The complex design of the floor structure forms the backbone of this "protective zone". Here, the engineers at Sindelfingen used three panel blanks of varying thicknesses which are welded together by laser beam. The centre of the three panels forms the transmission tunnel, with its high frontal and lateral load-bearing capacity. Strong side and cross members, torsionally rigid struts, triple-shell A, B and C-pillars as well as tubular reinforcements on the B-pillar give extra stability to the passenger cell. These are but a small sample of the many design measures featured in the occupants' "safety cage".
Next up on the test rig were the doors, which also had to prove their life-saving potential. The result is a new hinge technology, featuring mounting plates with a high load-bearing capacity, which are welded firmly to the inner door shells. A high-strength, flexible side member located at the bottom between the inner and outer shell of each door supplements the numerous design measures included to boost side impact protection.
Rear-end structure: keeping occupants' backs well covered
The three-phase, speed-related safety concept triggered off in the event of a collision from the rear is almost identical to that used for the frontal structure in the new E-Class:.
At higher impact speeds, the reinforced rear side members of the bodyshell prove their worth. Here, a continuous closed box section with carefully graduated material thicknesses is used to absorb high forces. The plastic fuel tank is located in front of the rear axle where it is protected from any impacts.