensile and elongation properties, this new primer is able to distribute the impact forces of a small stone with little or no paint de-lamination.
ANTI-CORROSION MEASURES
To ensure excellent corrosion protection, every CL outer body
panel
except the roof is made of double-sided galvanized steel.
In addition, the underbody is sprayed with an anti-chip, anti-corrosion PVC undercoating, and selected cavities are filled with an oil-impregnated wax material that inhibits moisture penetration and prevents rust. This, when combined with the excellent painting process, produces a corrosion-resistant body that carries a 5-year rust-through limited warranty.